Half-Bridge Module Traction Inverter Leakage Inductance
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Solution Overview
Problem
Traction inverters in electric and hybrid vehicles exhibit high inductance due to leakage inductance in the commutation cell and signal connections, leading to voltage surges and increased switching losses.
Innovation Solution
A half bridge module with semiconductor switching elements on a substrate encompassed by a casting compound, where power and signal connections are accessed from one side and extend through the compound, minimizing leakage inductance and allowing for compact orientation, reducing electrical losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If semiconductor switching elements are integrated into bridge modules with high degree of integration, then scalability is reduced, but assembly ease is improved
Solution Approach 1:
The power module is segmented into half-bridge modules, each containing two semiconductor switching elements. This segmentation enables modular assembly (improving ease of manufacture) while maintaining scalability by allowing flexible combination of half-bridge modules to form complete bridge modules (counteracting the loss of scalability).
Solution Approach 2:
The half-bridge modules are arranged in a planar layout on the substrate, with power connections and signal connections extending through the casting compound in a controlled manner. This dimensional arrangement optimizes both assembly processes and electrical performance while preserving scalability options.
2Loss of energy
If power connections and signal connections extend through casting compound from one side, then leakage inductance is reduced, but manufacturing complexity increases
Solution Approach 1:
The power connections and signal connections are merged into a unified structure that extends through the casting compound from the first side. This integration reduces the number of separate connection paths and minimizes leakage inductance, while the standardized design actually simplifies rather than complicates the manufacturing process.
Solution Approach 2:
The connections are positioned with specific local quality requirements - power connections for high current carrying capacity and signal connections for low inductance. This localized optimization of connection properties reduces overall electrical losses while maintaining manageable manufacturing complexity through clear design guidelines.
3Area of stationary object
If connections are located within base area of substrate, then structural space is minimized, but connection orientation flexibility is reduced
Solution Approach 1:
The connections extend through the casting compound in a controlled three-dimensional path from the first side of the substrate, utilizing the vertical dimension to achieve compact inductance while maintaining appropriate orientation. This 3D arrangement minimizes the footprint on the substrate base area while preserving the necessary connection orientations through precise spatial design.
Data Source
AI summary
The invention relates to a half bridge module in a traction inverter for a power electronics unit in an electric or hybrid vehicle, comprising a substrate, semiconductor switching elements on a first side of the substrate, power connections, to which power lines that conduct electrical traction energy are connected, signal connections, to which signal lines are connected for switching the semiconductor switching elements, and a casting compound, which encompasses the substrate and the semiconductor switching elements on the first side of the substrate, wherein the power connections and the signal connections are accessed from the first side of the substrate, such that the power connections and the signal connections extend through the casting compound, seen from the first side of the substrate, and are located within a base area spanning the substrate, seen from the direction they pass through the casting compound.