Integrated EV Power Module With Embedded PCB Charger and Drive
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge in electric vehicles (EVs) is the limited space for battery storage due to the need for separate off-board chargers, which restricts the driving range and flexibility of EVs, especially in small mobility vehicles like electric scooters.
Innovation Solution
An integrated power module (IPM) is designed for EVs, incorporating a motor drive printed circuit board (PCB) with a bare-die semiconductor device (BDSD) and an onboard charger PCB with a planar transformer, allowing for compact integration and efficient charging without reducing battery storage space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If separate off-board chargers are used for EVs, then charging function is provided, but vehicle space for battery storage is reduced
Solution Approach 1:
The patent combines the off-board charger and motor drive into a single integrated power module. The charger PCB and motor drive PCB are mounted together in a common housing, sharing cooling infrastructure and control systems. This integration eliminates the need for separate charger and motor drive units, freeing up vehicle space for additional battery storage while maintaining full charging functionality.
Solution Approach 2:
The integrated power module serves multiple functions: it acts as both a motor drive system and an onboard charger. The single unit can operate in motor drive mode during vehicle operation and switch to charging mode when connected to an external power source, eliminating the need for separate dedicated charger hardware and maximizing space utilization.
2Reliability
If separate off-board chargers are used for EVs, then charging capability is maintained, but vehicle flexibility and driving range are restricted
Solution Approach 1:
By integrating the charger and motor drive into one module, the system enables extended driving range through additional battery capacity. The unified design allows the vehicle to accommodate larger battery packs while maintaining reliable charging capability through the integrated onboard charger functionality.
3Ease of manufacture
If traditional PCB layouts are used with discrete components, then manufacturing is straightforward, but power density and space efficiency are limited
Solution Approach 1:
The patent transitions from traditional two-dimensional PCB layouts to three-dimensional embedded semiconductor devices. Power semiconductor devices are embedded within the PCB structure itself, utilizing vertical space and multiple PCB layers. This dimensional transition enables significantly higher power density while maintaining manufacturability through established embedded device techniques.
Solution Approach 2:
The integrated power module employs a nested structure where semiconductor devices are embedded within the PCB, which is then housed within a common housing that contains both charger and motor drive subsystems. This nested arrangement maximizes space utilization and achieves high power density while maintaining a compact form factor suitable for vehicle integration.
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
The IPM enhances power density and efficiency, enabling a compact design that fits within the limited space of EVs, thereby increasing the driving range and flexibility by eliminating the need for separate off-board chargers.
Implementation Method 1
The planar transformer includes a flyback transformer. The flyback transformer includes: a primary winding configured to generate primary winding magnetic flux from the first amount of electricity from the external electricity source
Implementation Method 2
a thermal via to provide a path for heat to flow from the embedded BDSD
Data Source
AI summary
An integrated power module is disclosed for use with an electric vehicle. The power module includes: a motor drive printed circuit board having a bare-die semiconductor device embedded therein; and an onboard charger printed circuit board having a planar transformer embedded therein and an electrical connector. The onboard charger printed circuit board is configured to operate in a charging mode to supply a first amount of electricity to a battery of the electric vehicle. The electrical connector is configured to supply the first amount of electricity from an external electricity source and to the planar transformer.