A power module of a hybrid power module and a dual motor controller

Abstract

The utility model provides a kind of power module of hybrid power module and double motor controller, and power module includes: heat dissipation plate, first power module and second power module installed on the heat dissipation plate and the circuit board connected with the first power module and the second power module;Wherein, the first power module and the second power module are different packaging type power module, the first power module is suitable for driving motor side, and the second power module is suitable for generator side.The utility model integrates different types, different packaging power module on the same heat dissipation plate, constructs a kind of hybrid power module architecture for double motor system, effectively solves the performance redundancy and cost problem caused by using same type high-cost module in traditional double inverter system or the contradiction that using same type low-performance module leads to driving side performance deficiency.

Description

Technical Field

[0001] This utility model belongs to the field of electric vehicle motor controller technology, specifically relating to a power module of a hybrid power module and a dual-motor controller. Background Technology

[0002] Currently, dual inverter systems generally use the same type of power modules, such as PM6 or TPAK packages. However, in actual applications, there are significant differences in power and performance requirements between the generator side and the drive motor side. For example, the generator side requires about 100kW and has lower performance requirements, while the drive motor side requires 150-200kW and has higher performance requirements. This results in the same module solution causing performance and cost redundancy on the generator side, while it is difficult to meet the high power requirements on the drive motor side, making it impossible to achieve the optimal overall system performance, size, and cost. Utility Model Content

[0003] In view of the shortcomings of the prior art, the purpose of this utility model is to provide a power module and dual motor controller for a hybrid power module, so as to solve the problem that the current dual inverter system generally uses the same type of power module, which leads to the same module solution causing performance and cost redundancy on the generator side, while making it difficult to meet the high power requirements on the drive motor side, and thus failing to achieve the optimal performance, size and cost of the overall system.

[0004] To achieve the above and other related objectives, this utility model proposes a power module for a hybrid power module, comprising:

[0005] A heat sink, a first power module and a second power module mounted on the heat sink, and a circuit board connected to the first power module and the second power module;

[0006] The first power module and the second power module are power modules with different packaging types. The first power module is suitable for the drive motor side, and the second power module is suitable for the generator side.

[0007] In one embodiment of the present invention, the first power module is packaged in a half-bridge package, and the second power module is packaged in a single-tube package.

[0008] In one embodiment of the present invention, the first power module and the second power module are mounted on the same side of the heat sink.

[0009] In one embodiment of the present invention, the first power module and the second power module are fixed on the heat sink by reflow soldering or sintering.

[0010] In one embodiment of the present invention, the height difference between the signal pins of the first power module and the second power module is less than or equal to 1.5 mm.

[0011] In one embodiment of the present invention, both the first power module and the second power module are connected to the power terminals using laser welding technology.

[0012] In one embodiment of the present invention, the first power module and the second power module are welded to opposite sides of the heat sink.

[0013] In one embodiment of the present invention, the heat sink includes a cold plate structure with an internally designed closed water channel and / or a cold plate structure with heat dissipation fins.

[0014] In one embodiment of the present invention, a thermally conductive medium is filled between the bottom surfaces of the first power module and the second power module and the heat sink.

[0015] This utility model also proposes a dual-motor controller, including a power module of a hybrid power module as described in any of the above embodiments, wherein the first power module is connected to the drive motor side circuit and the second power module is connected to the generator side circuit.

[0016] This invention provides a hybrid power module and a dual-motor controller. By integrating power modules of different types and packages on the same heat sink, a hybrid power module architecture for dual-motor systems is constructed. This effectively solves the contradictions in traditional dual-inverter systems, such as performance redundancy and excessive cost caused by using the same type of high-cost modules, or insufficient drive-side performance caused by using the same type of low-performance modules. It has the following beneficial effects:

[0017] This invention heterogeneously integrates low-cost, medium-performance power modules (such as TPAK and MiniPACK packages) suitable for the generator side with high-performance, high-power-density modules (such as PM6, MiniHPD, or DSC packages) suitable for the drive motor side, achieving "on-demand matching and precise configuration". While ensuring high-efficiency output capability on the drive side, it significantly reduces costs and achieves the optimal balance between system-level performance, size, and cost.

[0018] In terms of structure and process, although the two types of power modules have different packaging forms, this utility model achieves common substrate mounting with the heat sink through a unified reflow soldering process. Utilizing the compatibility of PM6 and TPAK packages in pad design and process window, dual-module mounting can be completed in a single reflow soldering operation, significantly simplifying the assembly process and improving production efficiency and product consistency. Simultaneously, the power terminals are connected to the power modules using laser welding technology. This process is applicable to both packages and can be continuously operated at the same workstation, further improving production line integration and manufacturing reliability.

[0019] To ensure stable connection of control signals, this invention features a unified design and precise control of the signal pin heights of the two types of modules. This ensures that the height difference between the top of the signal pins of the PM6 and TPAK modules after installation is less than or equal to 1.5mm, with an optimal equal-height design. This allows for direct connection of two different packaged modules on a single circuit board (PCB) without the need for adapter boards or layered wiring. This not only simplifies the electrical control structure and reduces PCB costs but also improves signal integrity and anti-interference capabilities, making it particularly suitable for harsh environments such as high vibration and high humidity in automotive applications. Attached Figure Description

[0020] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application. It is obvious that the drawings described below are merely some embodiments of this application, and those skilled in the art can obtain other drawings based on these drawings without any inventive effort.

[0021] Figure 1 This is a schematic diagram of the power module of the hybrid power module in one embodiment of the present invention.

[0022] Figure 2 This is an exploded view of the power module of the hybrid power module in one embodiment of the present invention.

[0023] Figure 3 This is a schematic diagram of the power module and heat sink in one embodiment of the present invention.

[0024] Figure 4 This is a schematic diagram of the power terminal connection of the power module in one embodiment of the present invention.

[0025] Figure 5 This is a schematic diagram of the signal pins of the power module in one embodiment of the present invention.

[0026] Figure 6 This is a schematic diagram of the first power module when it is arranged on both sides in one embodiment of the present invention.

[0027] Figure 7 This is a schematic diagram of the second power module when arranged on both sides in one embodiment of the present invention.

[0028] Figure 8 This is a schematic diagram of the heat sink in one embodiment of the present invention.

[0029] Figure 9 This is a schematic diagram of the heat sink in another embodiment of the present invention. Detailed Implementation

[0030] The following specific examples illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification. This utility model can also be implemented or applied through other different specific embodiments. Various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this utility model. In the absence of conflict, the following embodiments and features in the embodiments can be combined with each other.

[0031] It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. The drawings only show the components related to the present invention and are not drawn according to the actual number, shape and size of the components. In actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0032] In the following description, numerous details are explored to provide a more thorough explanation of embodiments of the present invention. However, it will be apparent to those skilled in the art that embodiments of the present invention may be practiced without these specific details. In other embodiments, well-known structures and devices are shown in block diagram form rather than in detail to avoid obscuring embodiments of the present invention.

[0033] Please see Figure 1 , Figure 2 and Figure 3 As shown, in this embodiment, the present invention proposes a power module and dual-motor controller for a hybrid power module to solve the problem that current dual-inverter systems generally use the same type of power module, resulting in performance and cost redundancy on the generator side and difficulty in meeting high power requirements on the drive motor side, thus failing to achieve optimal overall system performance, size, and cost. Specifically, the power module includes a heat sink 100, a first power module 200 and a second power module 300 mounted on the heat sink 100, and a circuit board 400 connected to the first power module 200 and the second power module 300.

[0034] Please see Figure 1 , Figure 2 and Figure 3As shown, in this embodiment, the first power module 200 is suitable for the drive motor side, requiring a high power output of 150–200kW, and has higher requirements for efficiency and thermal management; the second power module 300 is suitable for the generator side, with a working power of approximately 100kW and relatively lower performance requirements. In this embodiment, the first power module 200 and the second power module 300 use power modules of different packaging types. By matching modules of different performance levels to both sides, the optimal balance of overall system performance, size, and cost is achieved.

[0035] Please see Figure 1 , Figure 2 and Figure 3 As shown, for example, the first power module 200 is a power module suitable for the drive motor side, and it adopts a high-performance, high-power-density packaging type. For example, the first power module 200 adopts a half-bridge package, such as a PM6 package. This type of packaged power module has higher current carrying capacity and better heat dissipation performance, which can meet the power requirements of the drive motor side up to 150-200kW, and supports higher conversion efficiency. It can be understood that the half-bridge package integrates the upper and lower power switching transistors of one bridge arm and their anti-parallel diodes in one package, forming a half-bridge circuit.

[0036] Please see Figure 1 , Figure 2 and Figure 3 As shown, the second power module 300 is a power module suitable for the generator side, employing a low-power but cost-effective packaging type. For example, the second power module 300 uses a single-tube package, such as a TPAK package. This type of package typically has lower power density and more relaxed electrical characteristics, offering good reliability and supply stability. It is suitable for generator-side applications where cost is sensitive but performance requirements are not high, meeting the generator-side power demand of approximately 100kW, with relatively low requirements for conversion efficiency. The first power module 200 and the second power module 300 are mounted on the heat sink 100 via reflow soldering or sintering. Their bottoms are in close contact with the heat sink through a thermally conductive medium (such as solder) to achieve efficient heat dissipation. It can be understood that a single-tube package contains only one independent power switching device and its anti-parallel diode within a single package.

[0037] Of course, the power module of the hybrid power module described in this utility model can be flexibly matched with different types and packages of power modules according to the different power levels and performance requirements of the generator side and the drive motor side, so as to achieve the optimal balance of overall system performance, cost and size. For example, the first power module (suitable for the drive motor side, 150-200kW) can be packaged in PM6; the second power module 300 (suitable for the generator side, about 100kW) can be packaged in TPAK, or can be replaced with other high-performance packaged modules, such as full-bridge package, such as MiniHPD package or MiniPACK package. The full-bridge package integrates all 6 power switching transistors and their anti-parallel diodes of the complete three-phase inverter bridge in one package.

[0038] Please see Figure 1 , Figure 2 and Figure 3 As shown, in this embodiment, the first power module 200 and the second power module 300 are fixed to the heat sink 100 by reflow soldering or sintering, and are electrically connected to the circuit board 400. The circuit board 400 not only provides power to the power modules and transmits control signals, but also serves as an interface with external systems, such as a communication interface. In one embodiment, the first power module 200 and the second power module 300 are mounted on the same side of the heat sink 100. This layout facilitates unified heat dissipation design, simplifies the assembly process, and allows the circuit board 400 to complete signal and power connections on the same plane.

[0039] Please see Figure 6 and Figure 7 As shown, in another embodiment, the first power module 200 and the second power module 300 are respectively installed on opposite sides of the heat sink 100. This double-sided layout makes full use of the three-dimensional space of the heat sink 100 and is particularly suitable for application scenarios where the lateral dimensions of the modules are strictly limited.

[0040] Please see Figure 1 , Figure 2 and Figure 3As shown in this embodiment, due to the good compatibility of PM6 and TPAK packages in terms of bottom electrode structure and welding process requirements, the first power module 200 and the second power module 300 can be simultaneously fixed to the heat sink 100 via reflow soldering. Specifically, during assembly, solder paste or solder pads are pre-applied to the mounting area of ​​the heat sink 100. After the first power module 200 and the second power module 300 are mounted in predetermined positions, the entire assembly is placed in a reflow oven for heating. Under high temperature, the solder paste or solder pads melt and fill the interface between the power module base plate and the heat sink, forming a strong metallurgical bond after cooling. This connection method has low contact thermal resistance, which is beneficial for efficient heat conduction from the power module to the heat sink; it has high mechanical strength and can withstand vibration and thermal cycling stress during vehicle operation; it has good long-term reliability and meets the stringent durability requirements of automotive-grade applications. It is understood that because the pad design and process window of PM6 and TPAK packages are similar, they can be connected to the heat sink 100 in the same reflow soldering process, achieving one-time soldering and synchronous curing. This process significantly simplifies the assembly process, reduces production cycle time, avoids the risk of thermal damage caused by multiple welding operations, and reduces equipment investment and labor costs, which is conducive to achieving automated and mass production.

[0041] Please see Figure 2 , Figure 3 and Figure 4 As shown, in this embodiment, both the first power module 200 and the second power module 300 are electrically connected to the power terminal 500 using laser welding. Laser welding uses a high-energy-density laser beam to locally heat and melt the metal material, forming a high-quality solder joint without mechanical contact. This process has advantages such as a small heat-affected zone, low welding deformation, high solder joint strength, and good repeatability. It is particularly suitable for connecting high-current transmission paths, effectively reducing connection resistance and parasitic inductance, and improving power transmission efficiency and system reliability. It is understood that since both the PM6 package and the TPAK packaged power terminal 500 are made of metal (such as copper or plated copper) and have similar requirements for welding accuracy and heat input control, both can be adapted to similar laser welding process parameters. Therefore, in this embodiment, the power terminal 500 connected to the first power module 200 and the second power module 300 can complete the welding operation in the same automated workstation without changing equipment or adjusting the process flow. Leveraging the compatibility of PM6 and TPAK packages in the power terminal 500 connection process—both employing laser welding technology—allows for single-clamp, continuous welding, significantly improving production line integration and operational efficiency. This design not only reduces production downtime due to process changeovers but also enhances product consistency, facilitating efficient manufacturing in multi-variety, small-batch, or flexible production models.

[0042] Please see Figure 2 , Figure 3 and Figure 5 As shown, to ensure stable and reliable electrical connection between circuit board 400 and two different package types of power modules, this embodiment features a unified design and control over the height of the signal pins 600 of the first power module 200 (PM6 package) and the second power module 300 (TPAK package). Specifically, the height difference between the signal pins of the first power module 200 and the second power module 300 after mounting to the heat sink 100 is less than or equal to 1.5mm, preferably an equal-height design. This ensures that high-precision lead frame molds, consistent pin forming processes, and strict assembly process control are used during the module packaging stage to ensure that the tops of the signal pins 600 of the two types of modules are in similar planar positions after mounting. This design allows circuit board 400 to be directly connected to two different packaged power modules simultaneously using a single PCB board without adding an adapter board or layered wiring. In particular, the PM6 package and the TPAK package have a natural high similarity in signal pin structure design, which, after optimization, can fully meet the process requirements of co-board connection. Therefore, the circuit board 400 can adopt a continuous board design, meaning the entire PCB is not cut or separated, and simultaneously covers the signal connection areas of the first power module 200 and the second power module 300. This not only simplifies the wiring structure but also reduces the number of PCB layers and manufacturing costs, while improving the consistency and anti-interference capability of signal transmission. This design effectively avoids problems such as poor contact, cold solder joints, and uneven insertion and extraction force caused by inconsistent heights of the signal pins 600, significantly improving module assembly yield and long-term operational reliability. It is particularly suitable for power electronic systems in harsh automotive environments such as high vibration and high humidity.

[0043] Based on the foregoing embodiments, to adapt to the heat dissipation requirements of different application scenarios, the heat sink 100 can be designed in one or more of the following combinations as needed:

[0044] Please see Figure 8As shown, in a preferred embodiment, the heat sink 100 is internally designed with a closed water channel 101, forming one or more independent and sealed flow channel systems for the introduction of coolant (such as an aqueous ethylene glycol solution). This closed water channel structure is manufactured through precision casting, extrusion molding, or other methods to ensure smooth channel walls with no leakage risk and good mechanical strength and thermal conductivity. The internal water channels can be designed as single-channel or multi-channel layouts: depending on the heat load distribution of the power module, the water channels can be designed as single or multiple parallel / series channels to optimize the coolant flow path and improve heat exchange efficiency; serpentine or U-shaped flow channels can be used to increase the residence time of the coolant within the heat sink, increasing the heat exchange area, suitable for efficient heat dissipation of high-power-density modules. Furthermore, a layered or zoned design can be adopted. For different areas with varying heat generation, the heat sink can be configured with a layered or zoned cooling structure to achieve localized enhanced heat dissipation and avoid hotspot effects caused by heat accumulation.

[0045] Please see Figure 9 As shown, in another preferred embodiment, the heat sink 100 can also be designed with heat dissipation fins 102. The heat dissipation fins are typically arranged on the outer surface of the heat sink to enhance the effect of natural convection or forced air cooling by increasing the surface area, making them suitable for auxiliary heat dissipation or as a supplementary solution to the main liquid cooling system. Of course, the heat sink 100 can also be designed as a composite structure combining closed water channels and heat dissipation fins.

[0046] In one embodiment, a thermally conductive medium is further filled between the first power module 200, the second power module 300 and the heat sink 100 to improve heat conduction efficiency, enhance the heat dissipation efficiency of the first power module 200 and the second power module 300 and improve the heat dissipation effect.

[0047] This invention also provides a dual-motor controller, the core of which includes a power module of the hybrid power module as described in the above embodiments. The dual-motor controller is used in new energy vehicles to simultaneously control the generator-side motor and the main drive motor on the drive motor side. The first power module 200 (e.g., PM6 package) is electrically connected to the drive motor-side circuit to drive the main drive motor, supporting 150–200kW high power output to meet high-efficiency driving requirements. The second power module 300 (e.g., TPAK package) is electrically connected to the generator-side circuit to handle approximately 100kW of power generation or start-stop power, meeting operating conditions that are cost-sensitive and have moderate performance requirements. By using the hybrid power module power module described in this invention as the main power unit, this dual-motor controller significantly reduces the module cost and system complexity on the generator side while ensuring high performance on the drive side, achieving an optimal balance between power density, energy efficiency, and manufacturing cost for the overall controller.

[0048] This utility model also provides a vehicle, particularly a new energy vehicle, including a dual-motor controller as described in the above embodiments. The dual-motor controller includes a power module of the hybrid power module as described in the above embodiments, which will not be repeated here to avoid repetition.

[0049] The above embodiments are merely illustrative of the principles and effects of this utility model and are not intended to limit the scope of this utility model. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this utility model. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this utility model should still be covered by the claims of this utility model.

Claims

1. A power module for a hybrid power module, characterized in that, include: A heat sink, a first power module and a second power module mounted on the heat sink, and a circuit board connected to the first power module and the second power module; The first power module and the second power module are power modules with different packaging types. The first power module is suitable for the drive motor side, and the second power module is suitable for the generator side.

2. The power module of the hybrid power module according to claim 1, characterized in that, The first power module is packaged in a half-bridge package, and the second power module is packaged in a single-transistor package.

3. The power module of the hybrid power module according to claim 2, characterized in that, The first power module and the second power module are mounted on the same side of the heat sink.

4. The power module of the hybrid power module according to claim 3, characterized in that, The first power module and the second power module are fixed to the heat sink by reflow soldering or sintering.

5. The power module of the hybrid power module according to claim 3, characterized in that, The height difference between the signal pins of the first power module and the second power module is less than or equal to 1.5 mm.

6. The power module of the hybrid power module according to claim 3, characterized in that, Both the first power module and the second power module are connected to the power terminals using laser welding technology.

7. The power module of the hybrid power module according to claim 2, characterized in that, The first power module and the second power module are welded to opposite sides of the heat sink.

8. The power module of the hybrid power module according to claim 1, characterized in that, The heat sink includes a cold plate structure with an internally designed closed water channel and / or a cold plate structure with heat dissipation fins.

9. The power module of the hybrid power module according to claim 1, characterized in that, A thermally conductive medium is filled between the bottom surfaces of the first power module and the second power module and the heat sink.

10. A dual-motor controller, characterized in that, A power module including the hybrid power module as described in any one of claims 1 to 9, wherein the first power module is connected to the drive motor side circuit and the second power module is connected to the generator side circuit.

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