Vehicle Modular Power Conversion System

Abstract

A system for a modular power converter in a vehicle drive unit is disclosed. The modular power converter includes a first power converter unit, which includes a first power converter module located in a first housing, the first housing defining a first external recess. Furthermore, the modular power converter includes a second power converter unit, which includes a second power converter module located in a second housing. The second housing defines a second external recess and is configured to be coupled to the first housing, so that the first and second external recesses cooperate to form a first coolant channel between the first and second housings.

Claims

1. Transmission and A motor that is operationally coupled to the transmission, A power converter configured to supply power to the motor and Equipped with, The power converter includes a housing that can be fixed to at least one of the transmission and the motor. A drive unit for vehicles.

2. The housing is formed to correspond to the shape of the motor, and is configured to at least partially surround the motor. The drive unit according to claim 1.

3. The motor extends from the first side of the transmission along the motor shaft, The power converter extends parallel to the motor shaft, The drive unit according to claim 1.

4. The aforementioned transmission is An input configured to be operatively coupled to the motor, An output configured to be operatively coupled to the drive shaft, Includes, The input defines the input axis, and the output defines the output axis. The power converter is positioned between the input shaft and the output shaft, The drive unit according to claim 1.

5. The housing defines a first cylindrical concave side portion that is contoured along the circumference of the input shaft. The drive unit according to claim 4.

6. The housing is formed to correspond to the shape of the output, and the housing is configured to at least partially surround the output. The drive unit according to claim 4.

7. The housing defines a second cylindrical concave side portion that is contoured along the circumference of the output shaft. The drive unit according to claim 6.

8. The power converter defines a first coolant path that is in fluid communication with at least one of the second coolant path of the transmission and the third coolant path of the motor. The drive unit according to claim 1.

9. The coolant is configured to flow from the transmission to the power converter, and from the power converter to the motor. The drive unit according to claim 8.

10. The power converter includes a plurality of power conversion modules configured to supply power to the motor at a plurality of discrete maximum output levels. The drive unit according to claim 1.

11. The power converter is a modular power converter including a first power conversion unit and a second power conversion unit that can be coupled to each other. Each of the first power conversion unit and the second power conversion unit includes a unit housing and a power conversion module disposed within the unit housing. The drive unit according to claim 1.

12. The first power conversion unit and the second power conversion unit are selectively operable to supply power to the motor. The drive unit according to claim 11.

13. Furthermore, the system includes an electronic controller configured to selectively operate the first power conversion unit and the second power conversion unit based on the operating parameters of the drive unit. The drive unit according to claim 12.

14. The first power conversion unit and the second power conversion unit are coupled in a stack configuration so as to extend parallel to the motor shaft. The drive unit according to claim 11.

15. At least one of the power conversion modules of the first power conversion unit and the second power conversion unit is configured to operate in charging mode and supply power to the battery. The drive unit according to claim 11.

16. The housing of the first power conversion unit defines a first external recess, and the housing of the second power conversion unit defines a second external recess. The first external recess and the second external recess cooperate to form a common coolant channel between the first power conversion unit and the second power conversion unit. The drive unit according to claim 11.

17. Furthermore, it includes an end cap configured to be coupled to both the motor and the power converter, The motor and the power converter are fixed between the end cap and the transmission. The drive unit according to claim 1.

18. A first power conversion unit including a first power conversion module disposed within a first housing, wherein the first housing defines a first external recess, A second power conversion unit comprising a second power conversion module disposed within a second housing, wherein the second housing defines a second external recess and is configured to be coupled to the first housing, and the first external recess and the second external recess cooperate to define a first coolant channel between the first housing and the second housing, A modular power converter equipped with [a specific feature].

19. At least one of the first power conversion module and the second power conversion module is configured to operate in cooperation as both an inverter and a charger. The modular power converter according to claim 18.

20. At least one of the first power conversion module and the second power conversion module is configured to operate as both an inverter and a charger. The modular power converter according to claim 19.

21. At least one of the first power conversion module and the second power conversion module is configured to operate as a three-phase inverter. The modular power converter according to claim 19.

22. The second housing further defines a third external recess on the opposite side of the second external recess. The modular power converter according to claim 18.

23. Furthermore, the present invention includes a cover plate coupled to the second housing and configured to cover the third external recess, thereby defining a second coolant channel between the second housing and the cover plate. The modular power converter according to claim 22.

24. Furthermore, it includes a third power conversion unit which includes a third power conversion module located within the third housing, The third housing is configured to define a fourth external recess and to be coupled to the second housing, and the third external recess and the fourth external recess cooperate to define a second coolant channel between the second housing and the third housing. The modular power converter according to claim 22.

25. The first power conversion unit further includes a third power conversion module located within the first housing, the third power conversion module being positioned opposite the first power conversion module. The modular power converter according to claim 18.

26. Each of the power conversion units comprises multiple power conversion units, each having a first power conversion module within its housing. Multiple power conversion units, First power conversion unit, The second power conversion unit, A plurality of third power conversion units are arranged in a stack configuration between the first power conversion unit and the second power conversion unit, A modular power converter equipped with [a specific feature].

27. The plurality of power conversion units define a plurality of first coolant channels between each pair of coupled power conversion units. The modular power converter according to claim 26.

28. Each of the plurality of first coolant channels has a first lateral half defined by a first housing and a second lateral half defined by a second housing. The modular power converter according to claim 27.

29. A first cover coupled to the housing of the first power conversion unit, the first cover configured to form a second coolant channel between the first cover and the first power conversion unit, A second cover coupled to the housing of the second power conversion unit, the second cover configured to form a third coolant channel between the second cover and the second power conversion unit, The modular power converter according to claim 27, further comprising the following:

30. Each of the plurality of power conversion units further includes a second power conversion module located within the housing. The modular power converter according to claim 26.

31. The first power conversion module is positioned opposite the second power conversion module, and each of the first and second power conversion modules is coupled to a busbar extending between the first and second power conversion modules. The modular power converter according to claim 30.

32. At least one of the aforementioned power conversion units is configured to operate as a three-phase inverter. The modular power converter according to claim 26.

33. At least one of the plurality of power conversion units is configured to operate as a charger. The modular power converter according to claim 26.

34. Housing and A first power conversion module is disposed within the housing and configured to supply power at a first maximum output level, A second power conversion module is disposed within the housing and configured to supply power at a second maximum output level, A busbar fixed between the first power conversion module and the second power conversion module, wherein the first power conversion module and the second power conversion module are arranged facing each other with the busbar in between, A power converter equipped with the following features.

35. Each of the first power conversion module and the second power conversion module includes a circuit board, The aforementioned circuit board is The first side is configured to be coupled to the busbar, A second side configured to be coupled to an inductor and a field-effect transistor, To define, The power converter according to claim 34.

36. The aforementioned housing is A first external recess configured to receive the flow of the first coolant, A second external recess configured to receive the flow of the second coolant, Includes, The first external recess extends along the second side of the circuit board of the first power conversion module, The second external recess extends along the second side of the circuit board of the second power conversion module. The power converter according to claim 35.

37. The aforementioned housing is A first sheet configured to house the field-effect transistor of the first power conversion module, A second sheet configured to house the field-effect transistor of the second power conversion module, Includes, The first sheet is in fluid communication with the first external recess, The second sheet is in fluid communication with the second external recess. The power converter according to claim 36.

38. At least one of the first power conversion module and the second power conversion module is configured to operate as both an inverter and a charger. The power converter according to claim 34.

39. At least one of the first power conversion module and the second power conversion module is a three-phase inverter. The power converter according to claim 38.

40. The first power conversion module and the second power conversion module are configured to operate simultaneously to supply power at a third maximum output level. The power converter according to claim 34.

41. The housing is configured to be fixed to a drive unit including a transmission and a motor. The power converter according to claim 34.

42. The housing has a shape that at least partially surrounds the motor, The housing defines a cylindrical concave surface that is contoured along the shaft of the motor. The power converter according to claim 41.

43. A housing comprising a sheet having an internal region that is fluidly in communication with the cooling path, and a cooling path defined to receive the flow of a coolant, Power electronics components housed within the aforementioned sheet and arranged so that the coolant flows through them, A power converter equipped with the following features.

44. The power converter includes a coolant jet configured to inject the coolant jet from the cooling path toward the power electronics components, The power converter according to claim 43.

45. The coolant jet is integrally formed with the housing material. The power converter according to claim 44.

46. The aforementioned power electronics component defines a plane, The power electronics component is coupled to the circuit board, and the power electronics component is at an angle that is not perpendicular to the circuit board. The power converter according to claim 43.

47. The power converter according to claim 46, wherein the angle is approximately 45 degrees.

48. The power electronics component includes cooling fins housed within the sheet. The power converter according to claim 43.

49. The aforementioned power electronics component is a field-effect transistor. The power converter according to claim 43.

50. First conductive bar and A second conductive bar spaced apart from the first conductive bar, the second conductive bar forming a gap between the first conductive bar and the second conductive bar, A capacitor located within the gap and connected to the first conductive bar and the second conductive bar, A busbar assembly comprising the above features.

51. The first conductive bar and the second conductive bar each include a conductive tab and a conductive rail extending from the conductive tab, The capacitor is fixed between the conductive tab of the first conductive bar and the conductive tab of the second conductive bar. The busbar assembly according to claim 50.

52. The conductive tab defines a first height, The conductive rail defines a second height that is lower than the first height. The busbar assembly according to claim 51.

53. The conductive tab has a defined first length, The conductive rail defines a second length that is shorter than the first length. The busbar assembly according to claim 52.

54. The first bar is arranged concentrically with the second bar, and the gap has a substantially constant width along the length of the busbar assembly. The busbar assembly according to claim 50.

55. The capacitor is one of several capacitors. The busbar assembly according to claim 50.

56. The plurality of capacitors are arranged in series between the first conductive bar and the second conductive bar. The busbar assembly according to claim 55.

57. The plurality of capacitors are fixed to each other by mounting brackets and are fixed to the first conductive bar and the second conductive bar. The busbar assembly according to claim 55.

58. The aforementioned capacitor is First, a plurality of capacitors, Second multiple capacitors, A cavity formed between the first plurality of capacitors and the second plurality of capacitors, The busbar assembly according to claim 50.

59. The capacitor defines a plurality of slits configured to be coupled to a power electronics component. The busbar assembly according to claim 58.

60. The capacitor is a DC link capacitor. The busbar assembly according to claim 50.

61. Circuit board and Power electronics components connected to the circuit board, A cooling jacket surrounding the aforementioned power electronics component, A jacket housing connected to the circuit board and covering the cooling jacket, Equipped with, The cooling jacket defines coolant ducts that receive the flow of coolant and allow the coolant to flow over the power electronics components. Power conversion module.

62. The power electronics component is at least one of an FET and an inductor coil. The power conversion module according to claim 61.

63. A clearance of less than 10 millimeters is formed between the inner surface of the cooling jacket and the power electronics component. The coolant duct is formed within the clearance. The power conversion module according to claim 61.

64. The jacket housing is formed to correspond to the shape of the cooling jacket, and the jacket housing surrounds the cooling jacket at least partially. The power conversion module according to claim 61.

65. Inductor terminal ports are formed in the cooling jacket and the jacket housing. The power conversion module according to claim 61.

66. The cooling jacket includes an upper jacket configured to be coupled to a lower jacket. The power conversion module according to claim 61.

67. The jacket housing has an inlet opening at the first end and an outlet opening at the second end. The power conversion module according to claim 61.

68. The aforementioned cooling jacket is one of several cooling jackets. The power conversion module according to claim 61.

69. Two or more of the aforementioned multiple cooling jackets are connected in parallel, and the first inlet of the first cooling jacket and the second inlet of the second cooling jacket are connected to each other. The power conversion module according to claim 68.

70. Two or more of the aforementioned multiple cooling jackets are connected in series, and the outlet of the first cooling jacket is connected to the inlet of the second cooling jacket. The power conversion module according to claim 68.

71. A thermal regulation system for a power conversion module including power electronics components, The thermal regulation system includes a cooling jacket configured to surround the power electronics components. The cooling jacket includes an upper jacket and a lower jacket configured to be coupled to the upper jacket. At least one of the upper jacket and the lower jacket is formed in a shape corresponding to the power electronics component, defining a coolant duct between the cooling jacket and the power electronics component. The coolant duct is configured to receive the flow of coolant. Thermal regulation system.

72. The power electronics component includes an electrical contact, The cooling jacket has an opening, and the electrical contacts of the power electronics components extend through the opening. The thermal regulation system according to claim 71.

73. A clearance of less than 1 millimeter is formed between the inner surface of the cooling jacket and the power electronics component. The thermal regulation system according to claim 71.

74. The power electronics component is at least one of an FET and an inductor coil. The thermal regulation system according to claim 71.

75. The aforementioned cooling jacket further defines the FET jacket and the inductor jacket. The FET jacket defines the FET cavity in which the FET is housed. The inductor jacket defines a coil cavity in which the inductor coil is housed. The thermal regulation system according to claim 74.

76. The FET jacket has a duct inlet formed therein. The inductor jacket has a duct outlet formed therein. The coolant duct is defined between the duct inlet and the duct outlet. The thermal regulation system according to claim 75.

77. A power conversion module comprising power electronics components, The aforementioned power electronics component is The core and A coil wound around the core, A housing assembly coupled to at least one of the core and the coil, An insert coupled to at least one of the core and the housing assembly, defining a coolant duct configured to receive a flow of coolant and to allow the coolant to flow into the coil, Equipped with, Power conversion module.

78. The housing assembly is A first cap coupled to the first side of the core, A second cap coupled to the second side of the core, The first side wall is coupled to the first cap and the second cap, The second side wall is coupled to the first cap and the second cap, Equipped with, The power conversion module according to claim 77.

79. The first cap includes an inlet port configured to receive a flow of coolant and allow the coolant to flow into the core, The first and second side walls include a plurality of side outlet ports configured to guide the flow of the coolant to the outside of the housing assembly. The power conversion module according to claim 78.

80. The aforementioned core includes a first core and a second core, The insert is bonded between the first core and the second core. The power conversion module according to claim 77.

81. The insert includes a central opening radially aligned with the core, The insert defines a spacer outlet port positioned to allow coolant to flow from the central opening to the coil. The power conversion module according to claim 80.

82. The spacer outlet ports are arranged radially around the central opening. The power conversion module according to claim 81.

83. The aforementioned insert is configured as a coolant guide, The coolant guide includes a cylindrical baffle wall and a base extending radially from one end of the baffle wall. The power conversion module according to claim 78.

84. The core has a first diameter smaller than the second diameter of the baffle wall. The baffle wall is arranged radially between the coil and the core. The power conversion module according to claim 83.

85. An axial coolant duct is formed between the baffle wall and the core. The axial coolant duct is configured to guide the flow of the coolant along the core. The power conversion module according to claim 83.

86. The coolant guide further includes a plurality of pegs extending downward from the base, The peg is configured to engage with the housing assembly and position the base spaced apart from either the first cap or the second cap of the housing assembly. The power conversion module according to claim 85.

87. A radial coolant duct is formed between the base and either the first cap or the second cap. The radial coolant duct is in fluid communication with the axial coolant duct. The power conversion module according to claim 86.

88. Multiple cooling fins are formed on the core. The power conversion module according to claim 77.

89. A gasket for sealing the space between the first housing and the second housing, An outer rim, comprising an inner circumferential edge surrounding the internal region of the gasket and an outer circumferential edge, configured to be positioned between the first housing and the second housing, A wall formed as an integral part with the outer rim, extending from the inner circumferential edge of the outer rim toward the internal region, A gasket equipped with [the necessary components].

90. The wall has a wall area corresponding to at least 2% of the internal region. The gasket according to claim 89.

91. The aforementioned wall is one of a plurality of walls extending from the inner edge. The gasket according to claim 89.

92. The wall is a flange extending from the first portion of the outer rim into the internal region. The gasket according to claim 89.

93. The wall is a flange that extends from the first portion to the second portion of the outer rim, encompassing a part of the internal region. The gasket according to claim 89.

94. The first portion of the outer rim is positioned at a non-zero angle with respect to the second portion of the outer rim. The gasket according to claim 93.

95. The first portion of the outer rim is spaced apart from the second portion of the outer rim. The gasket according to claim 93.

96. A drive unit for electric vehicles, A housing comprising a first housing defining a first internal volume and a second housing defining a second internal volume, wherein the first housing is coupled to the second housing so that the first internal volume communicates with the second internal volume to form the internal volume of the housing, A gasket comprising an outer rim positioned to seal between the first housing and the second housing, and a wall extending from the outer rim and protruding into the internal volume of the housing, A drive unit equipped with the following features.

97. The wall is configured to control the flow of coolant between the first internal volume and the second internal volume. The drive unit according to claim 96.

98. The wall extends over at least 5% of the area enclosed by the inner edge of the outer rim. The drive unit according to claim 96.

99. The first housing includes a first projection extending from the first housing into the internal volume, the first projection being configured to guide the flow of coolant along the wall from the first internal volume to the second internal volume. The drive unit according to claim 96.

100. The first housing forms a trough for collecting the flow of the coolant, The gasket wall is positioned across the trough and includes an opening that exits the trough and controls the flow of the coolant from the first internal volume to the second internal volume. The drive unit according to claim 99.

101. Preparing 1 housing is a cover, and Preparing 2 housing is the main housing. The drive unit according to claim 96.

102. The first internal volume is configured to house the transmission system. The second housing further comprises a third internal volume for housing a power converter and a fourth internal volume for housing a motor. The drive unit according to claim 96.

103. Power electronics components, Cooling fins connected to the aforementioned power electronics component, Equipped with, The cooling fins are configured as a three-dimensional lattice structure, defining multiple channels through which the coolant passes. Power conversion module.

104. The cooling fins define one or more meandering paths for the coolant to pass through. The power conversion module according to claim 103.

105. The one or more meandering paths include a plurality of turns that create turbulence in the coolant within the cooling fins. The power conversion module according to claim 104.

106. The cooling jacket is further arranged to surround the cooling fins and defines at least one coolant duct that receives the flow of coolant. The power conversion module according to claim 103.

107. The at least one coolant duct includes a first coolant duct that guides the coolant into the interior of the cooling fins, and a second coolant duct that guides the coolant to the outside of the cooling fins. The power conversion module according to claim 106.

108. The cooling fin includes a first rail connected to a second rail via a connector. The connector bends convexly from the first rail to an inflection point, and then bends concavely from the inflection point toward the second rail. The power conversion module according to claim 103.

109. The connector is one of a plurality of connectors, the plurality of connectors are spaced apart from each other by a plurality of gaps, the plurality of gaps define the plurality of flow paths and guide the coolant through the cooling fins. The power conversion module according to claim 108.

110. The cooling fin is manufactured using at least one of open-cell or closed-cell metal foam, forming a metal matrix in which gas-containing pores are distributed throughout. The power conversion module according to claim 103.

111. The plurality of flow paths are defined by a plurality of cavities defined within the body of the cooling fin, and the plurality of cavities are arranged in a grid pattern within a three-dimensional grid structure. The power conversion module according to claim 103.

112. The plurality of flow paths include horizontal coolant channels and vertical coolant channels that guide the coolant through the cooling fins. The power conversion module according to claim 103.

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