Power-Module Assembly for a Vehicle

Patent metadata

Field	Value
Publication number	US-2016308480-A1
Application number	US-201514687404-A
Country	US
Kind code	A1
Filing date	Apr 15, 2015
Priority date	Apr 15, 2015
Publication date	Oct 20, 2016
Grant date	—

Abstract

A power-module assembly includes a plurality of power modules that each have a power stage with opposing major sides and minor sides surrounded by a frame. The frame extends past the major sides and cooperates with the major sides to define pockets on each side of the power module. The modules are arranged in a stack such that pockets adjacent to each other cooperate to form coolant chambers interleaved with the modules.

First claim

What is claimed is:

1 . A power inverter comprising:
a plurality of power modules each including a power stage having opposing major sides and minor sides surrounded by a frame, wherein the frame extends past the major sides and cooperates with the major sides to define pockets on each side of the power module, and wherein the modules are arranged in a stack such that pockets adjacent to each other cooperate to form coolant chambers interleaved with the modules.

2 . The power inverter of claim 1 wherein the plurality of power modules further includes a first module defining one end of the stack and a last module defining the other end of the stack, further comprising a first endplate disposed against the first module and a second endplate disposed against the last module.

3 . The power inverter of claim 2 wherein the first endplate cooperates with the first module to define an outer coolant chamber.

4 . The power inverter of claim 1 wherein the frame and power stage of each of the modules are arranged such that the frame is spaced apart from one of the minor sides of the power stage forming an opening between the frame and the minor side, and wherein the openings are aligned and cooperate to define a cavity extending along a length of the stack.

5 . The power inverter of claim 4 further comprising a manifold received within the cavity and in fluid communication with each of the coolant chambers.

6 . The power inverter of claim 5 wherein the manifold further includes an inlet chamber having a plurality of inlet ports in fluid communication with at least one of the coolant chambers, and an outlet chamber having a plurality of outlet ports in fluid communication with at least one of the coolant chambers.

7 . The power inverter of claim 1 wherein the frame and power stage of each of the power modules are arranged such that each of the power modules further includes a first opening defined between the frame and the power stage and a second opening defined between the frame and the power stage, and wherein the first and second openings in each of the power modules are aligned and cooperate with first and second openings on adjacent power modules to define a pair of cavities extending along a length of the stack.

8 . The power inverter of claim 7 further comprising an inlet manifold received in one of the cavities and an outlet manifold received in the other of the cavities.

9 . The power inverter of claim 8 wherein the inlet manifold further includes a plurality of inlet ports in fluid communication with at least one of the coolant chambers and wherein the outlet manifold further includes a plurality of outlet ports in fluid communication with at least one of the coolant chambers.

10 . The power inverter of claim 1 wherein the power stage of each of the power modules further includes at least one direct current terminal extending from one of the minor sides and projecting through an opening defined within the frame, and an alternating current terminal extending from another of the minor sides and projecting through an additional opening defined within the frame.

11 . The power inverter of claim 1 wherein the coolant chambers are arranged in a parallel flow configuration.

12 . A power-module assembly comprising:
a plurality of power modules each including opposing major sides that each define a pocket recessed therein, the modules being arranged in a stack such that pockets adjacent to each other cooperate to form coolant chambers interleaved with the modules.

13 . The assembly of claim 12 wherein the plurality of power modules further includes a first module defining one end of the stack and a last module defining the other end of the stack, further comprising a first endplate disposed against the first module and a second endplate disposed against the last module.

14 . The assembly of claim 13 wherein the first endplate cooperates with the first module to define an outer coolant chamber.

15 . The assembly of claim 12 wherein each of the power modules further include an opening, and wherein the openings are aligned and cooperate to define a cavity extending along a length of the stack.

16 . The assembly of claim 15 further comprising a manifold received within the cavity and in fluid communication with each of the coolant chambers.

17 . A vehicle comprising:
at least one electric machine; a fraction battery electrically connected to the at least one electric machine; wheels configured to be driven by the at least one electric machine; and a power inverter electrically connected between the battery and the at least one electric machine, and including a plurality of power modules each having a power stage with opposing major sides and minor sides surrounded by a frame, wherein the frame extends past the major sides and cooperates with the major sides to define pockets on each side of the power module, and wherein the modules are arranged in a stack such that pockets adjacent to each other cooperate to form coolant chambers interleaved with the modules.

18 . The vehicle of claim 17 wherein the frame and power stage of each of the power modules are arranged such that the frame is spaced apart from one of the minor sides of the power stage forming an opening between the frame and the minor side, and wherein the openings are aligned and cooperate to define a cavity extending along a length of the stack.

19 . The vehicle of claim 18 wherein the power inverter further includes a manifold received within the cavity and in fluid communication with each of the coolant chambers.

20 . The vehicle of claim 19 where the power stage further includes at least one direct current terminal extending from one of the minor sides and projecting through an opening defined within the frame, and an alternating current terminal extending from another of the minor sides and projecting through an additional opening defined within the frame.

Assignees

• Ford Global Tech Llc

Inventors

• Wang Tienli
• Lei Guangyin
• Jih Edward Chan-Jiun
• Degner Michael W

Classifications

• B60L2260/165

  of converters · CPC title

• B60L2210/42

  Voltage source inverters · CPC title

• B60L50/51 Primary

  characterised by AC-motors · CPC title

• B60K6/40

  characterised by the assembly or relative disposition of components · CPC title

• H02M7/003

  Constructional details, e.g. physical layout, assembly, wiring or busbar connections · CPC title