POWER MODULE ASSEMBLY FOR A VEHICLE INVERTER

Abstract

A power module assembly (120) for an inverter (56) of a vehicle (16), the power module assembly (120) comprising: a housing (238) including a plate extending between opposing end caps (124) and having an inner side defining a first connection feature extending along a longitudinal direction of the plate, the housing (238) further including a cavity (230) defined at least in part by the inner side and the end caps (124), and at least one of the end caps (124) defining a coolant port (232); and an array of cards (126) disposed within the cavity (230) and each having opposing major sides (132, 134) and minor sides (136) extending therebetween, at least one of the cards (126) defining a second connection feature extending across one of the major sides (132, 134) of the card (126) and interlocking with the first connection feature to connect the card (126) and to connect the plate, and wherein a coolant passage (242) in fluid communication with the coolant port (232) is provided between the at least one card (126) and the plate and is designed to transport coolant directly over the at least one card (126), wherein the at least one card (126) further defines a third connection feature extending across the other of the main sides (132, 134), further comprising a central spacer extending between the end caps (124) and defining a fourth connection feature that engages the third connection feature to connect the card (126) and the central spacer characterized in that the third connecting feature is a projection and the fourth connecting feature is a groove that receives the projection.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to power module assemblies for automotive inverters. STATE OF THE ART

[0002] Vehicles such as battery-electric vehicles (BEVs), plug-in hybrid-electric vehicles (PHEVs), and full hybrid-electric vehicles (FHEVs) contain a traction battery assembly that acts as a power source for one or more electric machines. The traction battery contains components and systems to support the management of vehicle performance and operation. An inverter is electrically connected between the battery and the electric machines to convert the direct current (DC) from the battery into alternating current (AC) suitable for electric machines. The inverter can also act as a rectifier to convert alternating current (AC) from the electric machines into direct current suitable for the battery.

[0003] US 2013 / 0 335 920 A1 describes a power module assembly for a vehicle inverter, the power module assembly comprising a housing including a plate extending between opposing housing ends and having an inner side defining a first connection feature extending along a longitudinal direction of the plate, the housing further including a cavity defined at least in part by the inner side and the housing ends, at least one of the housing ends defining a coolant port, and an array of cards disposed within the cavity and each having opposing major sides and minor sides extending therebetween, at least one of the cards defining a second connection feature extending across one of the major sides of the cards and intermeshing with the first connection feature to connect the card and the plate.and wherein a coolant passage, in fluid communication with the connector, is defined between the at least one card and the plate and is configured to transport coolant directly over the at least one card. Further relevant prior art relating to the background of the invention is provided by the document DE 10 2005 052 756 A1. SUMMARY

[0004] According to one embodiment, a power module assembly includes opposing end caps with shared coolant ports and a card row, each having a main side defining a protrusion extending beyond the card. A side plate extends between the end caps such that the plate and row define a channel in fluid communication with the ports and configured to transport coolant directly across the cards. The side plate defines a groove that receives the protrusions.

[0005] According to another embodiment, a power module assembly includes a card module with spaced-apart side plates defining a coolant chamber, and cards disposed therein. The assembly further includes opposing end caps, each having walls defining a cavity that receives an end of the card module such that an inner surface of the walls engages an outer surface of the plates. One of the end caps defines a port in fluid communication with the chamber for transporting coolant across the cards.

[0006] According to yet another embodiment, a power module assembly for a vehicle inverter includes a housing having a plate extending between opposing end caps. The plate has an interior surface defining a first connection feature extending in a longitudinal direction of the plate. The housing further includes a cavity defined at least in part by the interior surface and the end caps. An array of cards is disposed within the cavity and each has opposing major sides and minor sides extending therebetween. At least one of the cards defines a second connection feature extending across one of the major sides of the card and intermeshing with the first connection feature to connect the card and the plate.A coolant passage in fluid communication with the port is defined between the at least one card and the plate and is configured to transport coolant directly across the at least one card. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic diagram of an exemplary hybrid vehicle. Fig. Figure 2 is a schematic diagram of an adjustable voltage converter and an inverter. Fig. Figure 3 is a schematic diagram of a vehicle inverter. Fig. 4 is an exploded view of a power module assembly. Fig. 5 is a plan view of the power module assembly of Fig. 4. Fig. Figure 6 is a cross-sectional view taken along section line 6-6. Fig. 7 is a side view in cross section of an end portion of the power module assembly of Fig. 4. Fig. 8 is a perspective view of another power module assembly. Fig. 9 is an enlarged perspective view in cross section of a connection feature. Fig. 10 is an enlarged perspective view in cross section of another connection feature. Fig. 11 is a top view of an example map. Fig. 12 is an exploded view of the Fig. Map shown in 11. DETAILED DESCRIPTION

[0007] Embodiments of the present disclosure are described herein. It should be understood, however, that the disclosed embodiments are merely examples, and that other embodiments may take various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art how to variously employ the present invention.It will be apparent to one of ordinary skill in the art that various features illustrated and described with reference to any of the figures may be combined with features illustrated in one or more other figures to create embodiments not explicitly illustrated or described. The combinations of illustrated features provide representative embodiments for typical applications. However, various combinations and modifications of the features consistent with the teachings of the present disclosure may be desired for particular applications or implementations.

[0008] An example of a PHEV is shown in Fig. 1 and is referred to generally herein as vehicle 16. The vehicle 16 includes a transmission 12 and is powered by at least one electric machine 18 with selective assistance from an internal combustion engine 20. The electric machine 18 may be an AC electric motor operating in Fig. 1 as an "electric motor" 18. The electric machine 18 receives electrical power and provides torque for vehicle propulsion. The electric machine 18 also acts as a generator for converting mechanical power into electrical power through regenerative braking.

[0009] The transmission 12 may have a power-split configuration. The transmission 12 includes the first electric machine 18 and a second electric machine 24. The second electric machine 24 may be an AC electric motor that Fig. 1 as a "generator" 24. Like the first electric machine 18, the second electric machine 24 receives electrical power and provides output torque. The second electric machine 24 also acts as a generator to convert mechanical power to electrical power and optimize power flow through the transmission 12. In other embodiments, the transmission does not have a power-split configuration.

[0010] The transmission 12 may include a planetary gear unit 26 including a sun gear 28, a planet carrier 30, and a ring gear 32. The sun gear 28 is connected to an output shaft of the second electric machine 24 for receiving generator torque. The planet carrier 30 is connected to an output shaft of the internal combustion engine 20 for receiving engine torque. The planetary gear unit 26 combines the generator torque and the engine torque, providing a combined output torque via the ring gear 32. The planetary gear unit 26 acts as a continuously variable transmission, without any fixed or "stepped" ratios.

[0011] The transmission 12 may also include a one-way clutch (OWC) and a generator brake 33. The OWC is coupled to the output shaft of the engine 20 to allow rotation of the output shaft in only one direction. The OWC prevents reverse drive of the engine 20 through the transmission 12. The generator brake 33 is coupled to the output shaft of the second electric machine 24. The generator brake 33 can be activated to "brake" or prevent rotation of the output shaft of the second electric machine 24 and the sun gear 28. Alternatively, the OWC and generator brake 33 can be eliminated and replaced with control strategies for the engine 20 and the second electric machine 24.

[0012] The transmission 12 may further include a countershaft with intermediate gears including a first gear 34, a second gear 36, and a third gear 38. A planetary output pinion 40 is connected to the ring gear 32. The planetary output pinion 40 meshes with the first gear 34 to transmit torque between the planetary gear unit 26 and the countershaft. An output pinion 42 is connected to an output shaft of the first electric machine 18. The output pinion 42 meshes with the second gear 36 to transmit torque between the first electric machine 18 and the countershaft. A transmission output pinion 44 is connected to an input shaft 46. The input shaft 46 is connected to a pair of driven gears 48 through a differential 50. The transmission output pinion 44 meshes with the third gear 38 to transmit torque between the transmission 12 and the driven wheels 48.

[0013] The vehicle 16 includes an energy storage device, such as a traction battery 52, for storing electrical energy. The battery 52 is a high-voltage battery capable of outputting electrical power to operate the first electric machine 18 and the second electric machine 24. The battery 52 also receives electrical power from the first electric machine 18 and the second electric machine 24 when they operate as generators. The battery 52 is a battery pack comprised of a plurality of battery modules (not shown), each battery module including a plurality of battery cells (not shown). In other embodiments of the vehicle 16, different types of energy storage devices, such as capacitors and fuel cells (not shown), are contemplated for supplementing or replacing the battery 52.A high-voltage bus electrically connects the battery 52 to the first electric machine 18 and to the second electric machine 24.

[0014] The vehicle includes a battery energy control module (BECM) 54 for controlling the battery 52. ​​The BECM 54 receives inputs indicative of vehicle and battery conditions, such as battery temperature, voltage, and current. The BECM 54 calculates and estimates battery parameters, such as battery state of charge and battery performance. The BECM 54 provides outputs (BSOC, P cap ) that provide a battery state of charge (BSOC) and a battery performance capability (P cap ) indicate.

[0015] The vehicle 16 includes a DC-DC converter or variable voltage converter (VVC) 10 and a power inverter 56. The VVC 10 and the power inverter 56 are electrically connected between the traction battery 52 and the first electric machine 18 and between the battery 52 and the second electric machine 24. The VVC 10 steps up, or increases, the voltage potential of the electrical power provided by the battery 52. ​​The VVC 10 also steps down, or decreases, the voltage potential of the electrical power provided to the battery 52, according to one or more embodiments. The power inverter 56 converts the DC power supplied by the battery 52 (through the VVC 10) to AC power to operate the electric machines 18, 24.The inverter 56 also rectifies AC power provided by the electric machines 18, 24 to DC power for charging the traction battery 52. ​​Other embodiments of the transmission 12 include multiple inverters (not shown), for example, one inverter associated with each electric machine 18, 24. The VVC 10 includes an inductor assembly 14.

[0016] The transmission 12 includes a transmission control module (TCM) 58 for controlling the electric machines 18, 24, the VVC 10, and the inverter 56. The TCM 58 is configured to monitor, among other things, the position, speed, and power consumption of the electric machines 18, 24. The TCM 58 also monitors electrical parameters (e.g., voltage and current) at various locations within the VVC 10 and the inverter 56. The TCM 58 provides output signals to other vehicle systems corresponding to this information.

[0017] The vehicle 16 includes a vehicle system controller (VSC) 60 that communicates with other vehicle systems and controllers to coordinate their operation. Although the VSC 60 is shown as a single controller, it may include multiple controllers that can be used to control multiple vehicle systems according to overall vehicle control logic or software.

[0018] The vehicle controllers, including the VSC 60 and the TCM 58, generally include any number of microprocessors, ASICs, ICs, memory (e.g., FLASH, ROM, RAM, EPROM, and / or EEPROM), and software code to cooperate with each other to perform a series of operations. The controllers also include predetermined data or "lookup tables" based on calculations and test data stored in memory. The VSC 60 communicates with other vehicle systems and controllers (e.g., the BECM 54 and the TCM 58) via one or more wired or wireless vehicle connections using common bus protocols (e.g., CAN and LIN). The VSC 60 receives an input (PRND) representing a current position of the transmission 12 (e.g., park, reverse, neutral, or drive). The VSC 60 also receives an input (APP) representing an accelerator pedal position.The VSC 60 provides an output representing a requested wheel torque, requested engine speed, and generator brake command to the TCM 58, and contactor control to the BECM 54.

[0019] The vehicle 16 includes an engine control module (ECM) 64 for controlling the engine 20. The VSC 60 provides an output (requested engine torque) to the ECM 64 based on a series of input signals, including APP, and corresponding to a driver vehicle propulsion request.

[0020] If the vehicle 16 is a PHEV, the battery 52 may periodically receive AC energy from an external power supply or the electrical grid via a charging port 66. The vehicle 16 also includes an onboard charger 68 that receives the AC energy from the charging port 66. The charger 68 is an AC-to-DC converter that converts the received AC energy to DC energy suitable for charging the battery 52. ​​The charger 68, in turn, supplies DC energy to the battery 52 during recharging. Although illustrated and described in the context of a PHEV 16, it should be understood that the inverter 56 may be implemented in other types of electric vehicles, such as HEVs or BEVs.

[0021] With reference to Fig. 2, an electrical diagram of the VVC 10 and the power module assembly 57 of the inverter 56 is shown. The VVC 10 may include one or more boards having at least a first switching unit 70 and a second switching unit 72 to switch the input voltage (V bat ) to increase the output voltage (V dc). The first switching unit 70 may include a first transistor 74 connected in parallel with a first diode 76, but with their polarities reversed (antiparallel). In one embodiment, the switch 70 may be a reverse-conducting insulated-gate bipolar transistor (RCIGBT). The second switching unit 72 may include a second transistor 78 connected in antiparallel with a second diode 80. Each transistor 74, 78 may be any type of controllable switch (e.g., an insulated gate bipolar transistor (IGBT) or a field-effect transistor (FET). Additionally, each transistor 74, 78 may be individually controlled by the TCM 58. The inductor assembly 14 is shown as an input inductor connected in series between the traction battery 52 and the switching units 70, 72.The inductor 14 generates magnetic flux when a current is applied. As the current flowing through the inductor 14 changes, a time-varying magnetic field is generated, and a voltage is induced. Other embodiments of the VVC 10 include alternative circuit configurations.

[0022] The power module assembly 57 may include multiple cards (also known as power modules) stacked in an assembly. Each of the cards may include one or more half-bridges 82 having a positive DC conductor 84 coupled to a positive DC node from the battery and a negative DC conductor 86 coupled to a negative DC node from the battery. Each of the half-bridges 82 may also include a first switching unit 88 and a second switching unit 90. The first switching unit 88 may include a first transistor 92 connected in parallel with a first diode 94. The second switching unit 90 may include a second transistor 96 connected in parallel with the second diode 98. The first and second transistors 88, 96 may be IGBTs or FETs. The first and second switching units 88, 90 may be similar to the switching units 70, 72.The first and second switching units of each of the half-bridges 82 convert the DC power of the battery into a single-phase AC output on the AC conductor 100. Each of the AC conductors 100 is electrically connected to the electric motor 18 or the generator 24.

[0023] With reference to Fig. 3: A vehicle inverter 102 may be mounted on a vehicle component 104, such as a body structure, a frame component, or a powertrain component. The inverter 102 may include a power module assembly 106 electrically connected to a gate driver board 108, a capacitor bank 110, and a control board 112. The power module assembly 106 may include multiple cards (also known as power modules), each having one or more half-bridges housed therein.

[0024] The Fig. 4 to 10 and the associated discussion describe exemplary power module assemblies. With reference to the Fig. 4-7: An exemplary power module assembly 120 includes a card module 122 layered with a pair of opposing end caps 124. The card module 122 includes a plurality of cards 126, each including a first main side 132, a second main side 134, and minor sides 136 extending therebetween. The first main side 132 includes an upper connection feature 138 and a lower connection feature 140. The second main side 134 includes an upper connection feature 142 and a lower connection feature 144. Each of the illustrated connection features is a protrusion that extends between the minor sides along a corresponding main side. In other embodiments, the connection feature may be a groove or any other feature that enables the card to be mated with another component of the module 122.Each of the cards 126 also includes connectors 146 and signal pins 148 extending from the side panels 136.

[0025] The cards 126 may be arranged in an array having a first row 128 and a second row 130. The rows may be substantially parallel to one another. As used herein, the term "substantially parallel" shall be construed or understood to mean not intersecting along their length or at an angle of less than three degrees to one another. The cards 126 of each row may be arranged continuously with the minor sides 136 touching one another. The rows are positioned with respect to one another such that major sides of the cards in the first row 128 face major sides of the cards in the second row 130. It should be understood that the illustrated paired arrangement of cards is not limiting, and that the cards may be arranged in many other configurations. For example, the card module 122 may contain only a single row of cards, or it may contain three or more rows of cards.Each of the rows can also contain more or fewer than two cards.

[0026] The card module 122 also includes first and second side plates 150, 152 extending between the end caps 124. The side plates may be substantially parallel. The first side plate 150 includes an outer side 154 and an inner side 156. The first row 128 of cards 126 may be substantially parallel with respect to the first side plate 150, with the second major side 132 of the cards 126 facing the inner side 156 of the plate 150. An upper protrusion 160 and a lower protrusion 168 each extend inwardly from the inner surface 158 toward the first row 128 of cards 126. The upper projection 160 includes a connecting feature 162 that cooperates with the upper connecting feature 142, and the lower projection 168 includes a connecting feature 170 that cooperates with the lower connecting feature 144.In the illustrated embodiment, the connecting features 162, 170 are grooves that run along respective protrusions. The groove 162 receives the upper protrusions 142 of the cards in the first row 128, and the groove 170 receives the lower protrusions 144 of the cards in the first row 128.

[0027] The second side plate 152 includes an outer side 176 and an inner side 178. The second row 130 of cards 126 may be arranged substantially parallel with respect to the second side plate 152, with the main side 132 of the cards 126 facing the inner side 178 of the plate 152. The side plates 150, 152 may be profiled to position the inner surface closer to a corresponding row of cards. An upper projection 182 and a lower projection 186 each protrude inwardly from the inner side 178 toward the second row 130 of cards 126. The upper projection 182 includes a connecting feature 184 that cooperates with the upper connecting feature 138, and the lower projection 186 includes a connecting feature 188 that cooperates with the lower connecting feature 140. In the illustrated embodiment, the connecting features 184, 188 are grooves that run along respective projections.The groove 184 receives the upper projections 138 of the cards in the second row 130, and the groove 188 receives the lower projections 140 of the cards in the second row 130.

[0028] The card module 122 may also include an upper center spacer 198 and a lower center spacer 200, each extending between the end caps 124. The spacers 198, 200 may be substantially parallel to the side plates 150, 152. The upper spacer 198 includes a first longitudinal side 202 facing the first row of cards 128 and a second longitudinal side 206 facing the second row of cards 130. The first longitudinal side 202 includes a connection feature 204 that mate with the upper connection features 138. For example, the first longitudinal side 202 defines a groove 204 that receives the protrusions 138 of the cards in the first row 128. The second longitudinal side 206 includes a connection feature 208 that mate with the upper connection features 142. For example, the second long side defines a groove 208 that receives the protrusions 142 of the cards in the second row 130.

[0029] The lower center spacer 200 may include a first longitudinal side 212 facing the first row of cards 128 and a second longitudinal side 216 facing the second row of cards 130. The first longitudinal side 212 includes an interconnection feature 214 that mate with the lower interconnection features 140. For example, the first longitudinal side 212 defines a groove 214 that receives the protrusions 140 of the cards in the first row 128. The second longitudinal side 216 includes an interconnection feature 218 that mate with the lower interconnection features 144. For example, the second longitudinal side defines a groove 218 that receives the protrusions 144 of the cards in the second row 130.

[0030] The power module 120 can be constructed by first assembling the card module 122 and then inserting a first end 222 of the card module into one of the end caps 124 and inserting a second end 224 of the card module into the other of the end caps 124. Each of the end caps 124 includes walls 226 with inner surfaces 228 defining a cavity 230. The ends of the card module 122 can be received in the cavity 230 such that the outer surfaces 154, 176 of the side plates 150, 152 engage the inner surfaces 228 of the walls 226. Each of the end caps 124 also includes recesses 234 that each receive one of the tabs 172 of the first side plate 150 or one of the tabs 194 of the second side plate 152.

[0031] The first and second side plates 150, 152 and the end caps 124 cooperate to define a housing 238 of the power module assembly 120. The housing 238 defines a coolant chamber 240 with a plurality of coolant passages 242 that transport coolant directly across the main sides 126 of the cards. Each of the end caps 124 may define one or more coolant ports 232 for circulating coolant into or out of the coolant chamber 240. For example, one of the end caps may define an inlet port, and the other of the end caps may define an outlet port. In some embodiments, the inlet and outlet ports are defined in a same end cap. The coolant ports 232 may be connected to a coolant line 244 that is connected to a thermal management system of the vehicle.

[0032] In the illustrated embodiment, a first passage 242a is defined between the inner side 156 of the first plate 150 and the first card row 128. The second main side 134 of the cards 126 in the first row 128 is in direct contact with the coolant passing through the first passage 242a. A second passage 242b is defined between the first card row 128 and the second card row 130. The center spacers 198, 200 ensure that a gap is maintained between the first and second rows. The main side 132 of the cards 126 in the first row 128 and the main side 134 of the cards 126 in the second row 130 are in direct contact with the coolant passing through the second passage 242b. A third passage 242c is defined between the inner side 178 of the second plate 150 and the second card row 130.The main side 132 of the cards 126 in the second row 130 is in direct contact with the coolant passing through the third passage 242c.

[0033] Having the liquid coolant in direct contact with the cards 126 reduces the thermal resistance of the cooling system compared to cold plate and fin designs by eliminating the thermal resistance of the cold plate top or the fins. This results in more efficient heat transfer between the cards and the coolant compared to conventional designs.

[0034] The housing 238 must be watertight to prevent coolant from leaking from the power module assembly 120. The mating features of the various components may cooperate to form sealing surfaces. For example, the protrusions 142 and the grooves 162 form an upper sealing surface for the first coolant passage 242a. The junction between the grooves and the protrusions may be sealed by a gasket disposed within the groove, or it may be sealed by adhesive or solvent-based bonding to create a plastic weld. Other mating surfaces may be similarly sealed. A gasket or sealant may also be applied to mating side surfaces of adjacent cards 126. In the illustrated embodiment, a seal is created between the ends of the card module 122 and a respective end cap 124 via an O-ring 246.Alternatively, a sealant- or solvent-based bond may be applied between the side plates 150, 152 and the walls 226. A potting material may also be disposed along the top 248 and bottom 250 of the rows to further seal the cards to the side plates, spacers, and end caps.

[0035] With reference to Fig. 8: Another power module assembly 260 includes a card module 262 with a plurality of cards 264. The cards 264 may have main sides 266 and secondary sides 268. A connection feature 270 (e.g., a protrusion) may be provided on the main sides 266, as described above with reference to the other embodiments. The cards 264 may be arranged in the first and second rows 272, 274, with each row having two cards. (Note that the fourth card is not shown for illustrative purposes.) However, it should be understood that the cards may be arranged in more or fewer than two rows, and that each row may contain more or fewer than two cards. A first side plate 276 is arranged adjacent to the first card row 272, and a second side plate 278 is arranged adjacent to the second card row 274. A central spacer 290 is arranged between the first and second card rows 272, 274.The central spacer 290 includes an upper portion 292, a lower portion 294, and a stiffener 296 extending between the upper and lower portions. The central spacer 290 may include one or more interconnection features 298 (e.g., a groove) that cooperate with interconnection features 270. The first and second side plates 276, 278 may also include interconnection features that cooperate with interconnection features of the cards, as described above in the other embodiments.

[0036] The card module 262 is, as described above, layered with a first end cap 280 and a second end cap 282. The first end cap 280 may include an inlet port 284 and an outlet port 286, and the second end 282 may include an extension port 288. The ports may be arranged differently in other embodiments. Unlike the power module 120 (which circulates coolant straight through the module), the power module 260 has a U-shaped coolant circuit, with coolant circulating in and out of the same end cap. For example, the card module 262 includes a first coolant chamber (not visible) defined between the first side plate 276 and the central spacer 290, and a second coolant chamber 302 defined between the central spacer 290 and the second side plate 278.The first card row 272 is disposed within the first coolant chamber and is in direct contact with the coolant in the first chamber, and the second card row 274 is disposed within the second coolant chamber 302 and is in direct contact with the coolant in the second chamber. The second coolant chamber 302 may include a first passage 304 defined between the spacer 290 and the second card row 274, and a second passage 306 defined between the second card row 274 and the second side plate 278. The first coolant chamber may similarly include multiple passageways. In operation, coolant may be circulated from the inlet port 284, through the first coolant chamber, and to the second end cap 282. The second end cap 282 may include features for recirculating the coolant into the second cooling chamber 304, back to the first end cap 280, and out the outlet port 286.The inlet and outlet ports 284, 286 may be offset from the central spacer 290 (e.g., to the left or right) to place the ports in fluid communication with a respective coolant chamber. The power module 260 may include seals as described above for the other embodiments.

[0037] The card module 262 and the end caps 280, 282 may include connection features 308, 310 for connecting the module 262 to the end caps. These features 308, 310 may be used alone or in conjunction with other means (e.g., adhesives, solvent-based bonding, or techniques known in the art) to secure the end caps and the card module.

[0038] With reference to Fig. 9: An enlarged view of a connection feature 308 is shown. The side plate 278 includes an outer surface 318 with a clip 320 disposed thereon. The end cap 282 includes a side wall 312 with a U-shaped component 314 defining a slot 316. The clips 320 are inserted into the slot 316 to snap the end cap 282 onto the card module 262. The clips 320 include a stem 322 that is received in the slot 316 when the parts are mated, and a header 334 that is disposed on a back surface of the component 314 when the clip 320 is installed through the slot 316. The header 334 includes a barb 336 that cooperates with a wall of the component 314 to resist the clip 320 from being withdrawn from the slot 316.

[0039] With reference to Fig. 10: An enlarged view of a connection feature 310 is shown. The end cap 282 includes a top surface 338 with a detent 340. The detent 340 cooperates with a recess 344 defined in a top surface 342 of the central spacer 290 to secure the end cap 282 to the card module 262. It should be understood that the power module 260 may include only one type of the connection features 308, 310, both types of the connection features, or neither of the connection features, depending on the design parameters.

[0040] The Fig. 11 and Fig. 12 and the linked text describe an exemplary card (or power module) 350 for a power module assembly (such as power module assembly 120 or power module assembly 260). Card 350 may include a first substrate 352 and a second substrate 354, between which a plurality of switching units 356 are sandwiched. First substrate 352 includes an outer plate 358, an inner plate 360, and a dielectric layer 362 disposed between the inner and outer plates. Outer plate 358 defines a major outer side of the card, inner plate 360 ​​defines a major inner side of the substrate, and the thin edges of the plates and dielectric layer together define a portion of the minor sides of the card. The plates and dielectric layer are bonded together, for example, by a high-temperature oxidation process.The inner and outer plates 358, 360 may be made of metal, such as copper, aluminum, silver, or gold. In one embodiment, the outer plate 358 is unpatterned copper, and the inner plate 368 is patterned copper. The term "patterned" refers to a plate that has been etched to define an electrical circuit. The dielectric layer 362 may be ceramic. Example ceramics include aluminum oxide, aluminum nitride, and silicon nitride. In some embodiments, the ceramics may be doped. The second substrate 354 also includes an outer plate 364, an inner plate 366, and a dielectric layer 362. The materials of the inner and outer plates and the dielectric layer may be similar to those described above with reference to the first substrate 352.

[0041] The card 350 includes one or more switching units 356 (also known as chips or dies), such as six switching units, which in the illustrated embodiment consist of Fig. 12. Each of the switching units 356 includes a transistor 370 and a diode 372. The transistor 370 may be, but is not limited to, an IGBT or FET. Each of the switching units 356 is electrically connected to the inner plate 360 ​​and / or the inner plate 366. The card 350 includes a plurality of shims 378 that electrically connect the switching units 356 to one of the inner plates and serve as standoff features. A molding compound 380 encapsulates the internal components of the card 350.

[0042] The board 350 also includes a plurality of connectors 376 and signal pins 374. The board 350 may include, for example, a positive DC power connector 382, ​​a negative DC power connector 384, a generator AC power connector 386, and an electric motor AC power connector 388. The DC power connectors 382, ​​384 are electrically connected to the capacitor bank and the traction battery. The AC power connectors 386, 388 are electrically connected to an associated electric machine. The signal pins 374 are electrically connected to the gate driver board. The connectors and pins may be formed by a patterned internal plate or may be separate components attached to the switching units 356.

[0043] Although exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. The terms used in the description are for the purpose of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure. As previously described, the features of the various embodiments may be combined to form additional embodiments of the disclosure that may not have been explicitly described or illustrated. Although various embodiments may have been described as providing advantages over other embodiments or prior art implementations with respect to one or more desired characteristics.are preferable to these, those of ordinary skill in the art will understand that compromises may be made with respect to one or more features or characteristics in order to achieve desired properties of the overall system, which depend on the specific application and implementation. These features may include, but are not limited to, cost, strength, durability, lifetime cost, marketability, appearance, assembly, size, maintainability, weight, manufacturability, ease of installation, etc. Therefore, embodiments that have been described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for particular applications. List of reference symbols 10 adjustable voltage converter 12 gearboxes 14 Inductor assembly 16 vehicles 18 first electric machine 20 combustion engine 24 second electric machine 26 Planetary gear unit 28 Sun gear 30 planet carriers 32 ring gear 33 Generator brake 34 first gear 36 second gear 38 third gear 40 planetary output pinions 42 output pinions 44 Gearbox output pinion 46 Drive shaft 48 pairs of driven wheels 50 differential 52 Battery 54 Battery energy control module 56 inverters 57 power module assemblies 58 Transmission control module 60 Vehicle system control 64 Combustion engine control module 66 Charging port 68 Charger 70 First switching unit 72 Second switching unit 74 First transistor 76 First diode 78 Second transistor 80 Second diode 82 Half Bridge 84 Positive DC conductor 86 Negative DC conductor 88 First switching unit 90 Second switching unit 92 First transistor 94 First diode 96 Second transistor 98 Second diode 100 AC conductors 102 vehicle inverters 104 vehicle components 106 Power module assembly 108 Gate driver board 110 Capacitor bank 112 Control board 120 Power module assembly 122 card module 124 pairs of opposite end flaps 126 map 128 First line 130 Second line 132 First main page 134 Second main page 136 Side page 138 Upper connection feature of the first main page 140 Lower connection feature of the first main page 142 Upper connection feature of the second main page 144 Lower connection feature of the second main page 146 connections 148 signal pins 150 First side plate 152 Second side plate 154 Outer side of the first side plate 156 Inner side of the first side plate 158 interior surface 160 Upper projection 162 connection feature 168 Lower projection 170 connection feature 172 Nose 176 outer side of the second side plate 178 inner side of the second side plate 182 Upper projection 184 Connection feature 186 Lower projection 188 connection feature 194 Nose of the second side plate 198 Upper center spacer 200 lower center spacer 202 First long side 204 connection features 206 Second long side 208 Connection feature 212 First long side 214 Connection feature 216 Second long side 218 Connection feature 222 First end of the map module 224 Second end of the map module 226 walls 228 interior surfaces 230 cavity 232 coolant connection 234 Deepening 238 housings 240 coolant chamber 242 Coolant passage 242a First coolant passage 242b Second coolant passage 242c Third coolant passage 244 coolant line 246 O-ring 248 Top 250 subpage 260 power module assembly 262 card module 264 cards 266 Main page 268 Side page 270 connection feature 272 First line 274 Second line 276 First side plate 278 Second side plate 280 first end cap 282 second end cap 284 Inlet connection 286 Outlet connection 288 Expansion port 290 Central spacer 292 Upper Section 294 Subsection 296 stiffening 298 connection feature 302 Second coolant chamber 304 First Passage 306 Second Passage 308 connection features 310 connection feature 312 side wall 314 U-shaped component 316 slot 318 exterior area 320 bracket 322 shaft 334 headpiece 336 barbs 338 top 340 locking 342 top 344 Deepening 350 card 352 First substrate 354 Second substrate 356 switching unit 358 Outer plate 360 Inner Plate 362 dielectric layer 364 Outer plate 366 Inner plate 370 transistors 372 Diode 374 signal pins 376 connections 378 Supplement 380 molding compound 382 positive DC connection 384 negative DC connection 386 Generator AC connection 388 Electric motor AC connection

Claims

[1] A power module assembly (120) for an inverter (56) of a vehicle (16), the power module assembly (120) comprising: a housing (238) including a plate extending between opposing end caps (124) and having an inner side defining a first connection feature extending along a longitudinal direction of the plate, the housing (238) further including a cavity (230) defined at least in part by the inner side and the end caps (124), and at least one of the end caps (124) defining a coolant port (232); and an array of cards (126) disposed within the cavity (230) and each having opposing major sides (132, 134) and minor sides (136) extending therebetween, at least one of the cards (126) defining a second connection feature extending across one of the major sides (132, 134) of the card (126) and interlocking with the first connection feature to connect the card (126) and to connect the plate, and wherein a coolant passage (242) in fluid communication with the coolant port (232) is provided between the at least one card (126) and the plate and is designed to transport coolant directly over the at least one card (126), wherein the at least one card (126) further defines a third connection feature extending across the other of the main sides (132, 134), further comprising a central spacer extending between the end caps (124) and defining a fourth connection feature that engages the third connection feature to connect the card (126) and the central spacer characterized by , that the third connecting feature is a projection and the fourth connecting feature is a groove that receives the projection. [2] The power module assembly (120) of claim 1, wherein the first connection feature is a groove and the second connection feature is a protrusion disposed within the groove. [3] The power module assembly (120) of claim 1, wherein the first connection feature is a protrusion and the second connection feature is a groove that receives the protrusion. [4] The power module assembly (120) of any one of claims 1 to 3, wherein the other of the end caps (124) defines a second coolant port. [5] Power module assembly (120) comprising: opposite end caps (124) with coolant connections (232); a first row (128) of cards (126), each having a second main side (134) defining a projection extending above the card (126); and a first side plate (150) extending between the end caps (124) such that the first side plate (150) and first row (128) define a first passage (242a) in fluid communication with the ports (232) and adapted to transport coolant directly over the cards (126), the first side plate (150) defining a groove (162) receiving the projection, characterized by , that each of the cards (126) further includes a first main side (132) defining a second protrusion extending over the card (126), and the power module assembly (120) further includes a central spacer extending between the end caps (124) and having a first side defining a groove that receives the second protrusion. [6] The power module assembly (120) of claim 5, wherein each of the cards (126) in a second row (130) further includes a first main side (132) defining a second protrusion extending over the card (126), and wherein the power module assembly (120) further includes a second side plate (152) extending between the end caps (124) and defining a groove that receives the second protrusion. [7] The power module assembly (120) of claim 6, wherein the second side plate (152) and the second row (130) define a third passage (242c) in fluid communication with the ports (232). [8] The power module assembly (120) of claim 5, further comprising: a second side plate (152) extending between the end caps (124) and defining a groove; and a second row (130) of cards (126) each having a first main side (132) defining a third protrusion extending over the card (126) and disposed within the groove of the second side plate (152), and a second main side (134) having a fourth protrusion extending over the card (126) and disposed within a groove defined in a second side of the central spacer. [9] The power module assembly (120) of any one of claims 5 to 8, wherein the coolant ports (232) are an inlet port defined in one of the end caps (124) and an outlet port defined in the other end cap (124). [10] Power module assembly (120) comprising: a card module (122) including spaced-apart side plates defining a coolant chamber (240) and cards (126) disposed therein; and opposing end caps (124) including walls (226) defining a cavity (230) receiving one end of the card module (122) such that an inner surface (228) of the walls (226) engages an outer surface of the plates, one of the end caps (124) defining a coolant port (232) in fluid communication with the coolant chamber (240) for transporting coolant across the cards (126). [11] The power module assembly (120) of claim 10, wherein the inner surface (228) of each of the end caps (124) defines a first recess (234) receiving a portion of one of the side plates (150) and a second recess (234) receiving a portion of the other of the side plates (152). [12] The power module assembly (120) of claim 10 or 11, wherein at least some of the cards (126) are arranged in a first row (128) such that a major side of each of the cards (126) in the first row (128) faces one of the side plates, and wherein said one of the side plates has a projection extending therefrom and engaging the major side of each of the cards (126) in the first row (128) to define a first coolant passage (242a) between the first row (128) and said one of the side plates. [13] The power module assembly (120) of claim 12, wherein the protrusion defines a groove extending longitudinally across the side plate and wherein the main side of each of the cards (126) in the first row defines a protrusion that is received in the groove. [14] The power module assembly (120) of any one of claims 10 to 13, wherein the cards (126) are arranged in the first (128) and second substantially parallel rows (130), and wherein a central spacer is arranged between the first (128) and second rows (130) to create a second coolant passage (242b) defined between the first (128) and second rows (130) and in fluid communication with the coolant port (232). [15] The power module assembly (120) of claim 14, wherein the central spacer has a first side defining a groove that receives a portion of each of the cards (126) in the first row (128) and a second side opposite the first side that receives a portion of each of the cards (126) in the second row (130). [16] The power module assembly (120) of any one of claims 10 to 15, wherein the other of the end caps (124) defines a second coolant port (232) in fluid communication with the coolant chamber (240).

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