A power module, motor controller, electric control assembly and vehicle

Abstract

The application discloses a power module, a motor controller, an electric control assembly and a vehicle, and relates to the field of vehicle motor control equipment. The power module comprises a heat dissipation plate, a driving module for connecting a driving motor and a power generation module for connecting a power generation motor; wherein the driving module and the power generation module share one heat dissipation plate. In the technical scheme, the driving module and the power generation module share one heat dissipation plate, so that the driving module and the power generation module are packaged by using the same heat dissipation plate, the integration of the power module can be improved, the heat dissipation structure design of the power module is simplified, and the miniaturized design of the power module is realized.

Description

[0001] This application claims priority to Chinese Patent Application No. 202520405399.5, filed on March 7, 2025, entitled "A Power Module, Motor Controller, Electronic Control Assembly and Vehicle", the entire contents of which are incorporated herein by reference.

[0002] This application claims priority to Chinese Patent Application No. 202520405222.5, filed on March 7, 2025, entitled "Power Module and Motor Controller, Drive Assembly and Vehicle Including the Therein", the entire contents of which are incorporated herein by reference. Technical Field

[0003] This application relates to the field of vehicle motor control equipment, and more particularly to a power module, a motor controller, an electronic control assembly, and a vehicle. Background Technology

[0004] With the development of the new energy vehicle industry and increasingly fierce market competition, how to make more effective use of the limited space in new energy vehicles has attracted more and more attention.

[0005] Currently, the electronic control assembly of range-extended electric vehicles typically includes components such as a generator motor, a drive motor, a drive motor controller, and a generator motor controller. In existing technologies, the drive power module in the drive motor controller and the generator power module in the generator motor controller each use separate heat sinks. The total size of the two independent heat sinks is large, requiring independent heat dissipation packaging, resulting in low integration and hindering the miniaturization design of the power modules. Utility Model Content

[0006] In view of the above problems, this application provides a power module, a motor controller, an electronic control assembly, and a vehicle to achieve the goal of high integration and miniaturized design of the power module. The specific solution is as follows:

[0007] The first aspect of this application provides a power module, comprising:

[0008] Heat sink;

[0009] A drive module for connecting a drive motor and a generator module for connecting a generator motor;

[0010] The drive module and the power generation module share a single heat sink.

[0011] Optionally, in the power module described above, the drive module includes multiple first sub-power modules, and at least one first sub-power module has an independent first liner, which is disposed on the heat sink.

[0012] Optionally, in the power module described above, the thermal conductivity of the first liner is greater than 27 W / m·K.

[0013] Optionally, in the above power module, the power generation module includes multiple second sub-power modules, at least two of which share the same second liner, which is disposed on the heat sink.

[0014] Optionally, in the above power module, the plurality of second sub-power modules include at least one active switching chip and at least one passive freewheeling chip;

[0015] In the same second sub-power module, the ratio of the total area of ​​the passive freewheeling chip to the total area of ​​the active switching chip satisfies a first ratio, which is greater than or equal to 0.6.

[0016] Optionally, in the power module described above, the thermal conductivity of the second liner is greater than 27 W / m·K.

[0017] Optionally, in the power module described above, the first liner includes an aluminum nitride ceramic plate or a silicon nitride ceramic plate;

[0018] and / or;

[0019] The second liner includes an aluminum nitride ceramic plate or a silicon nitride ceramic plate.

[0020] Optionally, in the above power module, the first sub-power module includes:

[0021] Four first power chips and four second power chips are provided, wherein the first power chips and the second power chips are arranged in pairs. The first power chips include active switching chips and the second power chips include passive freewheeling chips.

[0022] Optionally, in the power module described above, the first liner and the second liner are arranged sequentially on the surface of the heat sink along a first direction; the first direction is parallel to the plane of the heat sink.

[0023] The length of the heat sink along the first direction is 185mm~200mm.

[0024] Optionally, in the power module described above, the first liner and the second liner are arranged sequentially on the surface of the heat sink along a first direction; the first direction is parallel to the plane of the heat sink.

[0025] In the first direction, the size of the second liner is larger than the size of a single first liner, but smaller than the sum of the sizes of all the first liners.

[0026] Optionally, in the above power module, the number of power chips in the second sub-power module is less than the number of power chips in the first sub-power module.

[0027] Optionally, in the above power modules, the power chip area in the first sub-power module is larger than the power chip area in the second sub-power module.

[0028] Optionally, in the power module described above, a coolant flow channel is formed within the heat sink.

[0029] Optionally, in the power module described above, the heat sink has a first surface and a second surface opposite to each other, and both the drive module and the power generation module are disposed on the first surface;

[0030] The power module includes a housing structure disposed on the second surface, and coolant flow channels are formed within the housing structure.

[0031] Optionally, in the power module described above, the heat sink has a first surface and a second surface opposite to each other, and both the drive module and the power generation module are disposed on the first surface;

[0032] The power module also includes a housing structure that connects to the second surface and forms a coolant flow channel with the second surface.

[0033] Optionally, in the power module described above, the housing structure includes a first housing having a first groove;

[0034] The second surface covers the opening of the first groove to form a coolant flow channel with the first groove; the first groove includes a first part corresponding to the position of the drive module and a second part corresponding to the position of the power generation module.

[0035] Optionally, in the power module described above, the first trench is configured as an integral trench.

[0036] Optionally, in the power module described above, the drive module has a plurality of first sub-power modules arranged sequentially along a first direction; the first direction is parallel to the plane where the heat sink is located.

[0037] The coolant flow channel includes at least two flow channel sections corresponding to multiple first sub-power modules. Along the flow direction of the coolant in the coolant flow channel, the depth of each flow channel section decreases sequentially in a second direction, wherein the second direction is perpendicular to the first direction.

[0038] Optionally, in the power module described above, the heat sink has a first surface and a second surface opposite to each other, and the drive module and the power generation module are arranged sequentially along a first direction on the first surface; the second surface includes a plurality of protrusion structures.

[0039] Optionally, in the power module described above, the multiple protrusion structures include a first region corresponding to the drive module and a second region corresponding to the power generation module, wherein the heat dissipation performance of the first region is greater than that of the second region.

[0040] Optionally, in the power module described above, the density of protrusions in the first region is greater than the density of protrusions in the second region.

[0041] A second aspect of this application provides a motor controller, including the power module described above.

[0042] A third aspect of this application provides an electronic control assembly, including the aforementioned motor controller.

[0043] The fourth aspect of this application provides a vehicle including the aforementioned electronic control assembly.

[0044] By means of the above technical solution, in the technical solution of this application, the drive module and the power generation module share the same heat sink for heat dissipation packaging, which can improve the integration of the power module and simplify the heat dissipation structure design of the power module, thereby realizing the miniaturization design of the power module. Attached Figure Description

[0045] To more clearly illustrate the technical solutions in the embodiments of this application or related technologies, the drawings used in the description of the embodiments or prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this application. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0046] The structures, proportions, sizes, etc., shown in the accompanying drawings are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the implementation conditions of this application. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and purposes that this application can produce, should still fall within the scope of the technical content disclosed in this application.

[0047] Figure 1 A topology diagram of a range-extended new energy vehicle provided in this application embodiment;

[0048] Figure 2 This is a three-dimensional schematic diagram of a power module;

[0049] Figure 3 for Figure 2 Exploded view of the power module shown;

[0050] Figure 4 for Figure 2 A schematic diagram of the back of the two heat sinks in the power module shown;

[0051] Figure 5 for Figure 2 A cross-sectional view of the power module shown;

[0052] Figure 6 for Figure 2 An exploded view of the drive module, power generation module, and heat sink in the power module shown.

[0053] Figure 7 for Figure 2 Top view of the power module shown;

[0054] Figure 8 This is a schematic diagram of the structure of a power module provided in an embodiment of this application;

[0055] Figure 9 for Figure 8 Exploded view of the power module shown;

[0056] Figure 10 A top view of a power module provided in an embodiment of this application;

[0057] Figure 11 for Figure 10 The power module shown is viewed in a cross section along P-P'.

[0058] Figure 12 A three-dimensional view of a power module provided in an embodiment of this application;

[0059] Figure 13 for Figure 12 Exploded view of the power module shown;

[0060] Figure 14 A cross-sectional view of a first housing provided in an embodiment of this application;

[0061] Figure 15 A cross-sectional view of a power module provided in an embodiment of this application;

[0062] Figure 16 A cross-sectional view of a power module relative to a drive module provided in an embodiment of this application;

[0063] Figure 17 A schematic diagram of the back structure of a heat sink provided in an embodiment of this application;

[0064] Figure 18 To adopt Figure 17 A cross-sectional view of the heat sink shown;

[0065] Figure 19 A cross-sectional view of a heat sink in the region corresponding to a driving module, provided in an embodiment of this application;

[0066] Figure 20 A simulated camber curve of a heat sink shared by a drive module and a heat dissipation module at different process stages, provided for an embodiment of this application;

[0067] Figure 21An equivalent circuit diagram of a motor controller provided in an embodiment of this application.

[0068] Figure label:

[0069] 1-Heat sink; 2-Drive module; 3-Power generation module; 401a-First sub-power module; 401b-First liner; 402a-Second sub-power module; 402b-Second liner; 5-Power chip; 6-Housing structure; 601-First housing; 602-Second housing; 603-Third housing; 604-Drive side groove; 605-Power generation side groove; 701-First groove; 701a-First part groove; 701b-Second part groove; 701c-Through hole; 702-Second groove; 703-Third groove; 8-Connector; 901-Inlet; 902-Outlet; 10-Protruding structure; 101-First surface; 102- Second surface; 11-Electric drive unit; 12-Drive motor; 13-Inverter; 14-Power battery; 15-Generator controller; 16-Generator; 17-Engine; 18-Range extender; 19-Transition area; 20-Cover plate; 21-Bridging groove; 22-Baffle; 23-Flow channel section; 24-Sub-region; 25-First copper cladding layer; 26-Second copper cladding layer; 27-Backing solder layer; 28-Chip solder layer; 29-Terminal; 301-Upper bridge arm circuit; 302-Lower bridge arm circuit; 303-Positive busbar; 304-Negative busbar; 305-First power chip; 306-Second power chip; 31-Coolant flow channel; X-First direction. Detailed Implementation

[0070] The embodiments of this application will now be clearly and completely described with reference to the accompanying drawings. Those skilled in the art will recognize that, with technological advancements and the emergence of new scenarios, the technical solutions provided in the embodiments of this application are equally applicable to similar technical problems.

[0071] New energy vehicles use electric drive systems (also known as electric drive assemblies or electric control assemblies) to drive the vehicle. Taking range-extended electric vehicles as an example, their topology is as follows: Figure 1 As shown.

[0072] refer to Figure 1 , Figure 1 This is a topology diagram of a range-extended new energy vehicle provided in an embodiment of this application. Figure 1 In the diagram, solid lines represent mechanical connections, and dashed lines represent electrical connections.

[0073] like Figure 1As shown, one of the core components of a range-extended electric vehicle is the range extender 18, which includes a generator motor 16 and a generator motor controller 15 connected thereto; the generator motor 16 is also connected to an engine 17. The generator motor controller 15 is connected to the power battery 14 and the inverter 13. The inverter 13 is connected to the drive motor 12, and the drive motor 12 is connected to the electric drive unit 11. The electric drive unit 11 includes a reducer and a differential.

[0074] In one scenario: when the charge of the power battery 14 drops to a certain level, the range extender 18 is activated, and the engine 17 drives the generator motor 16 to generate electricity. Part of the generated electricity can be used to supply the drive motor 12, and the other part can be used to charge the power battery 14.

[0075] Range-extended electric vehicles (REEVs) have many advantages. For example, in daily urban commuting, REEVs can be driven purely on electricity, achieving zero emissions, reducing exhaust pollution, and meeting environmental protection requirements. They are also more energy-efficient than fuel-powered vehicles, reducing energy consumption and operating costs. REEVs are equipped with an engine 17 as a range extender. When the power battery 14 is low on power, the engine 17 can start generating electricity to provide continuous power to the vehicle, avoiding the range anxiety problem caused by the limited range of pure electric vehicles and making long-distance travel more convenient.

[0076] Furthermore, range-extended electric vehicles (REEVs) offer numerous advantages in terms of driving experience. Essentially, a REEV is a pure electric drive system, where the vehicle's power is entirely provided by the drive motor 12. The engine 17 does not directly drive the vehicle but instead acts as a generator, starting when the battery 14 is low on power to convert fuel into electricity, either to power the drive motor 12 or to charge the battery 14. This pure electric drive method ensures a single and pure power source, consistent with the driving mechanism of pure electric vehicles, fundamentally guaranteeing a comfortable driving experience.

[0077] On the other hand, the characteristics of the drive motor 12 determine that it can output maximum torque instantly. In a range-extended topology vehicle, when the driver presses the accelerator pedal, the drive motor 12 can respond quickly and output powerful power to achieve rapid start and acceleration. This instantaneous power response is far superior to that of traditional fuel vehicles, allowing the driver to feel a more direct and rapid push-back feeling. Whether in the frequent start-stop of urban roads or overtaking operations on highways, it can easily cope with the situation and bring a smooth driving experience.

[0078] On the other hand, during the operation of the range-extended vehicle, since it is always driven by the drive motor 12, there is no power interruption problem when shifting gears as in traditional fuel vehicles. Whether driving at low speed or high speed, the power output remains continuous and stable. Even when the power battery 14 is low on power, during the process of the engine 17 starting to generate electricity, the system can ensure that the power output of the drive motor 12 is not affected through a precise control strategy, and there will be no jerking or power interruption. This provides the driver with a consistently stable driving experience, improving driving comfort and safety.

[0079] Currently, the electronic control assembly of range-extended electric vehicles can include components such as a generator motor 16, a drive motor 12, a generator motor controller 15, and a drive motor controller. Among them, the generator motor controller 15 and the drive motor controller are two independent components, and the generator module in the generator motor controller 15 and the drive module in the drive motor controller each require separate heat sinks.

[0080] In one implementation, to improve system integration, it can be done as follows: Figures 2-7 As shown, the drive module 2 and the power generation module 3 are packaged as a single unit.

[0081] refer to Figures 2-7 , Figure 2 This is a three-dimensional schematic diagram of a power module. Figure 3 for Figure 2 The exploded view of the power module shown. Figure 4 for Figure 2 The diagram shows the back of the two heat sinks in the power module. Figure 5 for Figure 2 The cross-sectional view of the power module shown is as follows. Figure 6 for Figure 2 The exploded view shows the drive module, power generation module, and heat sink in the power module shown. Figure 7 for Figure 2 The diagram shows a top view of the power module. In this configuration, the drive module 2 and the generator module 3 are integrated into a single unit, forming a dual-control structure. The drive module 2 is the core component that converts DC to AC. The generator module 3 is the core component that converts AC to DC.

[0082] In the dual-controller structure, the DC-to-AC conversion function can be achieved through the drive module 2, and the AC-to-DC conversion function can be achieved through the generator module 3. Therefore, the dual-controller structure can improve integration; integrating the power modules of the two motor controllers into a single structure increases integration density and reduces system size. Figures 2-7In the illustrated configuration, the drive module 2 and the power generation module 3 are respectively fixed to the surfaces of different heat sinks 1. Multiple first sub-power modules 401a in the drive module 2 are fixed to the same side surface of their respective heat sinks 1. Multiple second sub-power modules 402a in the power generation module 3 are fixed to the same side surface of their respective heat sinks 1. The two heat sinks 1 cover the surface of the same housing structure 6, forming a sealed coolant flow channel 31 with the housing structure 6.

[0083] Coolant can circulate inside the coolant flow channel 31. The coolant can be any of the following: ethylene glycol aqueous solution, propylene glycol aqueous solution, deionized water, and fluorinated liquid. This application embodiment does not limit the implementation method of the coolant. The flow direction of the coolant in the coolant flow channel 31 can be as follows: Figure 5 As shown by the hollow arrow, the two ends of the coolant flow channel 31 serve as the inlet 901 and the outlet 902, respectively. Optionally, multiple protruding structures 10 can be provided on the surface of the heat sink 1 facing the housing structure 6 to increase the thermal contact area with the coolant and improve heat dissipation efficiency.

[0084] exist Figures 2-7 In the illustrated configuration, the liquid inlet 901 is located at one end near the drive module 2, and the liquid outlet 902 is located at one end of the power generation module 3. In other configurations, the liquid outlet 902 can also be located at one end near the drive module 2, and the liquid inlet 901 can be located at one end of the power generation module 3.

[0085] The following diagram illustrates the process using an example where both drive module 2 and generator module 3 have three sub-modules. In drive module 2, the first sub-power modules 401a are all single-phase half-bridge circuits. Three first sub-power modules 401a can form a three-phase full-bridge circuit, used to connect to the three-phase AC terminals of the drive motor. In generator module 3, the second sub-power modules 402a are all single-phase half-bridge circuits. Three second sub-power modules 402a can form a three-phase full-bridge circuit, used to connect to the three-phase AC terminals of the generator motor. The three first sub-power modules 401a and the three second sub-power modules 402a correspond to six sets of single-phase half-bridge circuits.

[0086] exist Figures 2-7 In the dual-control structure shown, since the three-phase full-bridge circuits of the drive module 2 and the power generation module 3 each have independent heat sinks 1, at least the following problems exist:

[0087] First, both the drive module 2 and the power generation module 3 have open heat sinks 1. If the heat sinks 1 of both modules use the same housing structure 6, grooves need to be formed in the areas of the housing structure 6 corresponding to the two heat sinks 1 to form coolant channels 31 under the drive module 2 and the power generation module 3, respectively. Then, the coolant channels 31 under the drive module 2 and the power generation module 3 are connected in series. Specifically, the housing structure 6 has a drive-side groove 604 in the area corresponding to the drive module 2 and a power generation-side groove 605 in the area corresponding to the power generation module 3. The heat sink 1 under the drive module 2 covers the drive-side groove 604, and the heat sink 1 under the power generation module 3 covers the power generation-side groove 605, thereby forming coolant channels 31 under the drive module 2 and the power generation module 3, respectively. This method requires two independent heat sinks 1, which have a large overall size. The coolant flow path of the series-connected coolant channels 31 is long, resulting in high flow resistance, which is not conducive to the thermal management of the entire vehicle.

[0088] Second, in order to achieve the series connection of the coolant flow channel 31 below the drive module 2 and the power generation module 3, such as Figure 3 and Figure 5 As shown, a transition area 19 needs to be reserved in the middle of the shell structure 6. A baffle 22 is formed in the transition area 19 between the drive-side groove 604 and the power generation groove 605. Below the baffle 22, there is a bridging groove 21 connecting the drive-side groove 604 and the power generation groove 605. The shell structure 6 cannot be formed in one piece using methods commonly used for aluminum die casting. The bridging groove 21 needs to have an opening reserved on the surface of the shell structure 6 away from the heat sink 1. The opening needs to be sealed by welding a cover plate 20. The cover plate 20 is generally welded to the shell structure 6 by friction stir welding. Friction stir welding uses the heat generated by the friction between a high-speed rotating welding tool and two different workpieces to locally melt the workpieces and form a dense solid-phase weld under the pressure of the welding tool. Figures 2-7 As shown, friction stir welding has a relatively complex structure, low reliability, and poor economic efficiency.

[0089] Third, if the friction stir welding structure is to be eliminated, one feasible approach is to have the drive module 2 and the power generation module 3 share the same heat sink 1. Figures 2-7In the illustrated configuration, the three sub-power modules in drive module 2 and power generation module 3 are all independent single-phase half-bridge substrate structures, each with its own substrate. In the arrangement direction of drive module 2 and power generation module 3 (i.e., the first direction X below), the length of the shared heat sink 1 will be relatively large. If drive module 2 and power generation module 3 directly share the same large-size heat sink 1, the power chips 5 in the three first sub-power modules 401a are respectively welded and fixed to the surface of the heat sink 1 using separate substrates, and the power chips 5 in the three second sub-power modules 402a are also respectively welded and fixed to the surface of the heat sink 1 using separate substrates. Due to the influence of the substrates and power chips, in the first direction X (… Figure 7 In the horizontal direction, the dimensions b1 of the first sub-power module 401a and b2 of the second sub-power module 402a are relatively large. The dimensions B1 of the three-phase full-bridge of the drive module 2 and the three-phase full-bridge of the power generation module 3 are also large, resulting in a large heat sink 1 shared by both. Therefore, the simple mechanical integration scheme where the drive module 2 and the power generation module 3 directly share the same large heat sink 1 offers low size benefits, resulting in a large integrated module size, excessive warping deformation of the heat sink 1, and low system reliability.

[0090] To address the aforementioned problems, embodiments of this application provide a power module, comprising:

[0091] Heat sink;

[0092] A drive module for connecting a drive motor and a generator module for connecting a generator motor;

[0093] The drive module and the power generation module share the same heat sink.

[0094] In the technical solution of this application, the drive module and the power generation module are placed on the same surface of the heat sink, and the two share the same heat sink. This allows the drive module and the power generation module to use the same heat sink for heat dissipation and packaging, which can improve the integration of the power module, simplify the heat dissipation structure design of the power module, and reduce the system size.

[0095] Alternatively, the technical solution of this application can also reduce the length of the heat sink by optimizing the size of the power generation module, thereby reducing the system volume and reducing the degree of warping deformation of the heat sink in the power module, thus improving system reliability.

[0096] Alternatively, the technical solution of this application can also adopt an integrally formed shell structure to form an integral coolant flow channel 31 that does not require series connection, thereby avoiding the friction stir welding structure and simplifying the system structure and manufacturing process.

[0097] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0098] refer to Figure 8 and Figure 9 , Figure 8 This is a schematic diagram of the structure of a power module provided in an embodiment of this application. Figure 9 for Figure 8 The exploded view of the power module shown shows that the power module includes:

[0099] Heat sink 1;

[0100] The drive module 2 is used to connect the drive motor and the generator module 3 is used to connect the generator motor;

[0101] The drive module 2 and the power generation module 3 are disposed on the same side surface of the heat sink 1.

[0102] exist Figure 8 In the illustrated configuration, the drive module 2 and the power generation module 3 are mounted on the same surface of the heat sink 1, which allows the drive module 2 and the power generation module 3 to be heat-dissipated and packaged using the same heat sink 1. This improves the integration of the power module, simplifies the heat dissipation structure design of the power module, and reduces the system size.

[0103] If the drive module 2 and the power generation module 3 are respectively mounted on separate heat sinks 1, such as Figure 7 As shown, the right end of the heat sink 1 containing the drive module 2 needs to extend beyond the right side of the drive module 2 by a predetermined distance to allow for welding allowance between the drive module 2 and the corresponding heat sink 1, preventing the drive module 2 from exceeding the edge of the heat sink 1. Similarly, the left end of the heat sink 1 containing the power generation module 3 needs to extend beyond the left side of the power generation module 3 by a predetermined distance to allow for welding allowance between the power generation module 3 and the corresponding heat sink 1, preventing the power generation module 3 from exceeding the edge of the heat sink 1. Furthermore, a gap for welding is also provided between the two heat sinks 1.

[0104] and Figure 8 In the illustrated configuration, the drive module 2 and the power generation module 3 are mounted on the same surface of the heat sink 1. A predetermined distance can be reserved between the drive module 2 and the power generation module 3 on the same heat sink 1 to allow for welding allowance between them. Figure 7 The method shown can save the aforementioned set distance and gap, thereby reducing the overall size of the heat sink 1 in the first direction X, which can improve integration and reduce system size.

[0105] Based on other embodiments, in one embodiment of this application, the drive module 2 includes a plurality of first sub-power modules 401a, at least one of which has an independent first liner 401b, and the first liner 401b is disposed on the surface of the heat sink 1. Optionally, in one embodiment, it can be as follows: Figure 8 As shown, each of the first sub-power modules 401a in the drive module 2 is mounted on the surface of the heat sink 1 via a first liner 401b.

[0106] Based on other embodiments, in one embodiment of this application, the power generation module 3 includes a plurality of second sub-power modules 402a, and at least two second sub-power modules 402a share the same second liner 402b. Optionally, in one embodiment, it can be as follows: Figure 8 As shown, each of the second sub-power modules 402a in the power generation module 3 is mounted on the surface of the heat sink 1 based on the same second liner 402b.

[0107] Optionally, in the power generation module 3, the plurality of second sub-power modules 402a include at least one active switching chip and at least one passive freewheeling chip. Both the active switching chip and the passive freewheeling chip are power chips. The active switching chip can be an IGBT. The passive freewheeling chip can be an FRD (Fast Recovery Diode).

[0108] Optionally, in the power generation module 3, each second sub-power module 402a includes at least one active switching chip and at least one passive freewheeling chip.

[0109] Currently, the area of ​​active switching chips on the market is twice that of passive freewheeling chips. This means that IGBTs are much larger than diodes, resulting in relatively low power generation efficiency. To maximize the utilization of the area of ​​both active switching and passive freewheeling chips under the same current demand and avoid chip waste, the area of ​​the active switching chip is locked once the current demand is confirmed. Considering both cost and volume, maximizing the utilization of the passive freewheeling chip area reduces losses in power generation module 3, optimizes power generation efficiency, and improves driving range. To address this issue, optionally, in the same second sub-power module 402a, the ratio of the total area of ​​the passive freewheeling chip to the total area of ​​the active switching chip satisfies a first ratio, which is greater than or equal to 0.6. By optimizing this ratio, the total area of ​​the active switching chip and the passive freewheeling chip is significantly reduced. Correspondingly, with the reduction in the total chip area, the total number of chips can also be reduced. Optionally, such as... Figure 8As shown, the number of power chips 5 in the power generation module 3 can be reduced from 36 in the conventional scheme to 12. These power chips 5 include active switching chips and passive freewheeling chips, meaning the total number of active switching chips and passive freewheeling chips in the power generation module 3 is reduced from 36 to 12. This allows the power generation module 3 to achieve high power generation efficiency even when integrated onto a smaller area of ​​the second substrate 402b. Furthermore, the first ratio can be set to be greater than or equal to 1, less than or equal to 1.2, or less than or equal to 2. This allows for a good balance between the power generation efficiency and chip area of ​​the power generation module 3, minimizing the required heat dissipation area while ensuring output current capability and power generation efficiency.

[0110] Optionally, the drive module 2 may include three first sub-power modules 401a, each connected to one phase AC terminal of the drive motor; the generator module 3 may include three second sub-power modules 402a, each connected to one phase AC terminal of the generator motor. In other embodiments, the number of first sub-power modules 401a in the drive module 2 is not limited to three, and the number of second sub-power modules 402a in the generator module 3 is not limited to three. The number of first sub-power modules 401a and second sub-power modules 402a can be set according to the number and type of the adapted motors. This application does not limit the number of both.

[0111] In one embodiment, the first sub-power module 401a may include eight power chips 5, of which four are first power chips and the other four are second power chips. The first and second power chips are arranged in pairs, with the first power chip including an active switching chip and the second power chip including a passive freewheeling chip.

[0112] The drive module 2 is used to connect to the drive motor to control its operating state. The drive motor requires precise control of its output torque and speed to meet the vehicle's driving needs under different operating conditions. In this embodiment, each first sub-power module 401a in the drive module 2 is mounted on the surface of the heat sink 1 using a separate first substrate 401b. This allows for accurate and precise control of the power chip 5 in each first sub-power module 401a, thereby more accurately controlling the amplitude, phase, and frequency of the drive motor's current. This ensures that the torque and speed output by the drive motor accurately respond to operating commands and the requirements of the vehicle control system.

[0113] The power generation module 3 is used to connect to the generator motor to control its operating state. The main function of the generator motor is to convert mechanical energy into electrical energy to charge the power battery. In this process, energy conversion efficiency is paramount, aiming to convert as much mechanical energy as possible into electrical energy and store it in the power battery. In this embodiment, each second sub-power module 402a in the power generation module 3 is mounted on the surface of the heat sink 1 based on the same second substrate 402b. This reduces costs and increases integration while maintaining certain performance, without significantly impacting energy conversion efficiency.

[0114] In addition, compared with the drive motor, the operating current characteristics of the generator motor are relatively simple. During the power generation process, the AC power is converted into DC power through the generator module 3. The frequency and amplitude of the current change are relatively stable. It does not require complex control and regulation of the current as the drive motor. Therefore, the basic control requirements of the generator motor can be met by all the second sub-power modules 402a in the generator module 3 sharing the same second liner 402b.

[0115] This application embodiment can, at least by optimizing the size of the power generation module 3, allow all second sub-power modules 402a to share the same second liner 402b, thereby reducing the size of the power generation module 3 in the first direction X, and consequently reducing the length of the heat sink 1 in the first direction X. This reduces the system volume and the degree of warpage deformation of the heat sink 1 in the power module, thus improving system reliability. Furthermore, the reduced size of the heat sink 1 in the first direction X shortens the flow path of the coolant inside the power module, reducing flow resistance and simplifying the structural design of the housing structure 6 used to form the coolant flow channel 31.

[0116] In conventional power modules, drive module 2 and power generation module 3 typically use alumina ceramic plates as backing plates. However, the thermal conductivity of alumina (Al2O3) ceramic plates is approximately 27 W / m·K, which is relatively poor and affects the heat dissipation efficiency of drive module 2 and power generation module 3.

[0117] In one embodiment, the first liner 401b has a thermal conductivity greater than 27 W / m·K, thereby improving the heat dissipation performance of the drive module 2. Optionally, the first liner 401b can be a silicon nitride ceramic plate with a thermal conductivity greater than 27 W / m·K. Compared to alumina ceramic plates, silicon nitride ceramic plates have a higher thermal conductivity.

[0118] In the first sub-power module 401a of the drive module 2, the first substrate 401b uses a high thermal conductivity substrate 401b, replacing the conventional alumina ceramic plate with a silicon nitride ceramic plate. The area of ​​a single IGBT and a single FRD in the first sub-power module 401a remains unchanged. Principle: Temperature T = Dissipation P * Thermal Resistance R. With a constant temperature T, improved heat dissipation material reduces thermal resistance R, resulting in a smaller chip area and an increased P. Due to the reduced chip area, correspondingly, without changing the chip area of ​​a single IGBT and a single FRD, the number of power chips 5 in the drive module 2 will decrease accordingly. Specifically, optionally, such as... Figure 8 As shown, the number of power chips 5 in the driver module 2 can be reduced from 36 in the conventional scheme to 24, which greatly reduces the chip area of ​​the driver module 2.

[0119] Optionally, the thermal conductivity of the second liner 402b is greater than 27 W / m·K, so that the second liner 402b has a large thermal conductivity, thereby improving the heat dissipation performance of the power generation module 3.

[0120] In one embodiment of this application, based on other implementations, both the first liner 401b and the second liner 402b are ceramic plates, and the thermal conductivity of the ceramic plates is greater than 27 W / m·K. Therefore, both the first liner 401b and the second liner 402b have high thermal conductivity and good thermal conductivity performance, which allows the heat in the drive module 2 and the power generation module 3 to be quickly conducted to areas far away from the power chip 5 in the power submodule, thereby improving the heat dissipation efficiency of the drive module 2 and the power generation module 3.

[0121] Optionally, in this embodiment, the ceramic plate used for the first liner 401b can be an aluminum nitride ceramic plate (AlN) or a silicon nitride (Si3N4) ceramic plate.

[0122] Optionally, in this embodiment, the ceramic plate used for the second liner 402b can be an aluminum nitride ceramic plate (AlN) or a silicon nitride (Si3N4) ceramic plate.

[0123] The thermal conductivity of Si3N4 is about three times that of Al2O3, while the thermal conductivity of AlN can reach more than seven times that of Al2O3. Both of these materials have high thermal conductivity, which can significantly improve the heat dissipation efficiency of the drive module 2 and the power generation module 3 compared to the solution using Al2O3 ceramic plates.

[0124] In this embodiment, since both the first substrate 401b and the second substrate 402b are ceramic plates with high thermal conductivity, better heat dissipation can be achieved for the drive module 2 and the power generation module 3. This allows the performance of the power chip 5 to be fully utilized, and the size of the power chip 5 can be further reduced. When the drive module 2 and the power generation module 3 use smaller power chips, the need for improved heat dissipation performance due to the reduction in chip size can be effectively met. Therefore, this embodiment allows the drive module 2 and the power generation module 3 to use smaller power chips 5, reducing the size of the drive module 2 and the power generation module 3, thereby reducing the size of the heat sink 1 shared by them, and further reducing the volume of the power module.

[0125] refer to Figure 10 , Figure 10 This is a top view of a power module provided in an embodiment of this application. Based on other embodiments, in one embodiment of this application, the power module is as follows: Figure 10 As shown, the drive module 2 and the power generation module 3 are arranged sequentially on the surface of the heat sink 1 along the first direction X; the first direction X is parallel to the plane where the heat sink 1 is located; wherein, in the first direction X, the size B1' of the drive module 2 is larger than the size B2' of the power generation module 3, which can reduce the overall size B of the heat sink 1.

[0126] Optionally, in the drive module 2, multiple first sub-power modules 401a are arranged sequentially along the first direction X; in the power generation module 3, multiple second sub-power modules 402a are arranged sequentially along the first direction X.

[0127] In conventional methods, such as Figure 7 As shown, if both drive module 2 and power generation module 3 have three sub-power modules, and each sub-power module uses a separate liner, a total of six independent liners are required. The dimensional differences between the liners in the first direction X are small, i.e., the difference between b1 and b2 is small, and the difference between B1 and B2 is small. Figure 10In the illustrated configuration, each second sub-power module 402a in the power generation module 3 can share the same second substrate 402b to reduce the size b2' of each second sub-power module 402a and the overall size B2' of the power generation module 3. This allows b2' to be smaller than b1' with a significant difference between them, resulting in B2' being smaller than B1', thereby reducing the overall size B of the heat sink 1. In this embodiment, at least by using a first substrate 401b with high thermal conductivity, the heat dissipation efficiency of the drive module 2 can be improved, thereby reducing the size of the power chip 5 in the first sub-power module 401a. This reduces the size b1' of the first sub-power module 401a, making b1' < b1, and further reduces the overall size B1' of the drive module 2, making B1' < B1. Furthermore, in this embodiment, by employing a second substrate 402b with high thermal conductivity, the heat dissipation efficiency of the power generation module 3 can be improved, thereby reducing the size of the power chip 5 in the second sub-power module 402a. This reduces the size b2' of the second sub-power module 402a, and consequently reduces the overall size B2' of the power generation module 3. Alternatively, all second sub-power modules 402a can share the same second substrate 402b to further reduce the overall size B2' of the power generation module 3, ensuring that b2' < b2, and thus B2' < B2. Therefore, this embodiment can reduce the overall size B of the heat sink 1, ensuring that B < B1 + B2 + C. C is... Figure 7 The width of the gap between the two heat sinks 1.

[0128] The size of the second liner 402b is equivalent to the size B2' of the power generation module 3. The size B2' of the second liner 402b is larger than the size b1' of the first liner 401b, so as to ensure that the second liner 402b has enough space to carry multiple second sub-power modules 402a to meet the basic control requirements of the generator motor.

[0129] In this embodiment, by adopting a high thermal conductivity liner and an integrated liner design for each of the second sub-power modules 402a in the power generation module 3, the size of the heat sink 1 shared by the drive module 2 and the power generation module 3 in the first direction X can be effectively reduced. The size reduction of B relative to B1+B2+C can exceed one-third, thus achieving an effective reduction in the size of the heat sink 1 shared by the drive module 2 and the power generation module 3.

[0130] If each first sub-power module 401a and each second sub-power module 402a uses a separate substrate, simply... Figure 7 In the illustrated configuration, the two heat sinks 1 are replaced by a single large heat sink 1. The length of the single large heat sink 1 in the first direction X is approximately B1+B2, and this length is at least 200mm.

[0131] On the surface of the heat sink 1, a first liner 401b and a second liner 402b are arranged sequentially along a first direction X. In the first direction X, the size of the second liner 402b is larger than the size of a single first liner 401b, but smaller than the sum of the sizes of all the first liners 401b.

[0132] Based on other embodiments, in one embodiment of this application, the length of the heat sink 1 in the first direction X is 185mm~200mm, that is, the overall size B of the heat sink 1 is in the range of 185mm~200mm. As described above, the embodiments of this application can at least reduce the size b2' of each second sub-power module 402a in the power generation module 3 and the overall size B2' of the power generation module 3 by having each second sub-power module 402a in the power generation module 3 share the same second liner 402b, thereby achieving the purpose of reducing the length of the heat sink 1 shared by the power generation module 3 and the drive module 2 in the first direction X, so that the length of the heat sink 1 shared by the power generation module 3 and the drive module 2 does not exceed 200mm, thereby avoiding problems such as excessive warping deformation and low application reliability caused by the excessive length of the heat sink 1 shared by the two.

[0133] Optionally, the width of the heat sink 1 shared by the power generation module 3 and the drive module 2 can be 85mm to 100mm. In one embodiment, the size of the shared heat sink 1 can be 189mm × 92mm. The size of the shared heat sink 1 can be adjusted as needed.

[0134] refer to Figure 11 , Figure 11 for Figure 10 The diagram shows a cross-sectional view of the power module along line P-P'. The first sub-power module 401a includes a first substrate 401b. The surface of the first substrate 401b facing the heat sink 1 has a first copper plating layer 25, and the surface of the first substrate 401b facing away from the heat sink 1 has a second copper plating layer 26. The side of the first sub-power module 401a with the first copper plating layer 25 can be fixed to the surface of the heat sink 1 via a substrate solder layer 27. The power chip 5 can be soldered and fixed to the surface of the first sub-power module 401a with the second copper plating layer 26 via a chip solder layer 28. The side of the first sub-power module 401a with the second copper plating layer 26 also has a terminal 29 for connecting to external circuitry. Each first sub-power module 401a in the drive module 2 has an independent first substrate 401b and an independent surface copper plating layer.

[0135] and Figure 11The first sub-power module 401a shown has the same layer structure. In the second sub-power module 402a, the upper and lower surfaces of the second substrate 402b are also provided with copper plating layers. The copper plating layer on the lower surface of the second substrate 402b is soldered and fixed to the heat sink 1 through a substrate solder layer. The power chip 5 is soldered and fixed to the copper plating layer on the upper surface through a chip solder layer. The upper surface of the second substrate 402b is also provided with terminals for connecting external circuits. In the power generation module 3, each second sub-power module 402a shares the same second substrate 402b and the copper plating layers on the upper and lower surfaces.

[0136] In this embodiment, both the first substrate 401b and the second substrate 402b are DBC (Direct Bonded Copper) substrates, including ceramic plates, with copper-clad layers on the upper and lower surfaces respectively. The copper-clad layer on the upper surface is used for interconnection between power chips 5 and for designing circuit traces to form power loops, while the copper-clad layer on the lower surface is used for soldering and heat conduction.

[0137] Based on other implementations, in one embodiment of this application, both the first sub-power module 401a and the second sub-power module 402a include a plurality of power chips 5; wherein, the number of power chips 5 in the second sub-power module 402a is less than the number of power chips 5 in the first sub-power module 401a.

[0138] As described above, since the control requirements of the power generation module 3 are relatively low, compared with the drive module 2, the power generation module 3 can use fewer power chips 5, thereby further reducing the size b2' of the second sub-power module 402a, further reducing the overall size B2' of the power generation module 3, and reducing the overall size B of the heat sink 1.

[0139] In the embodiments of this application, such as Figure 8 As shown, the number of power chips 5 in the power generation module 3 can be reduced from 36 in the conventional scheme to 12, and the number of power chips 5 in the drive module 2 can be reduced from 36 in the conventional scheme to 24.

[0140] Optionally, the area of ​​the power chip in the first sub-power module 401a is larger than the area of ​​the power chip in the second sub-power module 402a. In this configuration, the total area of ​​all power chips 5 in the first sub-power module 401a is greater than the total area of ​​all power chips 5 in the second sub-power module 402a, which allows the drive module 2 to have higher control performance.

[0141] In one approach, to further improve heat dissipation performance, the heat sink 1 can be provided with coolant channels to improve heat dissipation performance through coolant in the coolant channels.

[0142] In one embodiment, the heat sink 1 has a first surface 101 and a second surface 102 facing each other. Both the drive module 2 and the power generation module 3 are disposed on the first surface 101. The power module also includes a housing structure disposed on the second surface 102, within which a coolant flow channel is formed. In this embodiment, the housing structure can be a tubular structure, a cylindrical structure, etc., and the sidewalls of the housing structure are in thermal contact with the second surface. A coolant flow channel can be formed independently through the housing structure.

[0143] refer to Figure 12 and Figure 13 , Figure 12 This application provides a three-dimensional view of a power module according to an embodiment. Figure 13 for Figure 12 An exploded view of the power module is shown. In one embodiment of this application, based on other implementations, such as... Figure 12 and Figure 13 As shown, the heat sink 1 has a first surface 101 and a second surface 102 facing each other. The drive module 2 and the power generation module 3 are both disposed on the first surface 101. The power module also includes a housing structure 6, which is connected to the second surface 102 and forms a coolant flow channel with the second surface 102. In this configuration, the housing structure 6 has grooves, and the second surface needs to cover the grooves in the housing structure 6 to form the coolant flow channel.

[0144] like Figure 12 and Figure 13 As shown, the shell structure 6 covers the second surface 102 and forms a coolant flow channel 31 with the second surface 102; wherein, the drive module 2 and the power generation module 3 are both located above the coolant flow channel 31.

[0145] Optionally, the housing structure 6 can be an aluminum press assembly. The housing structure 6 can form a coolant flow channel 31 with the heat sink 1 to facilitate the circulation of coolant.

[0146] The heat sink 1 shared by the drive module 2 and the power generation module 3 can form a coolant flow channel 31 with the housing structure 6 to achieve liquid cooling. In this case, the heat sink 1 can serve as an integrated liquid cooling plate for the drive module 2 and the power generation module 3 to improve the module's heat dissipation efficiency.

[0147] exist Figure 12 and Figure 13In the illustrated configuration, the power module can form a closed coolant channel 31 with the heat sink 1 through the housing structure 6. Based on the fact that the coolant channel 31 can circulate coolant, the low-temperature coolant enters from the inlet 901 of the coolant channel 31 and completes heat exchange with the drive module 2 and the power generation module 3 above. The high-temperature coolant can flow out from the outlet 902 of the coolant channel 31, thereby achieving active liquid cooling. Compared with the conventional gas environment heat exchange cooling method, it can significantly improve the heat dissipation efficiency of the drive module 2 and the power generation module 3.

[0148] In one embodiment of this application, such as Figure 12 and Figure 13 As shown, the housing structure 6 includes a first housing 601 with a first groove 701; wherein, a second surface 102 covers the opening of the first groove 701 to form a coolant flow channel 31 with the first groove 701; the drive module 2 and the power generation module 3 are both located above the sealed first groove 701. In this configuration, the first housing 601 is an integrally formed structure, and the coolant flow channel 31 can be formed below the drive module 2 and the power generation module 3 through the same first housing 601. The housing structure 6 of the power module has a simple design and high integration.

[0149] Optionally, such as Figure 13 As shown, the first trench 701 has a first part trench 701a opposite to the drive module 2 and a second part trench 701b opposite to the power generation module 3; wherein, the first part trench 701a and the second part trench 701b are integrally formed structures, and the two are different parts of the same first trench 701. In this way, the first trench 701 is configured as an integral trench. Specifically, the integral trench can avoid the use of bridging structures formed by friction stir welding, thereby simplifying the system structure and manufacturing process.

[0150] exist Figure 3 and Figure 5 As described above, since the drive module 2 and the power generation module 3 each have independent heat sinks 1 and there is a gap between the two heat sinks 1, in order for the two heat sinks 1 to be able to seal with the shell structure 6 below at the gap position, a baffle 22 needs to be set in the shell structure 6, and a bridging groove 21 needs to be set below the baffle 22. This results in the need to weld and fix the cover plate 20 to the opening of the bridging groove 21 on the back of the shell structure 6 by friction stir welding.

[0151] and Figure 12 and Figure 13 In the illustrated configuration, since the drive module 2 and the power generation module 3 use the same heat sink 1, a coolant flow channel 31 can be formed within the surface of the first housing 601 based on the integrally formed first groove 701a and second groove 701b, eliminating the need for additional cooling channels. Figure 13The position indicated by the dashed line is reserved as follows Figure 3 and Figure 5 The transition area 19 shown forms a baffle 22, which can directly form a coolant flow channel 31 without the need for bridging grooves 21. Therefore, this method can use a one-piece molded shell structure 6 to form an integral coolant flow channel 31 without series connection, thereby avoiding friction stir welding structure and simplifying system structure and manufacturing process.

[0152] refer to Figure 14 , Figure 14 This is a cross-sectional view of a first housing provided in an embodiment of this application. Based on other embodiments, Figure 14 In the illustrated configuration, the first housing 601 has a first trench 701 with a first part trench 701a opposite to the drive module 2 and a second part trench 701b opposite to the power generation module 3; wherein, a retaining wall 22 is provided between the first part trench 701a and the second part trench 701b, and the retaining wall 22 has a through hole 701c connecting the first part trench 701a and the second part trench 701b.

[0153] The through hole 701c penetrates the retaining wall 22 along the first direction X. Therefore, there is no need to set the bridging groove 21 below the retaining wall 22. Thus, the back of the first housing 601 does not need to be provided with the opening of the bridging groove 21, and the cover plate 20 does not need to be welded by friction stir welding, thereby eliminating the structure of friction stir welding.

[0154] refer to Figure 15 , Figure 15 This is a cross-sectional view of a power module provided in an embodiment of this application. Based on other implementation methods, Figure 15 In the illustrated configuration, the coolant flow channel 31 includes a first flow channel and a second flow channel; the housing structure 6 includes a second housing 602 having a second groove 702 and a third housing 603 having a third groove 703; wherein, the second surface 102 covers the opening of the second groove 702 to seal the second groove 702 to form the first flow channel, and covers the opening of the third groove 703 to seal the third groove 703 to form the second flow channel; the first flow channel and the second flow channel are connected by a connector 8; the drive module 2 is located above the second groove 702; the power generation module 3 is located above the third groove 703.

[0155] exist Figure 15 In the illustrated configuration, the drive module 2 and the power generation module 3 are respectively provided with a second housing 602 and a third housing 603. Compared with the scheme that uses an integrated first housing 601, this scheme can use two smaller housings. The second housing 602 and the third housing 603, relative to the integrated first housing 601, can reduce the stress applied by the housing structure 6 to the heat sink 1 shared by the drive module 2 and the power generation module 3.

[0156] Based on other embodiments, in one embodiment of this application, the housing structure 6 has a first end face and a second end face opposite to each other in a first direction X. The first end face is located on the side of the drive module 2 away from the power generation module 3, and the second end face is located on the side of the power generation module 3 away from the drive module 2. The coolant flow channel 31 has an inlet 901 located on the first end face and an outlet 902 located on the second end face. In this configuration, the inlet 901 is located on the first end face and the outlet 902 is located on the second end face, so that the coolant flows sequentially below the drive module 2 and below the power generation module 3. This allows the low-temperature coolant to flow first below the drive module 2 and then below the power generation module 3, achieving better heat dissipation for the drive module 2, which has higher temperature requirements.

[0157] In other embodiments, the inlet 901 can be located on the second end face and the outlet 902 can be located on the first end face. In this case, the coolant flows sequentially under the power generation module 3 and under the drive module 2.

[0158] The drive module 2 has a plurality of first sub-power modules 401a arranged sequentially along a first direction X. The coolant flow channel 31 includes at least two flow channel sections corresponding to the plurality of first sub-power modules 401a. Along the flow direction of the coolant within the coolant flow channel 31, the depth of each flow channel section decreases sequentially in a second direction, which is perpendicular to the plane of the heat sink 1. One flow channel section may correspond to one or at least two first sub-power modules 401a. (Reference) Figure 16 , Figure 16 This application provides a cross-sectional view of a power module in a region relative to the drive module, based on other implementation methods. Figure 16 In the manner shown, the coolant flow channel 31 includes flow channel sections 23 that are one-to-one with the first sub-power module 401a. Along the flow direction of the coolant in the coolant flow channel 31, the depth of each flow channel section 23 decreases sequentially.

[0159] like Figure 16As shown, if the coolant flow direction is the first direction X, that is, the coolant inlet 901 is close to the drive module 2 and the outlet 902 is close to the power generation module 3, the depth of each flow channel section 23 decreases sequentially along the first direction X. In this method, the coolant flows from the deeper flow channel section 23 to the shallower flow channel section 23. In the deeper flow channel section 23, a portion of the low-temperature coolant can not participate or participate to a lesser extent in heat exchange with the upper first sub-power module 401a, thereby better heat exchange for the lower-depth flow channel section 23 above the first sub-power module 401a. This ensures that the first sub-power modules 401a with different lateral distances from the inlet 901 have the same or approximately the same heat dissipation effect, and that the first sub-power modules 401a at different positions have the same or similar operating temperatures, thus ensuring the consistency of the operating state of each first sub-power module 401a and guaranteeing the reliability and stability of the drive module 2.

[0160] Optionally, the groove angle of the steps formed at the bottom of the flow channel sections 23 at different depths can be as follows: Figure 16 The right-angled structure shown.

[0161] In other methods, to reduce the flow resistance of the coolant and prevent the accumulation of dirt at the corners of the stepped grooves formed at the bottom of the flow channel sections 23 at different depths, the corners of the stepped grooves formed at the bottom of the flow channel sections 23 at different depths are rounded. The rounded corner structure can also avoid stress concentration at the bottom of the groove corners. In contrast, when the coolant impacts at a certain flow rate, the right-angle structure may lead to fatigue of the material near the right-angle structure under long-term action, resulting in cracks and other damage. The rounded corner structure can disperse stress, making the structure between different flow channel sections 23 more stable and durable.

[0162] In other methods, if the flow direction of the coolant is the opposite of the first direction X, that is, the coolant inlet 901 is close to the power generation module 3 and the outlet 902 is close to the drive module 2, then the depth of each flow channel section 23 decreases sequentially in the opposite direction of the first direction X.

[0163] In one embodiment of this application, based on other implementation methods, such as Figure 14 and Figure 15 As shown, the coolant flow channel 31 has an inlet 901 at one end and an outlet 902 at the other end. The depths of both the inlet 901 and the outlet 902 are greater than the depth of the coolant flow channel 31, and the bottoms of both the inlet 901 and the outlet 902 are rounded. The rounded corners at the inlet 901 and the outlet 902 reduce coolant flow resistance, prevent stress concentration at the bottom of the channel corners, and reduce dirt accumulation.

[0164] refer to Figure 17 and Figure 18 , Figure 17 This is a schematic diagram of the back structure of a heat sink provided in an embodiment of this application. Figure 18 To adopt Figure 17 A cross-sectional view of the heat sink is shown. Based on other embodiments, Figure 17 and Figure 18 In the illustrated configuration, the second surface 102 includes a plurality of protrusions 10. By providing a plurality of protrusions 10 on the second surface 102, the heat dissipation area can be increased, the heat exchange rate between the heat sink 1 and the coolant can be increased, and the heat dissipation efficiency can be improved.

[0165] The multiple protruding structures 10 include a first region corresponding to the drive module 2 and a second region corresponding to the power generation module 3. The heat dissipation performance of the first region is greater than that of the second region, so that the drive module 2, which has high control requirements, has better heat dissipation performance, thus ensuring the high heat dissipation performance requirements of the drive module 2.

[0166] Optionally, the density of protrusions in the first region is greater than that in the second region, which makes the heat dissipation performance of the first region greater than that of the second region.

[0167] In other ways, the height, surface area, and size of the raised structures in the first and second regions can be differentiated to make the heat dissipation performance of the first region greater than that of the second region.

[0168] Optionally, the protrusion structure 10 can be Figure 17 The elliptical cylinder shown has its major axis parallel to the flow direction of the coolant, i.e., parallel to the first direction X. This reduces the flow resistance of the protrusion structure 10 to the coolant. It is easy to see that the graphic structure of the protrusion structure 10 can be set according to requirements; the protrusion structure 10 can also be a cylinder, cone, triangular prism, or square prism, etc.

[0169] In one implementation, such as Figure 17 As shown, the protrusions 10 in the second surface 102 can be uniformly distributed to facilitate the fabrication process of the heat sink 1.

[0170] refer to Figure 19 , Figure 19 This is a cross-sectional view of a heat sink in the region corresponding to a driving module, as described above. In the driving module 2, the first sub-power modules 401a are arranged sequentially along the first direction X. The second surface 102 includes sub-regions 24 that are one-to-one with the first sub-power modules 401a. Along the first direction X, the density of the protrusion structures 10 in each sub-region 24 gradually increases or decreases. Figure 19The diagram illustrates the example of how the density of the protrusions 10 in each sub-region 24 gradually increases along the first direction X.

[0171] A housing structure 6 can be installed below the heat sink 1, forming a coolant flow channel 31 based on the housing structure 6 and the heat sink 1. If the density of the protruding structures 10 in each sub-region 24 gradually increases along the first direction X, the coolant flows in the first direction X. If the density of the protruding structures 10 in each sub-region 24 gradually decreases along the first direction X, the coolant flows in the opposite direction to the first direction X. This method allows sub-regions 24 farther from the coolant inlet 901 to have a higher density of protruding structures 10, thus ensuring a more consistent cooling effect for sub-regions 24 at different distances from the inlet 901. This improves the consistency of heat dissipation of the first sub-power module 401a at different locations, ensuring the reliability and stability of the drive module 2.

[0172] refer to Figure 20 , Figure 20 This application provides a simulation camber curve of a heat sink shared by a drive module and a heat dissipation module at different process stages. Before the heat sink 1 is welded and fixed to the drive module 2 and the power generation module 3 (corresponding to the raw material stage on the horizontal axis), its warpage is relatively large, and the vertical axis corresponds to a large simulation camber value. After the backing plates of the drive module 2 and the power generation module 3 are welded and fixed to the surface of the heat sink 1, its warpage decreases to a certain extent. After being fastened to the housing structure 6 and the frame of the power module with screws, its simulation camber value can be reduced to 0. In the subsequent silicone curing and high-temperature testing stages, the simulation camber value can be well maintained at 0. It can be seen that after the power module of the technical solution of this application is packaged, the heat sink 1 has good flatness, which can effectively prevent warpage problems, achieve controllable warpage trend, and make the deformation of the heat sink 1 meet the design requirements.

[0173] Furthermore, if the power module's housing structure 6 adopts an integrated first housing 601, the design structure of the housing structure 6 can be simplified, eliminating the need for friction stir welding, resulting in better reliability and stability.

[0174] Based on the above embodiments, another embodiment of this application provides a motor controller, which includes the power module provided in any of the above embodiments.

[0175] In this embodiment, the motor controller includes the power module provided in the above embodiments, and also integrates the drive module 2 and the power generation module 3, which improves the system integration and enables the integrated heat dissipation design of the drive module 2 and the power generation module 3, making it easy to achieve miniaturization design.

[0176] It should be noted that the operating conditions of drive module 2 in this application include not only drive conditions, such as drive motor 12, but also power generation conditions. Similarly, the operating conditions of power generation module 3 include not only power generation conditions, i.e., power generation for generator motor 16, but also drive conditions, such as driving engine 17. Specifically, in this operating condition, power battery 14 supplies power to generator motor 16, causing generator motor 16 to drive engine 17 to rotate until engine 17 reaches the target speed and maintains that speed for a set duration. After reaching the target speed and maintaining it for a certain period of time, engine 17 ignites and starts, and power battery 14 stops supplying power to generator motor 16. At this time, engine 17 begins to output mechanical energy, driving generator motor 16 to generate electricity.

[0177] Based on the above embodiments, another embodiment of this application provides an electronic control assembly, which includes the motor controller provided in the above embodiments.

[0178] In this embodiment, the electronic control assembly includes the motor controller provided in the above embodiments. It can not only realize the DC to AC conversion function through the drive module 2, but also realize the AC to DC conversion function through the power generation module 3, thereby improving the system integration.

[0179] Based on the above embodiments, another embodiment of this application provides a vehicle, which includes the electronic control assembly provided in the above embodiments.

[0180] Vehicles include new energy vehicles, which include electronic control assemblies, thus enabling the vehicle to be driven by electric energy.

[0181] In the vehicle provided in this application embodiment, the drive module 2 and the power generation module 3 can be integrated into one unit, which can reduce the overall weight and volume of the product and improve the integration level.

[0182] refer to Figure 21 , Figure 21 An equivalent circuit diagram of a motor controller provided in this application embodiment is shown. The motor controller includes a drive module 2 for connecting to a drive motor 12 and a power generation module 3 for connecting to a generator motor 16. The drive module 2 includes a plurality of first sub-power modules 401a, and the power generation module 3 includes a plurality of second sub-power modules 402a.

[0183] The first sub-power module 401a and the second sub-power module 402a each include a half-bridge circuit, which includes an upper bridge arm circuit 301 and a lower bridge arm circuit 302. The power chip 5 includes a first power chip 305 and a second power chip 306. Both the upper bridge arm circuit 301 and the lower bridge arm circuit 302 include the first power chip 305 and the second power chip 306 connected in parallel. The first power chip 305 can be an IGBT (Insulated Gate Bipolar Transistor), optionally a SiC chip. The second power chip 306 can be an FRD (Fast Recovery Diode). The collector of the IGBT is connected to the positive terminal of the FRD and connected to the positive bus 303; the emitter of the IGBT is connected to the negative terminal of the FRD and connected to the negative bus 304. The positive bus 303 and the negative bus 304 are respectively connected to the positive and negative terminals of the power battery.

[0184] For the first sub-power module 401a, the two ends of the upper bridge arm circuit 301 are respectively connected to the positive bus 303 and an AC terminal of the drive motor 12, and the two ends of the lower bridge arm circuit 302 are respectively connected to the negative bus 304 and an AC terminal of the drive motor 12. Within the same first sub-power module 401a, the upper bridge arm circuit 301 and the lower bridge arm circuit 302 are connected to the same AC terminal of the drive motor 12. Different first sub-power modules 401a are connected to different AC terminals of the drive motor 12.

[0185] For the second sub-power module 402a, the two ends of the upper bridge arm circuit 301 are respectively connected to the positive bus 303 and an AC terminal of the generator 16, and the two ends of the lower bridge arm circuit 302 are respectively connected to the negative bus 304 and an AC terminal of the generator 16. Within the same second sub-power module 402a, the upper bridge arm circuit 301 and the lower bridge arm circuit 302 are connected to the same AC terminal of the generator 16. Different first sub-power modules 401a are connected to different AC terminals of the generator 16.

[0186] The various embodiments in this application are described in a progressive, parallel, or combined manner. Each embodiment focuses on its differences from other embodiments, and similar or identical parts between embodiments can be referred to interchangeably. The embodiments provided in this application can be combined with each other without contradiction.

[0187] It should be noted that, in the description of this application, the accompanying drawings and embodiments are illustrative rather than restrictive. The same reference numerals throughout the embodiments identify the same structures. Additionally, for ease of understanding and description, the thicknesses of some layers, films, panels, regions, etc., may be exaggerated in the drawings. It is also understood that when an element such as a layer, film, region, or substrate is referred to as being "on" another element, the element may be directly on the other element or there may be intermediate elements. Furthermore, "on" means positioning an element on or below another element, but does not inherently mean positioning it above another element according to the direction of gravity.

[0188] The terms "upper," "lower," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application. When a component is considered to be "connected" to another component, it can be directly connected to the other component or there may be a component positioned centrally in the middle.

[0189] It should also be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that an article or apparatus comprising a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such an article or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the article or apparatus that includes the aforementioned element.

[0190] The above description of the disclosed embodiments enables those skilled in the art to make or use this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A power module, characterized in that, include: Heat sink; A drive module for connecting a drive motor and a generator module for connecting a generator motor; The drive module and the power generation module share a single heat sink.

2. The power module according to claim 1, characterized in that, The drive module includes multiple first sub-power modules, and at least one of the first sub-power modules has an independent first liner plate, which is disposed on the heat sink.

3. The power module according to claim 2, characterized in that, The thermal conductivity of the first liner is greater than 27 W / m·K.

4. The power module according to any one of claims 1-3, characterized in that, The power generation module includes multiple second sub-power modules, and at least two second sub-power modules share the same second liner plate, which is disposed on the heat sink plate.

5. The power module according to claim 4, characterized in that, The plurality of second sub-power modules include at least one active switching chip and at least one passive freewheeling chip; In the same second sub-power module, the ratio of the total area of ​​the passive freewheeling chip to the total area of ​​the active switching chip satisfies a first ratio, which is greater than or equal to 0.

6.

6. The power module according to claim 4, characterized in that, The thermal conductivity of the second liner is greater than 27 W / m·K.

7. The power module according to claim 5, characterized in that, The thermal conductivity of the second liner is greater than 27 W / m·K.

8. The power module according to claim 2 or 3, characterized in that, The first liner plate includes an aluminum nitride ceramic plate or a silicon nitride ceramic plate.

9. The power module according to claim 4, characterized in that, The second liner includes an aluminum nitride ceramic plate or a silicon nitride ceramic plate.

10. The power module according to claim 2 or 3, characterized in that, The first sub-power module includes: four first power chips and four second power chips, wherein the first power chips and the second power chips are arranged in pairs, the first power chip includes an active switching chip, and the second power chip includes a passive freewheeling chip.

11. The power module according to claim 4, characterized in that, The drive module includes multiple first sub-power modules, and at least one first sub-power module has an independent first liner plate, which is disposed on the heat sink plate. The first sub-power module includes: four first power chips and four second power chips, wherein the first power chips and the second power chips are arranged in pairs, the first power chip includes an active switching chip, and the second power chip includes a passive freewheeling chip.

12. The power module according to claim 4, characterized in that, The drive module includes multiple first sub-power modules, and at least one first sub-power module has an independent first liner plate, which is disposed on the heat sink plate. The first liner and the second liner are arranged sequentially along a first direction on the surface of the heat sink; the first direction is parallel to the plane of the heat sink. The length of the heat sink along the first direction is 185mm~200mm.

13. The power module according to claim 4, characterized in that, The drive module includes multiple first sub-power modules, and at least one first sub-power module has an independent first liner plate, which is disposed on the heat sink plate. The first liner and the second liner are arranged sequentially along a first direction on the surface of the heat sink; the first direction is parallel to the plane of the heat sink. In the first direction, the size of the second liner is larger than the size of a single first liner, but smaller than the sum of the sizes of all the first liners.

14. The power module according to claim 4, characterized in that, The drive module includes multiple first sub-power modules, and at least one first sub-power module has an independent first liner plate, which is disposed on the heat sink plate. The number of power chips in the second sub-power module is less than the number of power chips in the first sub-power module.

15. The power module according to claim 14, characterized in that, The area of ​​the power chip in the first sub-power module is larger than the area of ​​the power chip in the second sub-power module.

16. The power module according to any one of claims 1-3, characterized in that, Coolant channels are formed inside the heat sink.

17. The power module according to claim 4, characterized in that, Coolant channels are formed inside the heat sink.

18. The power module according to any one of claims 1-3, characterized in that, The heat sink has a first surface and a second surface opposite to each other, and the drive module and the power generation module are both disposed on the first surface; The power module includes a housing structure disposed on the second surface, and a coolant flow channel is formed within the housing structure.

19. The power module according to claim 4, characterized in that, The heat sink has a first surface and a second surface opposite to each other, and the drive module and the power generation module are both disposed on the first surface; The power module includes a housing structure disposed on the second surface, and a coolant flow channel is formed within the housing structure.

20. The power module according to any one of claims 1-3, characterized in that, The heat sink has a first surface and a second surface opposite to each other, and the drive module and the power generation module are both disposed on the first surface; The power module also includes a housing structure, which is connected to the second surface and forms a coolant flow channel with the second surface.

21. The power module according to claim 4, characterized in that, The heat sink has a first surface and a second surface opposite to each other, and the drive module and the power generation module are both disposed on the first surface; The power module also includes a housing structure, which is connected to the second surface and forms a coolant flow channel with the second surface.

22. The power module according to claim 20, characterized in that, The shell structure includes a first shell having a first groove; The second surface covers the opening of the first trench to form a coolant flow channel with the first trench; the first trench includes a first part of the trench corresponding to the position of the drive module and a second part of the trench corresponding to the position of the power generation module.

23. The power module according to claim 22, characterized in that, The first trench is configured as an integral trench.

24. The power module according to claim 22, characterized in that, The drive module has a plurality of first sub-power modules arranged sequentially along a first direction; the first direction is parallel to the plane where the heat sink is located; The coolant flow channel includes at least two flow channel sections corresponding to the plurality of first sub-power modules. Along the flow direction of the coolant in the coolant flow channel, the depth of each flow channel section decreases sequentially in a second direction, wherein the second direction is perpendicular to the plane where the heat sink is located.

25. The power module according to claim 23, characterized in that, The drive module has a plurality of first sub-power modules arranged sequentially along a first direction; the first direction is parallel to the plane where the heat sink is located; The coolant flow channel includes at least two flow channel sections corresponding to the plurality of first sub-power modules. Along the flow direction of the coolant in the coolant flow channel, the depth of each flow channel section decreases sequentially in a second direction, wherein the second direction is perpendicular to the plane where the heat sink is located.

26. The power module according to claim 1, characterized in that, The heat sink has a first surface and a second surface opposite to each other. The drive module and the power generation module are arranged sequentially on the first surface along a first direction. The second surface includes a plurality of protrusion structures.

27. The power module according to claim 26, characterized in that, The plurality of protruding structures include a first region corresponding to the drive module and a second region corresponding to the power generation module, wherein the heat dissipation performance of the first region is greater than that of the second region.

28. The power module according to claim 27, characterized in that, The density of protrusions in the first region is greater than that in the second region.

29. A motor controller, characterized in that, The power module included in any one of claims 1-28.

30. An electronic control assembly, characterized in that, Includes the motor controller as described in claim 29.

31. A vehicle, characterized in that, Includes the electronic control assembly described in claim 30.

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