POWER MODULE FOR AN ELECTRIFIED VEHICLE

Abstract

A three-phase power electronics module for an electric vehicle uses capacitor modules with power modules inserted between them. Different methods are proposed for establishing the electrical connections between the capacitor modules and the power modules. One method uses busbars that include overlapping planar regions. Another method uses the terminals of the capacitor modules to connect to the DC terminals of neighboring power modules.

Description

FIELD OF TECHNOLOGY

[0001] The present invention relates to a power electronics module for an electrified vehicle. In particular, it relates to means for electrically connecting capacitor modules and power modules that comprise the power electronics module. GENERAL STATE OF THE ART

[0002] Electric and hybrid vehicles may include power modules configured to convert electrical power from direct current (DC) to alternating current (AC) and / or vice versa. SUMMARY

[0003] A three-phase power electronics module includes three power modules, at least two capacitor modules, and two busbars. The three power modules are arranged in a series. Each power module has a positive DC terminal, a negative DC terminal, and an AC terminal and is configured to convert DC electrical power delivered through the two DC terminals into AC electrical power at the AC terminal. The capacitor modules are inserted between the power modules. A third capacitor module may be located at one end of the three power modules. Each capacitor module has a positive terminal and a negative terminal. A first busbar, having a first planar region, electrically connects the positive DC terminals of the power modules and the positive terminals of the capacitor modules.A second busbar, having a second planar region, overlaps and is spaced from the first planar region and electrically connects the negative DC terminals of the power modules and the negative terminals of the capacitor modules. An insulator may separate the first planar region from the second planar region. The first planar region and the second planar surface may be parallel or perpendicular to a top surface from which the DC terminals extend. One of the busbars may have a stepped profile, or one of the DC terminals may extend farther from the top surface than the other.

[0004] A three-phase power electronics module includes three power modules and at least two capacitor modules. The three power modules are arranged in a series. Each power module has a positive DC terminal, a negative DC terminal, and an AC terminal and is configured to convert DC electrical power delivered through the two DC terminals into AC electrical power at the AC terminal. The two capacitor modules are inserted between the power modules. Each capacitor module has a positive terminal and a negative terminal. The positive terminal of each capacitor module extends between and is electrically connected to the positive DC terminals of adjacent power modules. The negative terminal of each capacitor module extends between and is electrically connected to the negative DC terminals of adjacent power modules.Each power module may include a housing defining two slots, each providing access to one of the two DC terminals. Each of the power modules may also include a set of signal terminals extending through the housing. Each of the capacitor modules may include a housing adjacent to the housing of adjacent power modules. A third capacitor module may be adjacent to an outer power module of the three power modules. An end plate may be adjacent to the housing of the third capacitor module. The end plate may define two slots through which the positive DC terminal and the negative DC terminal of the third capacitor module extend.

[0005] A capacitor module for a power electronics module includes a capacitor element, positive and negative terminals, and an overmolded housing. The capacitor element has first and second charge collectors. The positive and negative terminals are each electrically connected to one of the charge collectors. Each of the terminals includes a tab extending through a first side of the housing and another tab extending through a second side of the housing opposite the first side. The tabs may be aligned or offset from each other. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 illustrates a block diagram of an electric vehicle. Fig. 2 illustrates a schematic representation of components of an electric drive system of the electric vehicle, wherein the components of the electric drive system include a traction battery, a power electronics module having a DC link capacitor and an inverter, and an electric motor. Fig. Figure 3 is a pictorial view of a three-phase power electronics module. Fig. 4 is a pictorial view of the three-phase power electronics module of Fig. 3 with overlapping busbars in a first configuration. Fig. 5 is a cross-sectional view of the busbars of Fig. 4 according to a first configuration. Fig. 6 is a cross-sectional view of the busbars of Fig. 4 according to a first configuration. Fig. Figure 7 is a pictorial view of the three-phase power electronics module of Fig. 3 with overlapping busbars in a second configuration. Fig. Figure 8 is a pictorial view of the three-phase power electronics module of Fig. 3 with overlapping busbars in a third configuration. Fig. 9 is a pictorial view of the three-phase power electronics module of Fig. 3 with overlapping busbars in a fourth configuration. Fig. 10 is a pictorial view of the three-phase power electronics module of Fig. 3 with overlapping busbars in a fifth configuration. Fig. 11 is a pictorial view of internal components of a power module. Fig. 12 is a pictorial view of a power module incorporating the Fig. 11 illustrated internal components and an over-molded housing. Fig. Figure 13 is a pictorial view of internal components of a capacitor module. Fig. 14 is a pictorial view of a capacitor module incorporating the Fig. 13 illustrated internal components and an over-molded housing. Fig. 15 is a pictorial view of internal components of a power module of Fig. 11, which is connected to the internal components of two adjacent capacitor modules from Fig. 13 are connected. Fig. Figure 16 is a pictorial view of the three-phase power electronics module comprising the power modules of Fig. 11 and Fig. 12 and the capacitor modules from Fig. 13 and Fig. 14 uses, as in Fig. 15 illustrates the connection. Fig. 17 is a pictorial view of internal components of a power module of Fig. 11, which are connected to the internal components of two adjacent capacitor modules with an alternative design. Fig. 18 is a pictorial view of internal components of a power module having an alternative configuration connected to the internal components of two adjacent capacitor modules having an alternative configuration. DETAILED DESCRIPTION

[0006] Detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be greatly exaggerated or reduced to show details of particular components. Therefore, specific structural and functional details disclosed in this specification are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

[0007] Now with reference to Fig. 1 shows a block diagram of an exemplary electric vehicle (“EV”) 22. In this example, the EV 22 is a plug-in hybrid electric vehicle (PHEV). The EV 22 includes one or more electric machines 24 (“e-machines”) mechanically connected to a transmission 26. The electric machine 24 is capable of operating as an electric motor and a generator. The transmission 26 is mechanically connected to an internal combustion engine 28 and to a driveshaft 30 that is mechanically connected to wheels 32. The electric machine 24 can provide propulsion and deceleration capability while the internal combustion engine 28 is on or off. The electric machine 24, acting as a generator, can recover energy that might normally be lost as heat.The electric machine 24 may reduce vehicle emissions by enabling the internal combustion engine 28 to operate at more efficient speeds and by enabling the EV 22 to operate in electric mode with the internal combustion engine 28 turned off under certain conditions.

[0008] A traction battery 34 ("battery") stores energy that can be used by the electric machine 24 to power the EV 22. The battery 34 typically provides a high-voltage direct current (HV-DC) output. The battery 34 is electrically connected to a power electronics module 36. The power electronics module 36 is electrically connected to the electric machine 24 and provides the ability to transfer energy bidirectionally between the battery 34 and the electric machine. For example, the battery 34 may provide a DC voltage, while the electric machine 24 may require a three-phase alternating current (AC) voltage to operate. The power electronics module 36 may convert the DC voltage to a three-phase AC voltage to operate the electric machine 24.In a regeneration mode, the power electronics module 36 can convert the three-phase AC voltage from the electric machine 24 acting as a generator into DC voltage compatible with the traction battery 34.

[0009] The battery 34 is rechargeable by an external power source 46 (e.g., the grid). An electric vehicle supply equipment (EVSE) 48 is connected to the external power source 46. The EVSE 48 provides circuitry and controls to control and manage the transfer of energy between the external power source 46 and the EV 22. The external power source 46 may provide DC or AC electrical power to the EVSE 48. The EVSE 48 may have a charging connector 50 for plugging into a charging port 44 of the EV 22. The charging port 44 may be any type of port configured to transfer power from the EVSE 48 to the EV 22. A power conversion module 42 of the EV 22 may condition power supplied by the EVSE 48 to provide the proper voltage and current levels to the battery 34.The power conversion module 42 may interface with the EVSE 48 to coordinate the delivery of power to the battery 34. Alternatively, various components described as electrically connected may transfer power using wireless inductive coupling.

[0010] The various components discussed may have one or more associated controllers to control and monitor the operation of the components. The controllers may be microprocessor-based devices. The controllers may communicate via a serial bus (e.g., a Controller Area Network (CAN)) or via separate conductors. For example, a system controller 58 (i.e., a vehicle controller) is present to coordinate the operation of the various components.

[0011] As described, in this example, the EV 22 is a PHEV, which includes an internal combustion engine 28 and a battery 34. In other embodiments, the EV 22 is a battery electric vehicle (BEV). In a BEV configuration, the EV 22 does not include an internal combustion engine.

[0012] Now with reference to Fig. 2 is with continuous reference to Fig. 1 shows a schematic representation of components of an electric drive system of the EV 22. As in Fig. 2, the electric drive system of the EV 22 includes the traction battery 34, the power electronics module 36, and the electric machine (i.e., “the electric motor”) 24.

[0013] As described above, the power electronics module 36 is coupled between the battery 34 and the electric motor 24. The power electronics module 36 converts DC electrical power provided by the battery 34 into AC electrical power for supply to the electric motor 24. In this way, the power electronics module 36 drives the electric motor 24 with power from the battery 34, allowing the electric motor to propel the EV 22.

[0014] The power electronics module 36 includes a DC link capacitor 72 and an inverter 70 (or an “Inverter Control System” (ICS)). Fig. The inverter 70 shown in Figure 2 is an exemplary inverter. The DC link capacitor 72 is disposed between the battery 34 and the inverter 70 and is connected in parallel with the battery 34. The DC link capacitor 72 is operable to absorb ripple currents generated by the operation of power switches of the inverter 70 and to stabilize a DC link voltage Vo for controlling the inverter 70.

[0015] As is known to those of ordinary skill in the art, inverters convert DC power into multi-phase AC power (three-phase being the most common). Inverters can move electrical power in either direction (bidirectional), thereby either driving (i.e., running) an electrical machine or electrically slowing (i.e., generating) the electrical machine. An inverter system consists of a combination of electronic power hardware (switches) and control software ( Fig. 2 is a representative drawing). The electric current can be quickly adjusted by opening and closing the circuit breakers in the inverter.

[0016] Many inverter systems, including inverters relevant to embodiments of the present invention, such as inverter 70, perform closed-loop current control to precisely control the electric machine. To achieve this, the electrical current in each phase of the inverter is sensed with a current sensor, and a corresponding signal is provided to the inverter system controller. The most common approach is to sense all phases, where any phase current can be derived from knowledge of the other phase currents. The current sensor can use and / or be implemented in different technologies and can Fig. The current sensors 80 shown in Figure 2, which are discussed below, are only one example. Such current sensors are typically integrated into the inverter.

[0017] The inverter 70 includes an inverter circuit and a plurality of power switching units 74. As known to those of ordinary skill in the art, the inverter 70 in the exemplary example includes three sets of pairs of power switching units 74 (i.e., three x two = a total of six power switching units 74, as shown in Fig. 2). Each pair of power switching units 74 includes two power switching units 74 connected in series. Each power switching unit 74 includes a power switch 76 in the form of a transistor arranged in anti-parallel with a diode 78. In this example, the transistor is an insulated gate bipolar transistor (IGBT). Each pair of power switching units 74 is connected in parallel with the battery 34 and the DC link capacitor 72, and thereby each pair of power switching units forms a "phase" of the inverter 70. In this manner, the inverter 70, which has three pairs of power switching units 74, is a three-phase inverter operable to convert DC electrical power from the battery 34 into three-phase AC electrical power for supply to the electric motor 24.

[0018] Furthermore, each phase of the inverter 70 includes a current sensor 80. For example, each current sensor 80 is a resistive shunt connected in series with the output of the corresponding phase. Current sensors 80 are operable to measure the electrical current (I AC ) output from the corresponding phases of the inverter 70 to the electric motor 24.

[0019] The power electronics module 36 has an associated controller 73. The controller 73 may be a microprocessor-based device. The controller 73 is configured to monitor the operation of the DC link capacitor 72 and to monitor and control the operation of the inverter 70. In particular, the controller 73 is operable to control the operation of the power switches 76 to cause the inverter 70 to convert a given DC electrical power provided by the battery 34 via the DC link capacitor 72 into a desired AC electrical power for provision to the electric motor 24. The controller 73 is in communication with current sensors 80 to monitor the AC electrical power provided to the electric motor 24 by the inverter 70.The controller 73 uses information from current sensors 80 as feedback in controlling the inverter 70 to output the desired AC electrical power to the electric motor 24.

[0020] Fig. Figure 3 is a pictorial view of a three-phase power electronics module 36. The switches of the inverter 70 are distributed among three power modules 81. The DC link capacitor is implemented using three capacitor modules 82. The power modules 81 and the capacitor modules 82 are nested together. As discussed in more detail below, each power module and each capacitor module include an over-molded housing. These housings, together with end covers 84 and 86, collectively form a power module housing. The end cover 86 includes an inlet port 88 and an outlet port 90 for cooling fluid. The power module and capacitor module housings together form a series of fluid passages for directing the cooling fluid past heat-generating components, as described in more detail in U.S. patent application Ser. No. 18 / 488,223, filed November 17, 2023, which is hereby incorporated by reference.

[0021] Each power module includes a positive DC terminal 92, a negative DC terminal 94, and an AC output terminal 96. Terminal 92 is electrically connectable to the positive terminal of battery 34. Terminal 94 is electrically connectable to the negative terminal of battery 34. Terminal 96 is electrically connectable to one of the phase leads of electric motor 24. Two elements are electrically connected when an electrical path is established between the elements, either by direct contact or via one or more electrically conductive components. Each power module 81 includes a pair of power switching units 74. Each power module is configured to convert direct current (DC) power delivered via the DC terminals into one phase of AC power delivered via terminal 96 based on control signals received via a set of signal terminals 98.

[0022] Each capacitor module includes a positive terminal 100 and a negative terminal 102. Terminal 100 is electrically connected to the positive DC terminals of the power modules and the positive terminal of the battery 34. Terminal 102 is electrically connected to the negative DC terminals of the power modules and the negative terminal of the battery 34.

[0023] Fig. Figure 4 illustrates one way in which the aforementioned electrical connections may be achieved. The positive busbar 104 electrically connects all of the positive DC terminals 92 of the three power modules 81 and all of the positive terminals 100 of the three capacitor modules 82. Likewise, the negative busbar 106 electrically connects all of the negative DC terminals 94 of the three power modules 81 and all of the negative terminals 102 of the three capacitor modules 82. The busbars are sheet metal parts made of electrically conductive materials, such as copper or aluminum. The busbars are held in contact with the terminals, such as by spot welding. Both busbars include a planar region 108 that overlaps the other busbar. This facilitates current cancellation and reduces parasitic power loop inductance.An insulating layer 110 separates the two busbars and prevents the flow of electrical current between them. The insulating layer 110 is made of an electrically non-conductive material, such as paper.

[0024] Fig. 5 and Fig. 6 illustrate two different ways of establishing electrical contact between the terminals 100 and 102 of the capacitor modules and the busbars 104 and 106 in the embodiment of Fig. 4. The same options also provide electrical contact between the DC terminals 92 and 94 of the power modules and the busbars. In the embodiment shown in Fig. 5, the terminal 102 extends further from the top surface of the housing to accommodate the thickness of the bus bar 104 and the insulator 110. In the embodiment of Fig. 6, terminals 100 and 102 extend the same distance, but busbar 106 has a stepped profile to accommodate the thickness of busbar 104 and insulator 110.

[0025] Fig. Figure 7 illustrates another embodiment. In this embodiment, terminals 92, 94, 100, and 102 all have vertical portions extending from the tops of the respective housings and providing a surface parallel to the sides of the respective housings. The terminals may also have other surfaces. Busbars 104 and 106 contact these vertical surfaces. An insulator (not shown) may separate the busbars. In addition to a light interference fit, the busbars may be spot-welded to the terminals. In this embodiment, the entire busbar forms the planar region that overlaps to provide flow cancellation.

[0026] Fig. Figure 8 illustrates another embodiment. In this embodiment, the busbars 104 and 106 include a set of first tabs 112 that extend at right angles to the planar regions. These first tabs may be spot-welded to corresponding tabs on the positive and negative terminals of the capacitor modules. In the embodiment of Fig. 9, the busbars also include a set of second tabs 114 extending at right angles from the planar regions. These second tabs may be spot-welded to corresponding tabs on the positive DC terminals and negative DC terminals of the capacitor modules.

[0027] In the embodiment from Fig. 10, each of the busbars includes a set of plugs 116 extending at right angles to the planar regions. The first tabs 118 and the second tabs 120 extend from the plugs at right angles to both the planar regions and the plugs. The first tabs are spot-welded to the positive and negative terminals of the capacitor modules. The second tabs are spot-welded to the positive and negative DC terminals of the power modules.

[0028] Fig. 11-18 illustrate another design concept for electrically connecting the components of the three-phase power module. Fig. Figure 11 illustrates a power module prior to housing molding. A circuit board 130 includes two power switching units 74 and a current sensor 80. Signal terminals 98 extend from one edge of the circuit board 130. The positive DC terminal 92, the negative DC terminal 94, and the AC output terminal 96 extend from another edge of the circuit board 130. The AC output terminal 96 extends farther from the edge than any of the DC terminals. The DC terminals include a surface perpendicular to the circuit board 130. Fig. Figure 12 illustrates a power module 81 after overmolding a housing 132 onto the assembly of Fig. 11. The AC output terminal 96 and the signal terminals 98 extend through the housing 132. The housing includes two through slots 134 and 136 that provide access to the positive DC terminal 92 and the negative DC terminal 94.

[0029] Fig. Figure 13 illustrates a capacitor module prior to housing molding. A capacitor element 140 includes two charge collectors. One charge collector is electrically connected to the positive terminal 100, and the other charge collector is electrically connected to the negative terminal 102. The positive terminal 100 includes a first tab 142 extending in one direction and a second tab 144 extending in an opposite direction. Similarly, the negative terminal 102 includes a third tab 146 extending in one direction and a fourth tab 148 extending in an opposite direction. Fig. Figure 14 illustrates a capacitor module 82 after overmolding a housing 150 onto the assembly of Fig. 13. The tabs 142, 144, 146 and 148 extend through the housing 150.

[0030] Fig. Figure 15 illustrates how a power module 81 is connected to the adjacent capacitor modules 82. The modules are shown without the housings so that the connections are visible. The first tab 142 of one capacitor module and the second tab 144 of the other capacitor module both extend into the slot 136 to make contact with the positive DC terminal 92. Likewise, the third tab 146 of one capacitor module and the fourth tab 148 of the other capacitor module both extend into the slot 138 to make contact with the negative DC terminal 94. The connections to the other two power modules are similar, except that the power module at that end may have a capacitor module on only one side. Fig. Figure 16 shows the fully assembled three-phase power electronics module 36 with the overmolded housings. An end plate 152 has slots through which the second tab 144 and the fourth tab 148 of one of the capacitor modules extend. This provides access for connecting the three-phase power electronics module to the battery 34.

[0031] Fig. 17 and Fig. 18 illustrate some variations of the design concept. In the embodiment of Fig. 17, the first tab 142 is offset from the second tab 144, unlike the embodiment of Fig. 13-15, in which they are aligned with each other. This allows the tabs to extend over the positive DC terminals of the adjacent power modules for better contact. This also allows the end capacitor tab to extend further through the faceplate, making battery connection easier. In the embodiment of Fig. 18, the AC output connector is located on one side of the DC connector, rather than between them. In some installations, this allows for a more convenient connection of the electric motor.

[0032] Although exemplary embodiments are described above, these embodiments are not intended to describe all possible forms of the present invention. Rather, the terms used in the description are terms of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the present invention. In addition, the features of various implementing embodiments may be combined to form further embodiments of the present invention.

[0033] According to the present invention, a three-phase power electronics module is provided, comprising: three power modules arranged in a series, each module having a positive DC terminal, a negative DC terminal, and an AC terminal and configured to convert DC electrical power output via the two DC terminals into AC electrical power at the AC terminal; two capacitor modules inserted between the power modules, each capacitor module having a positive terminal and a negative terminal; a first bus bar having a first planar region electrically connecting the positive DC terminals of the power modules and the positive terminals of the capacitor modules;and a second bus bar having a second planar region overlapping and spaced from the first planar region and electrically connecting the negative DC terminals of the power modules and the negative terminals of the capacitor modules;

[0034] According to one embodiment, the invention is further characterized by a third capacitor module at one end of the three power modules, the third capacitor module having a positive terminal electrically connected to the first busbar and a negative terminal electrically connected to the second busbar.

[0035] According to one embodiment, the invention is further characterized by an insulator between the first planar region and the second planar region.

[0036] According to one embodiment, the DC terminals of the power modules and the terminals of the capacitor modules extend from a top surface of the power electronics module; and the first planar region and the second planar surface are parallel to the top surface.

[0037] According to one embodiment, one of the first busbar and the second busbar has a stepped profile.

[0038] According to one embodiment, one of the positive DC terminals and the negative DC terminals extends farther from the top surface than the other of the positive DC terminals and the negative DC terminals and includes a portion parallel to the top surface that is connected to a region of one of the first busbar and the second busbar that is not the first planar region or the second planar region.

[0039] According to one embodiment, the DC terminals of the power modules and the terminals of the capacitor modules extend from a top surface of the power electronics module; and the first planar surface and the second planar surface are perpendicular to the top surface.

[0040] According to one embodiment, each of the positive terminal and the negative terminal of each of the capacitor modules includes a tab extending parallel to the top surface; the first bus bar includes a plurality of tabs extending from the first planar region parallel to the top surface and electrically connected to the tabs of respective positive terminals; and the second bus bar includes a plurality of tabs extending from the second planar region parallel to the top surface and electrically connected to the tabs of respective negative terminals.

[0041] According to one embodiment, each of the positive DC terminal and the negative DC terminal of each of the power modules includes a tab extending parallel to the top surface; the first bus bar includes a plurality of tabs extending from the first planar region parallel to the top surface and electrically connected to the tabs of respective positive DC terminals; and the second bus bar includes a plurality of tabs extending from the second planar region parallel to the top surface and electrically connected to the tabs of respective negative DC terminals.

[0042] According to one embodiment, the first bus bar includes a plurality of first tabs extending perpendicular to the top surface and perpendicular to the first planar region, each first tab being electrically connected to a positive DC terminal of a power module or to a positive terminal of a capacitor module; and the second bus bar includes a plurality of second tabs extending perpendicular to the top surface and perpendicular to the second planar region, each second tab being electrically connected to a negative DC terminal of a power module or to a negative terminal of a capacitor module.

[0043] According to the present invention, there is provided a three-phase power electronics module comprising: three power modules arranged in a series, each module having a positive DC terminal, a negative DC terminal, and an AC terminal and configured to convert DC electrical power output through the two DC terminals into AC electrical power at the AC terminal; and two capacitor modules inserted between the power modules, each capacitor module having a positive terminal and a negative terminal, the positive terminal of each capacitor module extending between and being electrically connected to the positive DC terminals of adjacent power modules; and the negative terminal of each capacitor module extending between and being electrically connected to the negative DC terminals of adjacent power modules.

[0044] According to one embodiment, each power module includes a housing defining two slots, each providing access to one of the two DC connectors; and the AC connector extends through the housing.

[0045] According to one embodiment, each of the capacitor modules includes a housing that is adjacent to the overmolded housing of an adjacent power module; and the positive terminals and the negative terminals of each of the capacitor modules extend into the slots of the adjacent power modules.

[0046] According to one embodiment, the invention is further characterized by a third capacitor module adjacent to an outer power module of the three power modules, wherein: the third capacitor module includes an over-molded housing adjacent to the over-molded housing of an outer power module; a positive terminal of the third capacitor module extends into one of the slots of the outer power module and is electrically connected to the positive DC terminal of the outer power module; and a negative terminal of the third capacitor module extends into the other slot of the outer power module and is electrically connected to the negative DC terminal of the outer power module.

[0047] According to one embodiment, the invention is further characterized by an end plate adjacent to the housing of the third capacitor module, the end plate defining two slots through which the positive DC terminal and the negative DC terminal of the third capacitor module extend.

[0048] According to one embodiment, each of the power modules further includes a set of signal terminals extending through the housing.

[0049] According to the present invention, there is provided a capacitor module for a power electronics module, comprising: a capacitor element having first and second charge collectors; a positive terminal electrically connected to the first charge collector; a negative terminal electrically connected to the second charge collector; and an over-molded housing having a first side and a second side opposite the first side; wherein the negative terminal includes a first tab extending through the first side and a second tab extending through the second side; and the positive terminal includes a third tab extending through the first side and a fourth tab extending through the second side.

[0050] According to one embodiment, the first tab is aligned with the second tab; and the third tab is aligned with the fourth tab.

[0051] According to one embodiment, the first tab is offset from the second tab; and the third tab is offset from the fourth tab. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] US 18 / 488,223

[0020]

Claims

[1] Three-phase power electronics module comprising: three power modules arranged in a series, each module having a positive DC terminal, a negative DC terminal, and an AC terminal and configured to convert DC electrical power delivered via the two DC terminals into AC electrical power at the AC terminal; two capacitor modules inserted between the power modules, each capacitor module having a positive terminal and a negative terminal; a first busbar having a first planar region electrically connecting the positive DC terminals of the power modules and the positive terminals of the capacitor modules; and a second bus bar having a second planar region overlapping and spaced from the first planar region and electrically connecting the negative DC terminals of the power modules and the negative terminals of the capacitor modules. [2] The three-phase power electronics module of claim 1, further comprising a third capacitor module at one end of the three power modules, the third capacitor module having a positive terminal electrically connected to the first bus bar and a negative terminal electrically connected to the second bus bar. [3] The three-phase power electronics module of claim 1, further comprising an insulator between the first planar region and the second planar region. [4] Three-phase power electronics module according to claim 1, wherein: the DC terminals of the power modules and the terminals of the capacitor modules extend from an upper surface of the power electronics module; and the first planar region and the second planar surface are parallel to the upper surface. [5] The three-phase power electronics module of claim 4, wherein one of the first busbar and the second busbar has a stepped profile. [6] The three-phase power electronic module according to claim 4, wherein one of the positive DC terminals and the negative DC terminals extends farther from the top surface than the other of the positive DC terminals and the negative DC terminals and includes a portion parallel to the top surface connected to a region of one of the first bus bar and the second bus bar other than the first planar region or the second planar region. [7] Three-phase power electronics module according to claim 1, wherein: the DC terminals of the power modules and the terminals of the capacitor modules extend from an upper surface of the power electronics module; and the first planar surface and the second planar surface are perpendicular to the upper surface. [8] Three-phase power electronics module comprising: three power modules arranged in a series, each module having a positive DC terminal, a negative DC terminal, and an AC terminal, and configured to convert DC electrical power delivered via the two DC terminals into AC electrical power at the AC terminal; and two capacitor modules inserted between the power modules, each capacitor module having a positive terminal and a negative terminal, wherein the positive terminal of each capacitor module extends between and is electrically connected to the positive DC terminals of adjacent power modules; and the negative terminal of each capacitor module extends between and is electrically connected to the negative DC terminals of adjacent power modules. [9] Three-phase power electronics module according to claim 8, wherein: each power module includes a housing defining two slots, each providing access to one of the two DC terminals; and the AC connection extends through the housing. [10] Three-phase power electronics module according to claim 9, wherein: each of the capacitor modules includes a housing that is adjacent to the overmolded housing of an adjacent power module; and the positive terminals and the negative terminals of each of the capacitor modules extend into the slots of the adjacent power modules. [11] A three-phase power electronics module according to claim 10, further comprising a third capacitor module adjacent to an outer power module of the three power modules, wherein: the third capacitor module includes an overmolded housing that is adjacent to the overmolded housing of an outer power module; a positive terminal of the third capacitor module extends into one of the slots of the outer power module and is electrically connected to the positive DC terminal of the outer power module; and a negative terminal of the third capacitor module extends into the other slot of the outer power module and is electrically connected to the negative DC terminal of the outer power module. [12] The three-phase power electronics module of claim 11, further comprising an end plate adjacent to the housing of the third capacitor module, the end plate defining two slots through which the positive DC terminal and the negative DC terminal of the third capacitor module extend. [13] Capacitor module for a power electronics module, comprising: a capacitor element having first and second charge collectors; a positive terminal electrically connected to the first charge collector; a negative terminal electrically connected to the second charge collector; and an overmolded housing having a first side and a second side opposite the first side; wherein the negative terminal includes a first tab extending through the first side and a second tab extending through the second side; and the positive terminal includes a third tab extending through the first side and a fourth tab extending through the second side. [14] Capacitor module according to claim 13, wherein: the first tab is aligned with the second tab; and the third tab is aligned with the fourth tab. [15] Capacitor module according to claim 13, wherein: the first tab is offset from the second tab; and the third tab is offset from the fourth tab.

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