Power module layout structure of integrated driving and power generation functional circuit
By integrating the drive and power generation circuits into a power module layout structure, the drive and power generation modules are located on the left and right sides respectively, which solves the problems of large size and high cost caused by the separate module design in traditional electric vehicles, and achieves increased power density and cost savings.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-03-28
- Publication Date
- 2026-03-17
AI Technical Summary
The separate design of control circuits for drive and power generation modules in traditional electric vehicles leads to problems such as large power system size and high cost.
The power module layout structure adopts integrated drive and power generation circuits, with the drive module and power generation module located on the left and right sides respectively. They are equipped with DC and AC busbars respectively and are connected by a copper-clad ceramic substrate, a welding layer and a module heat sink. The inside of the plastic shell is filled with insulating material and integrates a current sensor. The busbars are connected to the external circuit by laser welding or bolt fastening.
It increases power volume density, reduces power system size and equipment cost, reduces electromagnetic crosstalk, and improves heat dissipation performance and connection efficiency.
Smart Images
Figure CN224006617U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of electric vehicle controllers and power semiconductor packaging technology, and in particular to a power module layout structure that integrates drive and power generation functional circuits. Background Technology
[0002] Power semiconductors are widely used in electric and hybrid vehicles, serving as AC / DC conversion components in drive system controllers, AC / DC conversion components in power generation systems, and boost / buck converters in power supply circuits. Power devices in the controller account for a significant portion of the cost of an electric vehicle drive system. In traditional electric vehicle powertrain systems, the control circuits for the drive and power generation modules are typically designed separately, resulting in a larger system size and higher cost. Therefore, improving the power density of the controller and modular integration design have become important directions. Summary of the Invention
[0003] The technical problem to be solved by this utility model is to provide a power module layout structure that integrates drive and power generation functional circuits. This structure overcomes the defects of traditional separate design of drive and power generation module control circuits, improves power volume density, reduces power system volume, and saves equipment costs.
[0004] To solve the above-mentioned technical problems, the power module layout structure of the integrated drive and power generation circuit of this utility model includes a drive module and a power generation module respectively disposed on the left and right sides. The drive module is provided with a drive DC positive bus and a drive DC negative bus on the upper side and a drive AC three-phase bus on the lower side. The power generation module is provided with a power generation DC positive bus and a power generation DC negative bus on the upper side and a power generation AC three-phase bus on the lower side. The drive module and the power generation module are provided with a copper-clad ceramic substrate, a solder layer and a module heat sink from top to bottom. The module heat sink and the copper-clad ceramic substrate are surrounded by a plastic shell, and the inside of the plastic shell is filled with insulating material. The drive AC three-phase bus and the power generation AC three-phase bus are respectively provided with a current sensor and a current sensor interface. The copper-clad ceramic substrate of the drive module and the power generation module are respectively provided with a number of drive signal terminals. The current sensor is a fully encapsulated or PCB surface mount sensor.
[0005] Furthermore, the drive module includes a drive function circuit, the power generation module includes a power generation function circuit, the drive DC positive busbar, the drive DC negative busbar, and the drive AC three-phase busbar are respectively welded to the upper and lower sides of the copper-clad ceramic substrate of the drive module, and the power generation DC positive busbar, the power generation DC negative busbar, and the power generation AC three-phase busbar are respectively welded to the upper and lower sides of the copper-clad ceramic substrate of the power generation module.
[0006] Furthermore, the driving DC positive busbar, driving DC negative busbar, driving AC three-phase busbar, generating DC positive busbar, generating DC negative busbar, and generating AC three-phase busbar are respectively injection molded into the plastic shell, and the driving AC three-phase busbar and the generating AC three-phase busbar extend outside the plastic shell.
[0007] Furthermore, the copper-clad ceramic substrate and the module heat sink are connected by an intermediate solder or sintering layer.
[0008] Furthermore, the driving DC positive busbar, the driving DC negative busbar, the generating DC positive busbar, and the generating DC negative busbar are bent toward the module heat sink plate.
[0009] Furthermore, the driving DC positive busbar, driving DC negative busbar, driving AC three-phase busbar, generating DC positive busbar, generating DC negative busbar, and generating AC three-phase busbar are respectively connected to the external circuit by laser welding or bolt fastening.
[0010] Because the power module layout structure of this utility model, which integrates drive and power generation functions, adopts the above-mentioned technical solution, the structure includes a drive module and a power generation module respectively located on the left and right sides. The drive module has a drive DC positive and negative busbar on its upper side and a drive AC three-phase busbar on its lower side. The power generation module has a power generation DC positive and negative busbar on its upper side and a power generation AC three-phase busbar on its lower side. From top to bottom, the drive module and power generation module are sequentially equipped with a copper-clad ceramic substrate, a solder layer, and a module heat sink. A plastic shell is provided around the heat sink and the copper-clad ceramic substrate, and the inside of the plastic shell is filled with insulating material. Current sensors and current sensor interfaces are respectively located at the positions of the drive AC three-phase busbar and the power generation AC three-phase busbar. The copper-clad ceramic substrates of the drive module and the power generation module are each equipped with several drive signal terminals. This structure overcomes the shortcomings of traditional separate designs for drive and power generation module control circuits, improves power volume density, reduces the size of the power system, and saves equipment costs. Attached Figure Description
[0011] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments:
[0012] Figure 1 This is a schematic diagram of the power module layout structure of the integrated drive and power generation circuit of this utility model;
[0013] Figure 2 for Figure 1 Side view.
[0014] Figure 3 This diagram illustrates the use of molding compound instead of plastic shell and filling insulation material in this structure. Detailed Implementation
[0015] Implementation, for example Figure 1 and Figure 2 As shown, the power module layout structure of the integrated drive and power generation circuit of this utility model includes a drive module 1 and a power generation module 2 respectively disposed on the left and right sides. The drive module 1 is provided with a drive DC positive busbar 11 and a drive DC negative busbar 12 on the upper side and a drive AC three-phase busbar 13 on the lower side. The power generation module 2 is provided with a power generation DC positive busbar 21 and a power generation DC negative busbar 22 on the upper side and a power generation AC three-phase busbar 23 on the lower side. The drive module 1 and the power generation module 2 are provided with a copper-clad ceramic substrate 4, a welding layer 42 and a module heat sink 3 from top to bottom. The module heat sink 3 and the copper-clad ceramic substrate 4 are provided with a plastic shell 5 on the outer ring. The plastic shell 5 is filled with insulating material. The drive AC three-phase busbar 13 and the power generation AC three-phase busbar 23 are respectively provided with a current sensor 6 and a current sensor interface 61. The copper-clad ceramic substrate 4 of the drive module 1 and the power generation module 2 are respectively provided with a plurality of drive signal terminals 41. The current sensor 6 is a fully encapsulated or PCB surface mount sensor.
[0016] Preferably, the drive module 1 includes a drive function circuit, the power generation module 2 includes a power generation function circuit, the drive DC positive bus 11, the drive DC negative bus 12, and the drive AC three-phase bus 13 are respectively welded to the upper and lower sides of the copper-clad ceramic substrate 4 of the drive module 1, and the power generation DC positive bus 21, the power generation DC negative bus 22, and the power generation AC three-phase bus 23 are respectively welded to the upper and lower sides of the copper-clad ceramic substrate 4 of the power generation module 2.
[0017] Preferably, the driving DC positive busbar 11, driving DC negative busbar 12, driving AC three-phase busbar 13, generating DC positive busbar 21, generating DC negative busbar 22, and generating AC three-phase busbar 23 are respectively injection molded into the plastic shell 5, and the driving AC three-phase busbar 13 and the generating AC three-phase busbar 23 extend outside the plastic shell 5.
[0018] Preferably, the copper-clad ceramic substrate 4 and the module heat sink 3 are connected by an intermediate solder or sintering layer.
[0019] Preferably, the driving DC positive busbar 11, driving DC negative busbar 12, and power generation DC positive busbar 21 and power generation DC negative busbar 22 are bent towards the module heat sink 3. After bending, the driving DC positive and negative busbars 11 and 12 and the power generation DC positive and negative busbars 21 and 22 are closer to the module heat sink 3, which improves the heat dissipation performance of the busbars and effectively increases the volume density of the power module.
[0020] Preferably, the driving DC positive busbar 11, driving DC negative busbar 12, driving AC three-phase busbar 13, generating DC positive busbar 21, generating DC negative busbar 22, and generating AC three-phase busbar 23 are connected to the external circuit 9 by laser welding or bolt fastening. This reduces the connection length, lowers the parasitic inductance and resistance of the circuit, and reduces operating losses.
[0021] like Figure 3 As shown, the plastic shell 5 and the filling insulation material in this structure can be replaced by molding compound 7 to save costs.
[0022] The drive AC three-phase busbar 13 and the generator AC three-phase busbar 23 are respectively provided with through holes 8 at the ends so as to connect to the external circuit by bolt fastening.
[0023] This structure arranges the drive module (drive function circuit) and the power generation module (power generation function circuit) in two separate areas, left and right, to reduce electromagnetic crosstalk in the circuit. By integrating drive and power generation functions and incorporating a layout design with an integrated current sensor, the power volume density of the entire power module is improved.
Claims
1. A power module layout structure integrating drive and power generation functions, characterized by: The application relates to a drive module and a power generation module arranged on the left and right sides, wherein the upper side of the drive module is respectively provided with a drive direct-current positive busbar and a drive direct-current negative busbar, the lower side is provided with a drive alternating-current three-phase busbar, the upper side of the power generation module is respectively provided with a power generation direct-current positive busbar and a power generation direct-current negative busbar, the lower side is provided with a power generation alternating-current three-phase busbar, the drive module and the power generation module are sequentially provided with a copper-clad ceramic substrate, a welding layer and a module heat dissipation plate from top to bottom, the outer circle of the module heat dissipation plate and the copper-clad ceramic substrate is provided with a plastic shell, the plastic shell is filled with insulating material, the drive alternating-current three-phase busbar and the power generation alternating-current three-phase busbar are respectively provided with a current sensor and a current sensor interface, the copper-clad ceramic substrate of the drive module and the power generation module is respectively provided with a plurality of drive signal terminals, and the current sensor is a fully-enclosed or PCB patch sensor.
2. The power module layout of integrated drive and power generation function circuit according to claim 1, characterized in that: The drive module comprises a drive function loop, the power generation module comprises a power generation function loop, the drive direct-current positive busbar, the drive direct-current negative busbar and the drive alternating-current three-phase busbar are welded on the upper side and the lower side of the copper-clad ceramic substrate of the drive module, and the power generation direct-current positive busbar, the power generation direct-current negative busbar and the power generation alternating-current three-phase busbar are welded on the upper side and the lower side of the copper-clad ceramic substrate of the power generation module.
3. The power module layout of integrated drive and power generation function circuit according to claim 1 or 2, characterized in that: The drive direct-current positive busbar, the drive direct-current negative busbar, the drive alternating-current three-phase busbar, the power generation direct-current positive busbar, the power generation direct-current negative busbar and the power generation alternating-current three-phase busbar are respectively injected into the plastic shell, and the drive alternating-current three-phase busbar and the power generation alternating-current three-phase busbar extend out of the plastic shell.
4. The power module layout of integrated drive and power generation function circuit according to claim 3, characterized in that: The copper-clad ceramic substrate and the module heat dissipation plate are connected through an intermediate welding material or a sintering layer.
5. The power module layout of integrated drive and power generation function circuit according to claim 3, characterized in that: The drive direct-current positive busbar and the drive direct-current negative busbar and the power generation direct-current positive busbar and the power generation direct-current negative busbar are respectively bent towards the module heat dissipation plate.
6. The power module layout for integrated drive and power generation functions circuit according to claim 3, wherein: The drive direct-current positive busbar, the drive direct-current negative busbar, the drive alternating-current three-phase busbar, the power generation direct-current positive busbar, the power generation direct-current negative busbar and the power generation alternating-current three-phase busbar are respectively connected to an external circuit through laser welding or bolt fastening.