Stacked Inverter Power Module Layout for EV Thermal Management
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Solution Overview
Problem
Inverters used in electric vehicles face challenges with heat management and thermal characteristics due to the layout and design of power modules, which can lead to incorrect device operation or overheating, compromising the inverter's performance.
Innovation Solution
The proposed solution involves a power module design that includes a first and second substrate with a semiconductor die in between, coupled with electrically conductive spacers to maintain distance and provide an electrically conductive path, along with a flex circuit for electrical connections, enhancing thermal management and electrical conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the power module uses a compact layout to reduce size, then the device complexity is reduced, but the thermal management becomes difficult leading to overheating
Solution Approach 1:
The patent transitions from a planar substrate layout to a three-dimensional stacked architecture where substrates are vertically arranged with spacers. This dimensional change allows compact horizontal footprint while creating vertical thermal pathways through the substrate stack, enabling effective heat dissipation without increasing device complexity.
Solution Approach 2:
Electrically conductive spacers are introduced as intermediary elements between substrates. These spacers serve dual functions: providing electrical connection between substrate layers and acting as thermal conduction pathways. The spacers mediate the thermal management problem by conducting heat away from active devices through their thermally conductive material composition.
2Productivity
If the substrate distance is reduced to minimize module height, then the productivity increases, but the electrical isolation between substrates deteriorates
Solution Approach 1:
The electrically conductive spacers perform multiple functions simultaneously: they maintain the required electrical isolation between substrates, provide mechanical spacing to control module height, and establish electrical connections between substrate layers. This multi-functionality resolves the contradiction by eliminating the need for separate isolation and connection elements.
Solution Approach 2:
The spacers are constructed from composite materials that combine electrical conductivity with precise dimensional stability. This allows the spacers to maintain reliable electrical isolation properties while providing consistent spacing to control the overall module height, achieving both productivity and reliability requirements.
3Ease of manufacture
If traditional substrate connection methods are used, then the ease of manufacture is maintained, but the electrical conductivity and thermal management performance are insufficient
Solution Approach 1:
The patent changes the key parameter of spacer material composition from traditional insulating materials to electrically conductive materials. This parameter change enables the spacers to provide both mechanical spacing and electrical conduction functions, significantly improving electrical conductivity and thermal management while remaining compatible with standard manufacturing processes.
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 design improves the thermal characteristics and electrical performance of the power module, reducing the risk of overheating and enhancing the overall efficiency and reliability of the inverter for electric vehicles.
Implementation Method 1
an electrically conductive spacer connecting the first substrate to the second substrate
Implementation Method 2
The layout and design of the power module affects the operation of the devices and the thermal characteristics of the power module
Data Source
AI summary
A system includes: an inverter configured to convert DC power from a battery to AC power to drive a motor, wherein the inverter includes: a power module including: a first substrate including a first conductive layer; a second substrate including a second conductive layer; a power switch between the first substrate and the second substrate; and a flex layer between the first substrate and the second substrate, the flex layer electrically connected to the power switch.