Power module

Patent metadata

Field	Value
Publication number	US-2024215193-A1
Application number	US-202318346878-A
Country	US
Kind code	A1
Filing date	Jul 5, 2023
Priority date	Dec 27, 2022
Publication date	Jun 27, 2024
Grant date	—

Abstract

The present application discloses a power module, including: at least one transformer, each transformer including a primary side magnetic core and a secondary side magnetic core; a primary side power element, the primary side magnetic core and the primary side power element forming a primary side conversion unit; a secondary side power element, the secondary side magnetic core and the secondary side power element forming a secondary side conversion unit; and an insulating plate, disposed between the primary side conversion unit and the secondary side conversion unit, and including a first area, the first area being adaptively disposed between the primary side magnetic core and the secondary side magnetic core, and the first area having at least one buckling part and/or at least one bending part.

First claim

What is claimed is:

1 . A power module, comprising:
at least one transformer, each transformer comprising a primary side magnetic core and a secondary side magnetic core; a primary side power element, the primary side magnetic core and the primary side power element forming a primary side conversion unit; a secondary side power element, the secondary side magnetic core and the secondary side power element forming a secondary side conversion unit; and an insulating plate, disposed between the primary side conversion unit and the secondary side conversion unit, and comprising a first area, the first area being adaptively disposed between the primary side magnetic core and the secondary side magnetic core, and the first area having at least one buckling part and/or at least one bending part.

2 . The power module according to claim 1 , wherein the insulating plate comprises a first surface and a second surface provided opposite to each other, and the first surface and the second surface are respectively provided with semi-conducting layers.

3 . The power module according to claim 1 , wherein,
when the at least one transformer comprises a single transformer, the single transformer is provided in the middle, the first side or the second side of the power module along a first direction; when the at least one transformer comprises a plurality of transformers, the plurality of transformers are simultaneously provided in the middle, the first side or the second side of the power module along the first direction, or respectively provided at the first side and the second side of the power module.

4 . The power module according to claim 1 , further comprising a primary side PCB, a secondary side PCB, a primary side heat dissipation unit and a secondary side heat dissipation unit, wherein the primary side conversion unit is provided on the primary side PCB, and the secondary side conversion unit is provided on the secondary side PCB; the primary side PCB is provided on the primary side heat dissipation unit, and the secondary side PCB is provided on the secondary side heat dissipation unit.

5 . The power module according to claim 1 , wherein,
the bending angle of the at least one buckling part is θ 1 , which meets the following conditions: 0<θ 1 <180°; or the buckling radian of the at least one bending part is θ 2 , which meets the following conditions: 0<θ 2 <360°.

6 . The power module according to claim 1 , wherein,
the at least one buckling part buckles from the secondary side magnetic core to the primary side magnetic core or from the primary side magnetic core to the secondary side magnetic core; the at least one bending part bends from the secondary side magnetic core to the primary side magnetic core or from the primary side magnetic core to the secondary side magnetic core.

7 . The power module according to claim 1 , further comprising an insulating housing, wherein the insulating housing comprises a first housing, and the primary side conversion unit is provided between the first housing and the insulating plate.

8 . The power module according to claim 7 , wherein an upper surface of the first housing is provided with a semi-conducting layer or conducting layer, and a lower surface of the first housing is provided with a semi-conducting layer or conducting layer.

9 . The power module according to claim 7 , wherein the first housing is made of an insulating material.

10 . The power module according to claim 7 , wherein the insulating housing further comprises a second housing, and the secondary side conversion unit is provided between the second housing and the insulating plate.

11 . The power module according to claim 10 , wherein the second housing is made of an insulating material or metal material, the primary side conversion unit is a HV side of the power module, and the secondary side conversion unit is a LV side of the power module.

12 . The power module according to claim 10 , wherein the first housing, the second housing and part of the insulating plate form a cavity, and the cavity is used to accommodate the primary side conversion unit and the secondary side conversion unit.

13 . The power module according to claim 10 , wherein the insulating housing further comprises a part of the insulating plate, wherein the insulating housing is integrally molded; or, the insulating housing is molded by assembly, and the first housing, the second housing and the part of the insulating plate are connected to form the insulating housing by screws or buckles.

Assignees

• Delta Electronics Shanghai Co

Inventors

• Lan Lin
• Zhang Quanliang
• Zhang Weiqiang
• Xie Yicong

Classifications

• H01F27/324

  Insulation between coil and core, between different winding sections, around the coil; Other insulation structures · CPC title

• H01F27/263

  Fastening parts of the core together · CPC title

• H05K7/2089

  for power electronics, e.g. for inverters for controlling motor · CPC title

• H05K7/02

  Arrangements of circuit components or wiring on supporting structure · CPC title

• H02M1/00 Primary

  Details of apparatus for conversion · CPC title