EV Inverter Module Triplet Configuration for Power Density
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Solution Overview
Problem
Existing power converter systems for electric vehicles face challenges in achieving a compact, high-performance design that balances cost, engineering flexibility, manufacturing, packaging, thermal design, and electrical design, often resulting in undesirable compromises that impact performance.
Innovation Solution
The development of an inverter module comprising three half-bridge modules arranged in a triplet configuration, with each module featuring a cold plate, ceramic layer, transistors, and a gel tray, which minimizes electrical parasitics, maximizes current capacity, and reduces component temperatures, while allowing for mass production compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If traditional power converter systems are used, then cost and manufacturing simplicity are maintained, but power density and performance are insufficient
Solution Approach 1:
The power converter system is divided into multiple independent half-bridge modules (first, second, third, and fourth half-bridge modules), each capable of operating autonomously. This segmentation allows the system to achieve higher power density through parallel operation while maintaining manufacturing simplicity, as each module can be produced using standard processes and assembled in modular fashion.
2Volume of moving object
If compact design is pursued, then power density increases, but thermal management becomes more difficult
Solution Approach 1:
By dividing the power converter into separate half-bridge modules, each module generates less heat individually, making thermal management more effective. The modular structure allows for distributed cooling strategies where each module can be cooled independently, preventing heat accumulation even in compact configurations.
Solution Approach 2:
The patent introduces a common rail structure that serves as an intermediary element for interconnecting the half-bridge modules. This common rail provides both electrical connection and thermal management pathways, allowing heat to be efficiently conducted away from multiple modules through a shared thermal management system.
3Power
If additional components are added to improve performance, then power density increases, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines multiple functional elements into integrated half-bridge modules that can be manufactured using existing processes. Each module integrates power switches, capacitors, and cooling structures into a single assembly unit, reducing the number of separate components that need to be handled during manufacturing while achieving high power density through the parallel arrangement of these integrated modules.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration achieves a compact, high-power-density design with low electrical losses and uniform heat dissipation, reducing the need for additional components and assembly steps, thereby enhancing performance and reducing costs.
Implementation Method 1
each module featuring a cold plate, ceramic layer, transistors, and a gel tray, which minimizes electrical parasitics, maximizes current capacity, and reduces component temperatures
Implementation Method 2
a gel tray, which minimizes electrical parasitics, maximizes current capacity, and reduces component temperatures, while allowing for mass production compatibility
Data Source
AI summary
Provided herein is a power converter component to power a drive unit of an electric vehicle drive system. The power converter component includes an inverter module formed having three half-bridge modules arranged in a triplet configuration for electric vehicle drive systems. Positive inputs, negative inputs, and output terminals of the different half-bridge inverter modules are aligned with each other. The inverter module includes a positive bus-bar coupled with the positive inputs and a negative bus-bar coupled with the negative inputs of the half-bridge inverter modules. The positive bus-bar is positioned adjacent to and parallel with the negative bus-bar. The inverter module can be coupled with a drive train unit of the electric vehicle and provide three phase voltages to the drive train unit. Each of the half bridge modules can generate a single phase voltage and three half-bridge modules arranged in a triplet configuration can provide three phase voltages.