Power Module Interconnection in Rotary Machines
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Solution Overview
Problem
The existing architecture of rotary electrical machines with synchronous rectification, particularly in alternators, is complex and costly due to the use of mechatronic cases for electronic power modules, increasing the number of mechanical parts and interconnection complexity.
Innovation Solution
The power modules are directly integrated into a heat sink, eliminating the need for mechatronic cases, and using DBC technology substrates with good thermal conductivity, along with flat connectors and ultrasound welding for interconnections, to simplify the interconnection structure and reduce mechanical parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechatronic cases are used for electronic power modules, then the modules are protected and mechanically supported, but the device complexity and number of mechanical parts increase
Solution Approach 1:
The patent merges the protective housing function with the heat sink structure. The heat sink is designed to directly receive and secure the electronic power modules without requiring separate mechatronic cases. This integration eliminates additional mechanical parts while maintaining both thermal management and mechanical protection functions.
Solution Approach 2:
The heat sink structure is given multiple functions: thermal dissipation, mechanical support, and protective housing for the electronic power modules. This multi-functional design replaces the need for dedicated mechatronic cases, reducing overall device complexity while maintaining module protection.
2Strength
If mechatronic cases are used for electronic power modules, then the modules are mechanically supported, but the number of mechanical parts and cost increase
Solution Approach 1:
The mechanical support function previously provided by separate mechatronic cases is merged into the heat sink structure. The heat sink directly receives and secures the electronic power modules through its designed geometry, eliminating the need for additional mechanical support parts.
3Reliability
If traditional interconnection methods are used, then electrical connections are established, but the interconnection complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts the complex interconnection structure from the mechatronic case design and replaces it with a simplified approach using flat connectors and ultrasound welding. This extraction of the essential connection function from the protective housing reduces manufacturing complexity while maintaining electrical connectivity.
Solution Approach 2:
The patent replaces traditional mechanical soldering and complex wiring harnesses with ultrasound welding technology. This substitution simplifies the interconnection process, reduces manufacturing steps, and lowers costs while maintaining reliable electrical connections between the power modules and heat sink.
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 approach simplifies the interconnection structure, reduces costs, and maintains performance by ensuring efficient thermal management and electrical connectivity without the need for mechatronic cases, thus optimizing the polyphase rotary electrical machine's architecture.
Implementation Method 1
The power modules are implemented directly in a heat sink with which they are bonded directly on the base of cavities in the sink. The substrates are constituted by three layers comprising a lower layer made of copper, a median insulating layer made of ceramic (alumina, beryllium oxide, etc.), and an upper layer made of conductive material, generally copper.
Implementation Method 2
The connection elements are soldered or welded by ultrasound directly onto the substrates and/or onto the electronic power components of the said power modules
Data Source
AI summary
A method for interconnecting electronic power modules of a polyphase rotary electric machine. The power modules are disposed in open cavities of a heat sink and comprise substrates on which are provided MOSFETs of a synchronous rectifier bridge and integrated control circuits. The method comprises the production of: a planar connector (6) including at least one layer of conductive traces (64); a plurality of interconnection elements (512) arranged in multiple geometric formations and ultrasonically welded or brazed (S2) directly to the substrates (51) and/or the MOSFETs; and openings (65) in the planar connector (6) allowing the free passage of the upper ends (5120) of the connection elements (512) and a mechanical contact with the conductive traces (64). The electrical connections are obtained by means of laser (8) transmission welding (S1) or electric resistance welding.