Power-Module Assembly and Method

Patent metadata

Field	Value
Publication number	US-2016308481-A1
Application number	US-201514687415-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 inverter includes a plurality of power modules that each have a frame defining a cavity, and a power stage disposed within the cavity. Each of the frames have a pair of engaging surfaces. The frames are arranged in a stack such that the engaging surfaces adjacent to each other abut. A plurality of seals are interleaved with the modules such that each of the seals is disposed between engaging surfaces of the frames abutting each other.

First claim

What is claimed is:

1 . A power inverter comprising:
a plurality of power modules each including a frame defining a cavity and a power stage disposed within the cavity, each of the frames having a pair of engaging surfaces and being arranged in a stack such that engaging surfaces adjacent to each other abut; and a plurality of seals interleaved with the modules such that each of the seals is disposed between the engaging surfaces of frames abutting each other.

2 . The power inverter of claim 1 wherein each of the seals is a gasket, sealant, or adhesive.

3 . The power inverter of claim 1 wherein each of the frames further includes a recess defined in at least one of the engaging surfaces and wherein at least a portion of each of the seals is disposed within at least one of the recesses.

4 . The power inverter of claim 1 further comprising a pair of endplates arranged to sandwich the stack.

5 . The power inverter of claim 4 further comprising tension members connected between the endplates and configured to hold the stack and endplates together.

6 . The power inverter of claim 1 wherein each of the engaging surfaces extends past the power stage and cooperates with the power stage to define pockets on opposing sides of the power module, and wherein the modules are arranged in the stack such that pockets adjacent to each other cooperate to form coolant chambers interleaved with the modules.

7 . The power inverter of claim 1 further comprising a manifold extending across the stack and disposed within the cavity of each of the frames.

8 . A method of assembling a power inverter including a plurality of power modules having a frame and a power stage disposed within the frame, comprising:
placing a seal on an engaging surface of each of the frames; and assembling the modules into a stack such that engaging surfaces adjacent to each other abut and compress the seal forming a water tight connection.

9 . The method of claim 8 further comprising:
installing an endplate on each end of the stack; and
installing at least one tension member between each of the endplates to hold the stack together.

10 . The method of claim 9 wherein each of the frames defines a hole and each of the endplates defines a hole and wherein the method further comprises:
positioning the frames such that each of the holes align to create a bore extending through the stack;
positioning the endplates such that the hole in each of the endplates aligns with the bore; and
inserting the tension member through the bore.

11 . The method of claim 8 further comprising:
providing a recess on the engaging surface of each of the frames; and
placing the seal in the recess.

12 . The method of claim 8 further comprising:
installing a manifold in the stack such that the manifold is received within a cavity defined by the power stage and the frame.

13 . The method of claim 8 wherein the seal is a mechanical seal.

14 . The method of claim 13 wherein the mechanical seal is a gasket or an O-ring.

15 . The method of claim 8 wherein the seal is a sealant.

16 . The method of claim 15 wherein the sealant includes epoxy, silicon, adhesive, or RTV.

17 . The method of claim 15 further comprising:
curing the sealant.

18 . The method of claim 15 further comprising:
providing a recess on the engaging surface of each of the frames; and
applying the sealant in the recess.

19 . A vehicle comprising:
at least one electric machine; a traction 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 frame defining a cavity and a power stage disposed within the cavity, each of the frames having a pair of engaging surfaces and being arranged in a stack such that engaging surfaces adjacent to each other abut; and a plurality of seals interleaved with the modules such that each of the seals is disposed between the engaging surfaces of frames abutting each other.

20 . The vehicle of claim 19 wherein each of the seals includes a gasket, sealant, or adhesive.

Assignees

• Ford Global Tech Llc

Inventors

• Lei Guangyin
• Degner Michael W
• Jih Edward Chan-Jiun
• Schamel Andreas R

Classifications

• H02M7/003

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

• H05K7/1432

  specially adapted for power drive units or power converters · CPC title

• B60L50/50

  using propulsion power supplied by batteries or fuel cells · CPC title

• B60R16/03

  for supply of electrical power to vehicle subsystems {or for (circuit arrangements for charging batteries H02J7/00)} · CPC title

• H02P27/06 Primary

  using DC to AC converters or inverters (H02P27/05 takes precedence) · CPC title