Branch of a power converter

Abstract

Branch (512, 532, 536) of a power converter, wherein branch (512) comprises: a first of (a) a first power module (604) and (b) a first chip, the first comprising a high-side switch (516) with a first terminal configured to be connected to a first DC busbar (304) at a first potential; and a second of (a) a second power module (608) and (b) a second chip, the second of which includes a low-side switch (520) with a first terminal configured to connect to a second DC busbar (308) having a second potential different from the first potential; and an alternating current (AC) busbar (704) arranged vertically (a) between the first and the second and (b) between the first DC busbar (304) and the second DC busbar (308), wherein the AC busbar (704) is arranged between a first, vertically lower surface of the First and a second, vertically upper side of the Second and is electrically connected to second terminals of the high- and low-side switches (516, 520); characterized by the fact that the branch (512, 532, 536) further comprises an electrically insulating material arranged between: the first, vertically lower surface of the first and the AC busbar (704); and the second, vertical upper surface of the second and the AC busbar (704).

Description

introduction

[0001] The information provided in this section serves the purpose of presenting the general context of the disclosure. The work of the inventors mentioned herein, insofar as it is described in this section, as well as aspects of the description that were not designated as prior art at the time of filing, are neither expressly nor implicitly recognized as prior art with respect to the present disclosure.

[0002] The present disclosure relates to inverters for vehicle engines and, in particular, to systems and methods for controlling the switching of inverters. Comparable items are known, for example, from JP 2004 - 364 427 A and JP 2007 - 215 396 A.

[0003] Some vehicle types have only an internal combustion engine that generates the drive torque. Electric vehicles do not necessarily have to have an internal combustion engine and can rely on one or more electric motors for propulsion.

[0004] Hybrid vehicles have both an internal combustion engine and one or more electric motors. Some types of hybrid vehicles use the electric motor and the internal combustion engine to achieve greater fuel efficiency than would be possible with the internal combustion engine alone. Other types of hybrid vehicles use both the electric motor and the internal combustion engine to achieve higher output torque than the internal combustion engine could produce on its own.

[0005] Some exemplary types of hybrid vehicles include parallel hybrids, series hybrids, and other types. In a parallel hybrid, the electric motor works in parallel with the internal combustion engine to combine the power and range advantages of the combustion engine with the efficiency and regenerative braking benefits of the electric motor. In a series hybrid, the combustion engine drives a generator to produce electricity for the electric motor, and the electric motor drives a transmission. This allows the electric motor to take over some of the power delivery from the combustion engine, which may permit the use of a smaller and potentially more efficient engine. Summary

[0006] The subject matter of the present invention is defined by the features of independent main claim 1. Advantageous embodiments are given in the following description and in the dependent claims.

[0007] According to the invention, a branch of a power converter comprises: a first of (a) a first power module and (b) a first chip, wherein the first includes a high-side switch with a first terminal configured to be connected to a first DC busbar having a first potential; and a second of (a) a second power module and (b) a second chip, wherein the second includes a low-side switch with a first terminal configured to be connected to a second DC busbar having a second potential different from the first potential; and an AC busbar arranged vertically (a) between the first and the second and (b) between the first DC busbar and the second DC busbar.

[0008] According to the invention, the AC busbar is arranged between a first, vertically lower surface of the first and a second, vertically upper side of the second and is electrically connected to second terminals of the high-side and low-side switches.

[0009] Preferably, the AC busbar is configured so that it can be electrically connected to one phase of an electric motor.

[0010] According to the invention, an electrically insulating material is arranged between the first, vertically lower surface of the first and the AC busbar and the second, vertically upper surface of the second and the AC busbar.

[0011] Preferably, a first heat sink is configured to dissipate heat from the first, and a second heat sink is configured to dissipate heat from the second.

[0012] Preferably, the first heat sink is arranged on a first, vertically upper surface of the first, and the second heat sink is arranged on a second, vertically lower surface of the second.

[0013] Alternatively, the first heat sink is preferably arranged on a first, vertically lower surface of the first and the second heat sink is arranged on a second, vertically upper surface of the second.

[0014] Preferably, a first heat sink is arranged on a first, vertically upper surface of the first, a second heat sink is arranged on a first, vertically lower surface of the first, a third heat sink is arranged on a second, vertically upper surface of the second, and a fourth heat sink is arranged on a second, vertically lower surface of the second.

[0015] Preferably, the AC busbar comprises a first electrically conductive section or part that is arranged vertically above a first vertically upper surface of the first, a second electrically conductive part that is arranged vertically below a second vertically lower surface of the second, and a third electrically conductive part that can be electrically connected to the first and second electrically conductive parts.

[0016] Preferably, the AC busbar is configured so that it can be electrically connected to one phase of an electric motor.

[0017] Preferably, an electrically insulating material is arranged between the first, vertically upper surface of the first and the first electrically conductive part, and between the second, vertically lower surface of the second and the second electrically conductive part.

[0018] Preferably, a capacitor is arranged vertically between the first and second DC busbars.

[0019] Preferably, the capacitor is arranged horizontally next to the first and second capacitors.

[0020] Preferably, the capacitor is arranged either vertically above the first or vertically below the second.

[0021] Preferably, the AC busbar extends horizontally through an opening in the capacitor.

[0022] Preferably, a system comprises a housing, the branch, wherein the branch is arranged inside the housing, and a coolant inside the housing.

[0023] Preferably, the first and second DC busbars each contain a first and a second copper layer bonded directly to a ceramic layer.

[0024] Preferably, a first metal layer is configured to electrically connect the first terminal of the high-side switch to the first DC busbar, a second metal layer is configured to electrically connect a second terminal of the high-side switch to an output busbar, a third metal layer is configured to electrically connect the first terminal of the low-side switch to the second DC busbar, and a fourth metal layer is configured to electrically connect a second terminal of the low-side switch to the AC busbar.

[0025] Preferably, a spacer is arranged vertically between the first DC busbar and the AC busbar or between the second DC busbar and the AC busbar.

[0026] Preferably, the spacer includes an internal coolant channel configured to receive a coolant.

[0027] Further applications of the present disclosure will become apparent from the detailed description, the claims, and the drawings. The detailed description and specific examples serve only for illustrative purposes and are not intended to limit the scope of the disclosure. Brief description of the drawings

[0028] The present disclosure is more fully understood from the detailed description and the accompanying drawings, whereby: Fig. 1 is a functional block diagram of an exemplary vehicle system; Fig. 2 is a functional block diagram of an exemplary drive control system; Fig. 3. A schematic representation containing an exemplary implementation of a power control system; Fig. 4 shows a schematic representation of an exemplary implementation of an inverter module; Fig. 5 is a perspective view illustrating electrical conductors arranged on the same horizontal plane; Fig. 6 is a perspective view illustrating electrical conductors arranged on different horizontal planes and separated vertically; Fig. 7-17 Cross-sectional views of examples of the first branch of the inverter module are shown; Fig. Figure 18 shows a cross-sectional view of an exemplary implementation of a spacer; and Fig. Figure 19 is a functional block diagram of an example cooling system.

[0029] Reference numbers can be reused in the drawings to identify similar and / or identical elements. Detailed description

[0030] An inverter module in a vehicle comprises branches of switches that control the power flow (a) from a battery to an electric motor and (b) from the electric motor to the battery. A DC bus capacitor may be connected between the inverter module and the battery. Pulse-width modulated (PWM) signals are used to control the switching of the branches. Each branch includes a high-side switch, implemented in a high-side module, and a low-side switch, implemented in a separate low-side module. The low- and high-side modules contain chips and may be arranged on the same horizontal plane (see, for example, [reference]). Fig. 5).

[0031] According to the present application, the low-side and high-side modules are arranged on the same vertical plane (see e.g. Fig. 6) and vertically separated from each other. In other words, the high-side module is arranged vertically above or below the low-side module. The magnetic fields of the low-side and high-side modules overlap to a greater extent and therefore cancel each other out more than if the low-side and high-side modules were arranged in the same horizontal plane. This minimizes parasitic inductance and improves the thermal performance of the inverter module. In some implementations, an output AC busbar may be placed between the low-side and high-side modules to further increase the magnetic field cancellation.

[0032] Referring to Fig. Figure 1 presents a functional block diagram of an exemplary vehicle system. While a vehicle system for a hybrid vehicle is shown and described, the present disclosure is also applicable to electric vehicles that do not contain an internal combustion engine (including pure electric vehicles), fuel cell vehicles, autonomous vehicles, semi-autonomous vehicles, non-autonomous vehicles, and other vehicle types. Even though the example of a vehicle is provided, the present application is also applicable to implementations not related to vehicles.

[0033] An engine 102 can burn an air / fuel mixture to produce drive torque. An engine control module (ECM) 114 controls the engine 102. For example, the ECM 114 can control the actuation of engine actuators, such as a throttle valve, one or more spark plugs, one or more fuel injectors, valve actuators, camshaft adjusters, an exhaust gas recirculation (EGR) valve, one or more boost pressure devices, and other suitable engine actuators. In some types of vehicles (e.g., electric vehicles), the engine 102 may be omitted.

[0034] The motor 102 can deliver torque to a transmission 195. A transmission control module (TCM) 194 controls the operation of the transmission 195. For example, the TCM 194 can control the gear selection within the transmission 195 and one or more torque transmission devices (e.g., a torque converter, one or more clutches, etc.).

[0035] The vehicle system includes one or more electric motors, such as electric motor 198. An electric motor can operate as either a generator or a motor at any given time. When operating as a generator, an electric motor converts mechanical energy into electrical energy. This electrical energy can be used, for example, to charge a battery 199. When operating as a motor, an electric motor generates torque, which can be used, for example, to propel a vehicle. Although the example of one electric motor is given, the vehicle can contain more than one electric motor.

[0036] A motor control module 196 controls the power flow from the battery 199 to the electric motor 198 and from the electric motor 198 to the battery 199. The motor control module 196 supplies the electric motor 198 with electrical energy from the battery 199 to cause the electric motor 198 to deliver positive torque, for example, for vehicle propulsion. The battery 199 can, for example, comprise one or more batteries and / or battery packs.

[0037] The electric motor 198 can deliver torque, for example, to an input shaft or an output shaft of the gearbox 195. A clutch 200 can be engaged to couple the electric motor 198 to the gearbox 195 and disengaged to decouple the electric motor 198 from the gearbox 195. One or more gear units can be implemented between an output of the clutch 200 and an input of the gearbox 195 to provide a predetermined ratio between the rotation of the electric motor 198 and the rotation of the input of the gearbox 195.

[0038] The motor control module 196 can also selectively convert the vehicle's mechanical energy into electrical energy. More precisely, the electric motor 198 generates power via back EMF and delivers it when the electric motor 198 is driven by the transmission 195 and the motor control module 196 is not supplying the electric motor 198 with power from the battery 199. The motor control module 196 can charge the battery 199 using the power delivered by the electric motor 198.

[0039] Referring now to Fig. Figure 2 presents a functional block diagram of an exemplary powertrain control system. A driver torque module 204 determines a driver torque request 208 based on a driver input 212. The driver input 212 can include, for example, an accelerator pedal position (APP), a brake pedal position (BPP), a cruise control input, and / or an autonomous input. In various implementations, the cruise control input can be provided by an adaptive cruise control system that attempts to maintain at least a predetermined distance between the vehicle and objects in the vehicle's path. The autonomous input can be provided by an autonomous driving system that controls the movement of a vehicle from place to place while avoiding objects and other vehicles.The driver torque module 204 can determine the driver torque requirement 208 using one or more lookup tables or equations that relate the driver inputs to the driver torque requirements. APP and BPP can be measured using one or more APP sensors and BPP sensors, respectively.

[0040] Driver torque requirement 208 may be an axle torque requirement. Axle torques (including axle torque requirements) refer to the torque at the wheels. As explained below, drive torques (including drive torque requirements) differ from axle torques in that drive torques may refer to the torque at a transmission input shaft.

[0041] An axle torque arbitration module 216 decides or mediates between the torque request of the driver 208 and other axle torque requests 220. The axle torque (torque at the wheels) can be generated by various sources, including the motor 102 and / or one or more electric motors such as the electric motor 198.Examples of the other axle torque requirements 220 include, but are not limited to, a torque reduction requested by a traction control system when positive wheel slip is detected; a torque increase request to counteract negative wheel slip; brake management requests to reduce axle torque to ensure that the axle torque does not exceed the brakes' ability to hold the vehicle when stopped; and vehicle torque requirements upon exceeding the speed limit to reduce axle torque to prevent the vehicle from exceeding a predetermined speed. The axle torque arbitration module 216 outputs one or more axle torque requirements 224 based on the results of the arbitration between the received axle torque requirements 208 and 220.

[0042] In hybrid vehicles, a hybrid module 228 can determine how much of the one or more axle torque requirements 224 should be generated by the motor 102 and how much by the electric motor 198. For simplicity, the example of the electric motor 198 is continued; however, multiple electric motors can be used. The hybrid module 228 outputs one or more motor torque requirements 232 to a drive torque arbitration module 236. The motor torque requirements 232 specify a requested torque output from the motor 102.

[0043] The hybrid module 228 also outputs a motor torque request 234 to the motor control module 196. The motor torque request 234 specifies a requested (positive or negative) torque output from the electric motor 198. In vehicles where the motor 102 is not present (e.g., in electric vehicles) or is not connected to provide drive torque to the vehicle, the axle torque arbitration module 216 can output an axle torque request, and the motor torque request 234 can correspond to this axle torque request.

[0044] In the example of an electric vehicle, the ECM 114 can be omitted, and the driver torque module 204 and the axle torque arbitration module 216 can be implemented within the engine control module 196. In electric vehicles, the driver torque module 204 can input the driver torque request 208 into the engine control module 196, and the components related to controlling the engine actuators can be omitted.

[0045] The drive torque arbitration module 236 converts the motor torque requirements 232 from an axle torque domain (torque at the wheels) to a drive torque domain (e.g., torque at a transmission input shaft). The drive torque arbitration module 236 mediates or arbitrates the converted torque requirements with other drive torque requirements 240. Examples of the other drive torque requirements 240 include, but are not limited to, torque reductions requested to protect against excessive motor speed and torque increases requested to prevent stalling. The drive torque arbitration module 236 can output one or more drive torque requirements 244 as a result of the arbitration.

[0046] An actuator control module 248 controls the actuators 252 of the engine 102 based on the drive torque requirements 244. For example, based on the drive torque requirements 244, the actuator control module 248 can control the opening of a throttle valve, the timing of the sparks delivered by the spark plugs, the timing and quantity of fuel injected by the fuel injectors, the activation / deactivation of cylinders, the phase position of intake and exhaust valves, the output of one or more boost pressure devices (e.g., turbochargers, compressors, etc.), the opening of an EGR valve, and / or one or more other engine actuators. In various implementations, the drive torque requirements 244 can be adjusted, set, or modified before use by the actuator control module 248, for example, to create a torque reserve.

[0047] The motor control module 196 controls the switching of switches of an inverter module based on the motor torque requirement 234, as explained below. The inverter module converts direct current (DC) power into alternating current (AC) power. The inverter module supplies the motor 198 with AC power. The switching of the inverter module controls the torque of the electric motor 198. The inverter module also converts power generated by the electric motor 198 into DC power and supplies the DC power to the battery 199, for example, to charge the battery 199.

[0048] The inverter module comprises a variety of switches, such as n branches of switches, where n is an integer greater than or equal to 1 (e.g., 2, 3, etc.). The motor control module switches the switches to supply alternating current (AC) power to the electric motor 198 to drive it. For example, the inverter module can generate n-phase AC power and apply the n-phase AC power to n stator windings of the electric motor 198 (e.g., a, b, and c or u, v, and w). In some implementations, n is equal to 3. The magnetic flux generated by the current flowing through the stator windings drives a rotor of the electric motor 198. The rotor is connected to an output shaft of the electric motor 198 and drives it into rotation. The output shaft of the electric motor 198 is connected to one or more wheels of the vehicle.

[0049] In various implementations, one or more filters (e.g., capacitors) can be electrically connected between the inverter module and battery 199. The one or more filters can, for example, be implemented to filter the power flow to and from battery 199. As an example, a filter comprising one or more capacitors and resistors can be electrically connected in parallel with battery 199 and the inverter module.

[0050] Fig. Figure 3 shows a schematic representation that includes an exemplary implementation of a power control system. Battery 199 can also be referred to as a battery pack, or it can contain one, as discussed above.

[0051] The high (positive, DC+) and low (negative, DC-) sides 304 and 308 (busbars) are connected to the positive and negative terminals of battery 199, respectively. One or more capacitors, such as capacitor 312, are connected in parallel with battery 199 between the high and low sides 304 and 308. The capacitor(s) stabilize the DC bus and provide a low-impedance voltage source for the inverter module, as battery 199 may have a higher impedance.

[0052] An inverter module 316 comprises three branches, each branch being connected to one phase of the electric motor 198. The inverter module 316 controls the current flow to the branches / phases of the electric motor 198. The inverter module 316 converts DC power from the high and low sides 304 and 308 into three-phase AC power and supplies the AC power to the electric motor 198.

[0053] Fig. Figure 4 shows a schematic representation of an exemplary implementation of the inverter module 316. As stated above, the inverter module 316 comprises three branches. Each branch is connected to one phase of the electric motor 198.

[0054] A first branch 512 comprises first and second switches 516 and 520. Switches 516 and 520 each comprise a first terminal, a second terminal, and a control terminal. Each of switches 516 and 520 can be an insulated-gate bipolar transistor (IGBT), a field-effect transistor (FET) such as a metal-oxide-semiconductor MOSFET, or another suitable type of switch. In the example of IGBTs and FETs, the control terminal is referred to as the gate.

[0055] The first terminal of the first switch 516 is connected to the high-side 304. The second terminal of the first switch 516 is connected to a node 504. The second terminal of the second switch 520 can be connected to the low-side 308. The node 504 is connected to the second terminal of the first switch 516, the first terminal of the second switch 520, and a first phase (e.g., a) of the electric motor 198.

[0056] The first branch 512 can include the first and second diodes 524 and 528, which are connected antiparallel to switches 516 and 520, respectively. In other words, an anode of the first diode 524 can be connected to the second terminal of the first switch 516, and a cathode of the first diode 524 can be connected to the first terminal of the first switch 516. An anode of the second diode 528 can be connected to the second terminal of the second switch 520, and a cathode of the second diode 528 can be connected to the first terminal of the second switch 520. Diodes 524 and 528 form one phase of a three-phase rectifier for converting power from the electric motor 198 into power for the battery 199. However, diodes 524 and 528 can be omitted, for example, if switches 516, 540, 556, 520, 544, and 560 are MOSFETs (with a built-in diode).The diodes 524 and 528 can be located in the respective chips of the power modules with the first and second switches 516 and 520, as explained below.

[0057] The inverter module 316 also includes second and third branches 532 and 536. The second and third branches 532 and 536 can be (circuit-wise) similar to or identical with the first branch 512. In other words, the second and third branches 532 and 536 can each contain corresponding switches and diodes, such as switches 516 and 520 and diodes 524 and 528, connected in the same way as the first branch 512. For example, the second branch 532 includes switches 540 and 544 and antiparallel diodes 548 and 552. A node 542 is connected to the first terminal of switch 544 and to a second stator winding (e.g., b) of the electric motor 198. The third branch 536 includes switches 556 and 560 and antiparallel diodes 564 and 568. A node 570 is connected to the first terminal of switch 560 and a third stator winding (e.g. c) of electric motor 198.Like diodes 524 and 528, diodes 548, 552, 564 and 568 can also be omitted.

[0058] The control terminals of the switches of inverter module 316 are connected to the switching signals 576 from motor control module 196. Motor control module 196 generates the switching signals 576 such that the high-side switch of one branch is on while the low-side switch of that branch is off, and vice versa. Motor control module 196 generates the switching signals 576 using pulse-width modulation (PWM) control.

[0059] The control signals of the gates of the low-side switches 520, 544 and 560 can be inverted so that the control signals applied to the low-side switches 520, 544 and 560 have a polarity opposite to the control signals applied to the gates of the high-side switches 516, 540 and 556.

[0060] Fig. 5 and Fig. Figures 6 show exemplary side (horizontal) perspective views of arrangements of first and second electrical conductors (e.g., busbars, power modules, etc.) 504 and 508. As in Fig. As illustrated in Figure 5, the first and second conductors 504 and 508 could be arranged on the same horizontal plane. However, according to the present application, as shown in Figure 5, the first and second conductors 504 and 508 are arranged on the same horizontal plane. Fig. Figure 6 illustrates that the first and second conductors 504 and 508 are arranged in different vertical planes. More precisely, the first conductor 504 is arranged vertically above the second conductor 508.

[0061] The first and second conductors 504 and 508 generate a magnetic flux when current flows through the first and second conductors 504 and 508 respectively. Fig. Figure 5 shows exemplary magnetic flux lines if the first and second conductors 504 and 508 are arranged in the same horizontal plane. As in Fig. As illustrated in Figure 6, the magnetic fluxes generated by the first and second conductors 504 and 508 overlap to a greater extent and therefore cancel each other out more strongly when the first conductor 504 is arranged vertically above the second conductor 508. The present application minimizes the parasitic inductance and optimizes the switching and thermal performance of the inverter module 316.

[0062] A first power module 604 contains the first switch 516. The first power module 604 does not contain the second switch 520. The first module 604 may also contain the antiparallel diode 524. A second power module 608 contains the second switch 520. The second power module 608 does not contain the first switch 516. The second power module 608 may also contain the antiparallel diode 528. While the switches of the first branch 512 are described, the switches of the other branches can be implemented and arranged in power modules in a similar manner. Although an example of an inverter module is provided, the present application is also applicable to power modules of other types of power converters that contain half-bridges of switches, such as boost converters, buck converters, boost / blow converters, and other types of voltage converters.While the example of the first and second power modules is described, the present application is also applicable to the high- and low-side switches 516 and 520 and the first and second chips containing the first and second switches 516 and 520.

[0063] The first and second power modules 604 and 608 are arranged on different vertical planes. More precisely, the first power module 604 is arranged vertically above the second power module 608. The edges of the first power module 604 can each be arranged vertically above the corresponding edges of the second power module 608.

[0064] The first and second power modules 604 and 608 generate a magnetic flux when current flows through them. The magnetic flux generated by the first and second power modules 604 overlaps to a greater extent and therefore cancels out more when the first power module 604 is arranged vertically above (and parallel to) the second power module 608. If the busbars are parallel to each other, this also cancels out the magnetic flux to a greater extent. Although the example of the first power module 604 arranged vertically above the second power module 608 is shown, the present application is also applicable to the second power module 608 arranged vertically above the first power module 604. The present application minimizes the parasitic inductance and optimizes the switching and thermal performance of the inverter module 316.

[0065] Fig. Figure 7 is a cross-sectional view of an exemplary implementation of the first branch 512 of the inverter module. As illustrated, the high-side (busbar) 304 (+DC) is connected to the first power module 604, and the low-side (busbar) 308 is connected to the second power module 608. The arrows in Fig. Figure 7 illustrates exemplary current flow directions. Although only one branch is shown, each of the branches can be identical.

[0066] An AC phase conductor 704, electrically connected between junction 504 (between the first and second switches 516 and 520) and a winding of motor 198, extends vertically between the first power module 604 and the second power module 608. The current flow through conductor 704 opposes the current flow through power modules 604 and 608, thus minimizing magnetic flux and increasing magnetic flux cancellation. The AC conductor 704 cancels the magnetic flux of power modules 604 and 608 and also cancels the magnetic flux of the high- and low-side busbars 304 and 308. Electrically insulating material can be placed between the first power module 604 and conductor 704, and between the second power module 608 and conductor 704.

[0067] While in Fig. Figure 7 illustrates that 304 and 308 extend only in one direction (left). However, 304 and 308 can extend in both directions (left and right), as shown in Figure 7. Fig. 4 is illustrated.

[0068] Fig. Figure 8 is a cross-sectional view of an exemplary implementation of the first branch 512 of the inverter module. As shown in Fig. As illustrated in Figure 8, the capacitor(s) 312 can be arranged vertically between the high- and low-sides 304 and 308. The capacitor(s) 312 can also be arranged horizontally away from the first and second power modules 604.

[0069] In various implementations, heat sinks can be provided on one or both of the first and second power modules 604 and 608. For example, in Fig. A first heat sink 804 is arranged on a vertically upper side of the first power module 604, and a second heat sink 808 is arranged on a vertically lower side of the second power module 604. The first and second heat sinks 804 and 808 facilitate heat transfer from the first and second power modules 604 and 608, respectively.

[0070] In various implementations, an encapsulation material 812 may be included, encapsulating the first and second power modules 604 and 608, the first and second heat sinks 804 and 808, and part of the conductor 704. Gate signals (G1 and G2) are routed to the first and second switches 516 via conductors 816 and 820, which extend through the encapsulation material 812. In various implementations, the first and second heat sinks 804 and 808 may be made of a metal such as aluminum or another suitable thermally conductive material. In various implementations, the first and second heat sinks 804 and 808 may consist of sintered or soldered metal fins.

[0071] Although the example of Fig. Figure 8 illustrates that conductor 704 extends vertically downwards; conductor 704 can also extend horizontally (e.g., as in Fig. 7 shown) through an opening through the capacitor(s) 312.

[0072] Fig. Figure 9 is a cross-sectional view of an exemplary implementation of the first branch 512 of the inverter module. As shown in Fig. As illustrated in Figure 9, the capacitor(s) 312 can be arranged vertically above the first and second power modules 604 and 608. While the capacitor(s) 312 are shown arranged vertically above the first and second power modules 604 and 608, the capacitor(s) 312 can alternatively be arranged vertically below the first and second power modules 604 and 608. The conductor 704 can be arranged horizontally (e.g., as in Figure 9). Fig. 9 shown) extend or vertically (e.g. as in Fig. (shown in section 8) extend.

[0073] Fig. Figure 10 is a cross-sectional view of an exemplary implementation of the first branch 512 of the inverter module. In the example of Fig. 10. The first heat sink 804 can be arranged on a vertically lower side of the first power module 604 and touch it, and the second heat sink 808 can be arranged on a vertically upper side of the second power module 608 and touch it.

[0074] A first electrical conductor 1004 can be arranged vertically above the first power module 604 and connected to the first power module 604 and the node 504. A second electrical conductor 1008 can be arranged vertically below the second power module 608 and connected to the second power module 608 and the node 504. The node 504 can be arranged vertically between the first and second power modules 604 and 608. The first and second electrical conductors 1004 and 1008 can be considered parts of conductor 704.

[0075] Fig. Figure 11 is a cross-sectional view of an exemplary implementation of the first branch 512 of the inverter module. In the example of Fig. 11. A thermal interface material (TIM) 1104 can be arranged on a vertically upper side of the first power module 604 and on a vertically lower side of the second power module 608. The TIM 1104 can be, for example, a thermal paste or another suitable type of thermally conductive material. The first and second conductors 1004 and 1008 can directly contact the TIM 1104. The TIM 1104 can be made of an electrically insulating material.

[0076] A third heat sink 1108 can be arranged vertically above the first conductor 1004, and a fourth heat sink 1112 can be arranged vertically below the second conductor 1008. The first and second heat sinks 804 and 808 can be arranged to facilitate heat transfer from the first and second power modules 604 and 608, respectively, via the first and second conductors 1004 and 1008 and the TIM 1104.

[0077] Fig. Figure 12 is a cross-sectional view of an exemplary implementation of a power module, such as the first branch 512 of the inverter module. A soldered metal layer 1204 can be arranged vertically above a first chip 516 / 524 and between the first chip 516 / 524 and the high-side 304. The first chip 516 / 524 contains the first switch 516 and the first diode 524. In this example, the high-side 304 can contain a conductor hard-soldered with an active metal (AMB) or directly bonded with copper (DBC), comprising first and second copper layers 1208 and 1212, which are directly bonded to a ceramic layer 1216 sandwiched between the first and second copper layers 1208 and 1212. The first heat sink 804 can directly contact the second copper layer 1212.

[0078] A metal-sintered or soldered layer 1220 can be arranged vertically between the first chip 604 and a spacer 1224. The spacer 1224 can be made of an electrically conductive material such as a metal. The spacer 1224 is arranged vertically between the sintered layer 1220 and the first conductor 704, which is connected to the motor 198.

[0079] A metal-sintered or soldered layer 1228 can be arranged vertically beneath a second chip 520 / 528 and between the second chip 520 / 528 and the low-side 308. In this example, the low-side 308 can contain an AMB or DBC conductor comprising first and second copper layers 1232 and 1236, respectively, which are directly bonded to a ceramic layer 1240 sandwiched between the first and second copper layers 1232 and 1236. The second heat sink 808 can directly contact the second copper layer 1236.

[0080] Fig. 13 and Fig. Figure 14 shows cross-sectional views of an exemplary implementation of the first branch 512 of the inverter module. In the example of Fig. 13 and Fig. In the example shown, the first conductor 704 extends in one direction away from the capacitor 312 and does not extend vertically between the first and second power modules 604 and 608. The first and second heat sinks 804 and 808 are shown in the example of Fig. 13 are arranged on the vertical upper and lower sides of the first and second power modules 604 and 608, respectively. In the example of Fig. 14 The first and second heat sinks 804 and 808 are arranged on the vertical lower and upper sides of the first and second power module 604 and 608, respectively.

[0081] Fig. Figure 15 is a cross-sectional view of an exemplary implementation of a power module, such as the first branch 512 of the inverter module. In the example of Fig. 15 The spacer 1224 is arranged directly between the conductor 704 and the copper layer 1232.

[0082] Fig. 16 is similar to the Fig. 13 and Fig. Figure 14 shows a cross-sectional view of an exemplary implementation of the first branch 512 of the inverter module. In the example of Fig. 16. Ladder 704 extends to the right and not further between the high and low sides (ladders) 304 and 308.

[0083] Fig. Figure 17 shows a cross-sectional view of an exemplary implementation of the first branch 512 of the inverter module. As illustrated, the first and second power modules 604 and 608 can be arranged within a housing 1704. A coolant 1708 can circulate through the interior of the housing 1704 (a coolant channel), such as through fins or ribs of the heat sink, to increase heat transfer away from the first and second chips 516 / 524 and 520 / 528. The coolant 1708 can be, for example, a liquid, a gas, or a phase-change material. Fig. 12 and 15-17 show an exemplary (single) performance module that includes both the first and second performance modules 604 and 608.

[0084] Fig. Figure 18 is a cross-sectional view of an exemplary implementation of the spacer 1224. As shown in Fig. As illustrated in Figure 18, the spacer 1224 can contain a hollow core (coolant channel) 1804. Additionally or alternatively to Fig. 17. The coolant 1708 can circulate through the core 1804 to increase heat transfer away from the first and second power modules 604 and 608. The example in Fig. Figure 17 illustrates a form of immersive cooling, while the example in Fig. 18 illustrates a form of internal cooling.

[0085] Fig.Figure 19 is a functional block diagram of an exemplary cooling system. A coolant pump 1904 pumps a cooler coolant through the coolant channel(s) 1908, such as 1704 and / or 1804. The coolant extracts heat from the first and second chips 604 and 608. The now warmer coolant flows to a heat exchanger 1912, which increases the heat transfer away from the coolant to a medium (e.g., air) passing through the heat exchanger 1912. The coolant pump 1904 pumps the cooled coolant from the heat exchanger back into the coolant channel(s) 1908 for further cooling.

[0086] The parallel and vertically spaced alignment of the first and second power modules 604 and 608, such that the upper and lower surfaces of the first power module 604 are parallel to the upper and lower surfaces of the second power module 608, ensures stronger magnetic field cancellation and lower stray inductance. The AC output conductor, located between the power modules 604 and 608 and between the DC busbars 304 and 308, also enhances electromagnetic field cancellation. This minimizes stray and loop inductance. The above concepts are combined with a thermal material design that allows for single- or double-sided cooling to reduce thermal impedance. Lower stray inductance results in lower switching losses and reduces parasitic oscillations.(ringing), reduces electromagnetic interference (EMI) and decreases voltage and current peaks as well as the stress on the device. This also minimizes the parasitic inductance of the inverter module. The above also minimizes the overall loop size of the chip / power modules and the capacitor(s) to minimize parasitic inductance. The output bus (704) can be placed between the chips and their connected busbars for increased magnetic field cancellation. Even if the chip's current flow direction is perpendicular to the AC busbar, the DC busbars and the high-side and low-side busbars still cancel electromagnetic fields with the AC busbar.

[0087] Although the example of the inverter module is provided or cited, the present application is also applicable to other types of power converters, including half-bridges such as those in power modules and as described above.

[0088] The preceding description is merely illustrative and intended to limit the scope of the revelation, its application, or uses. The comprehensive doctrine of revelation can be implemented in a multitude of forms. Therefore, although this revelation contains particular examples, the true scope of the revelation should not be so limited, since other modifications will become apparent upon study of the drawings, the description, and the following claims. It should be understood that one or more steps within a process may be carried out in a different order (or simultaneously) without altering the principles of the present revelation.Furthermore, although each of the embodiments described above is characterized by certain features, one or more of these features described in relation to any embodiment of the disclosure may be implemented in one of the other embodiments and / or combined with features of one of the other embodiments, even if this combination is not expressly described. In other words, the described embodiments are not mutually exclusive, and permutations of one or more embodiments with each other remain within the scope of this disclosure.

[0089] Spatial and functional relationships between elements (for example, between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including "connected," "interlocked," "coupled," "adjacent," "near or beside," "on," "above," "below," and "arranged." Unless explicitly described as "direct," when a relationship between first and second elements is described in the above disclosure, this relationship may be a direct relationship, in which no other intervening elements exist between the first and second elements, or it may be an indirect relationship, in which one or more intervening elements (either spatial or functional) exist between the first and second elements.As used here, the phrase “at least one of A, B and C” should be understood as meaning a logical (A OR B OR C) using a non-exclusive logical OR, and should not be understood as meaning “at least one of A, at least one of B and at least one of C”.

[0090] In the diagrams, the direction of an arrow, as indicated by its tip, generally illustrates the flow of information (e.g., data or instructions) that is relevant to the illustration. For example, if Element A and Element B exchange a variety of information, but information transferred from Element A to Element B is important for the illustration, the arrow may point from Element A to Element B. This unidirectional arrow does not imply that no other information is transferred from Element B to Element A. Furthermore, Element B may send requests for, or acknowledgments of, information to Element A in connection with the information transferred from Element A to Element B.

[0091] In this application, including the definitions below, the term "module" or the term "controller" may be replaced by the term "circuit". The term "module" may refer to, be part of, or include an application-specific integrated circuit (ASIC); a digital, analog, or mixed analog / digital discrete circuit; a digital, analog, or mixed analog / digital integrated circuit; a combinational logic circuit; a field-programmable gate array (FPGA); a processor circuit (shared, dedicated, or group) that executes code; a memory circuit (shared, dedicated, or group) that stores code executed by the processor circuit; other suitable hardware components that provide the described functionality; or a combination of some or all of the above components, such as in a system-on-a-chip.

[0092] The module may contain one or more interface circuits. In some examples, the interface circuits may include wired or wireless interfaces connected to a local area network (LAN), the internet, a wide area network (WAN), or combinations thereof. The functionality of any given module of this disclosure may be distributed among multiple modules connected via interface circuits. For example, multiple modules may enable load balancing. In another example, a server module (also known as a remote or cloud module) may perform some functions for a client module.

[0093] The term "code," as used above, can include software, firmware, and / or microcode, and can refer to programs, routines, functions, classes, data structures, and / or objects. The term "shared processor circuit" refers to a single processor circuit that executes some or all of the code from multiple modules. The term "group processor circuit" refers to a processor circuit that, in combination with additional processor circuits, executes some or all of the code from one or more modules. References to multiple processor circuits include multiple processor circuits on separate chips, multiple processor circuits on a single chip, multiple cores of a single processor circuit, multiple threads of a single processor circuit, or a combination of the above.The term shared memory circuit refers to a single memory circuit that stores some or all of the code from multiple modules. The term group memory circuit refers to a memory circuit that, in combination with additional memory, stores some or all of the code from one or more modules.

[0094] The term storage circuit is a subset of the term computer-readable medium. The term computer-readable medium, as used here, does not include transitory electrical or electromagnetic signals that propagate through a medium (such as on a carrier wave); the term computer-readable medium can therefore be considered material and non-transient.Non-restrictive examples of a non-transient, physical, computer-readable medium include non-volatile memory circuits (such as a flash memory circuit, a erasable programmable read-only memory circuit, or a mask read-only memory circuit), volatile memory circuits (such as a static random access memory circuit or a dynamic random access memory circuit), magnetic storage media (such as an analog or digital magnetic tape or a hard disk drive), and optical storage media (such as a CD, a DVD, or a Blu-ray Disc).

[0095] The devices and methods described in this application can be partially or fully implemented by means of a special-purpose computer created by configuring a general-purpose computer to perform one or more specific functions embodied in computer programs. The functional blocks, flowchart components, and other elements described above serve as software specifications that can be translated into computer programs through the routine work of a person skilled in the art or a programmer.

[0096] Computer programs contain instructions executable by processors, stored on at least one non-transient, physical, computer-readable medium. Computer programs may also contain or rely on stored data. Computer programs may include a basic input / output system (BIOS) that interacts with the computer's special-purpose hardware, device drivers that interact with specific devices of the computer for special purposes, one or more operating systems, user applications, background services, background applications, etc.

[0097] The computer programs can contain: (i) descriptive text to be parsed, such as HTML (Hypertext Markup Language), XML (Extensible Markup Language), or JSON (JavaScript Object Notation); (ii) assembly code; (iii) object code generated from source code by a compiler; (iv) source code for execution by an interpreter; (v) source code for compilation and execution by a just-in-time compiler; etc. For example, source code can be written using syntax from languages ​​such as C, C++, C#, Objective-C, Swift, Haskell, Go, SQL, R, Lisp, Java®, Fortran, Perl, Pascal, Curl, OCaml, Javascript®, HTML5 (Hypertext Markup Language 5th Revision), Ada, ASP (Active Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Flash®, and Visual Basic®. Include Lua, MATLAB, SIMULINK and Python®.

Claims

[1] Branch (512, 532, 536) of a power converter, wherein branch (512) comprises: a first of (a) a first power module (604) and (b) a first chip, the first comprising a high-side switch (516) with a first terminal configured to be connected to a first DC busbar (304) at a first potential; and a second of (a) a second power module (608) and (b) a second chip, the second of which includes a low-side switch (520) with a first terminal configured to connect to a second DC busbar (308) having a second potential different from the first potential; and an alternating current (AC) busbar (704) arranged vertically (a) between the first and the second and (b) between the first DC busbar (304) and the second DC busbar (308), wherein the AC busbar (704) is arranged between a first, vertically lower surface of the First and a second, vertically upper side of the Second and is electrically connected to second terminals of the high- and low-side switches (516, 520); characterized by , that the branch (512, 532, 536) further comprises an electrically insulating material arranged between: the first, vertically lower surface of the first and the AC busbar (704); and the second, vertical upper surface of the second and the AC busbar (704). [2] Branch (512, 532, 536) according to claim 1, wherein the AC busbar (704) is configured to be electrically connected to a phase of an electric motor (198). [3] Branch (512, 532, 536) according to claim 1, further comprising: a first heat sink (804) configured to dissipate heat from the first; and a second heat sink (808) configured to dissipate heat from the second one. [4] Branch (512, 532, 536) according to claim 3, wherein: the first heat sink (804) is arranged on a first, vertically upper surface of the first; and the second heat sink (808) is arranged on a second, vertically lower surface of the second.

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