Power module

Patent metadata

Field	Value
Publication number	US-2025079070-A1
Application number	US-202418818606-A
Country	US
Kind code	A1
Filing date	Aug 29, 2024
Priority date	Aug 30, 2023
Publication date	Mar 6, 2025
Grant date	—

Abstract

The present application provides a power module, including a first side plate, a second side plate, and an insulating board. The insulating board includes a flat plate portion, at least one protrusion portion, and at least one connecting bridge, the flat plate portion is parallel to a plane formed by a first direction and a second direction; at least one of the protrusion portion and the connecting bridge protrudes along a third direction to form an insulation cavity; the insulating board, the first side plate, and the second side plate in combination form a first accommodating space and a second accommodating space along the third direction, the first accommodating space is provided with a first power device, and the second accommodating space is provided with a second power device; and a transformer, including a magnetic core and a winding wound on the magnetic core.

First claim

What is claimed is:

1 . A power module, comprising:
a first side plate, a second side plate, and an insulating board; the insulating board comprising a flat plate portion, at least one protrusion portion, and at least one connecting bridge, the flat plate portion being parallel to a plane formed by a first direction and a second direction; at least one of the protrusion portion and the connecting bridge protruding along a third direction to form an insulation cavity; the insulating board, the first side plate, and the second side plate in combination forming a first accommodating space and a second accommodating space along the third direction; the first accommodating space being provided with a first power device, and the second accommodating space being provided with a second power device; and a transformer, comprising a magnetic core and a winding wound on the magnetic core, the winding comprising a first winding and a second winding, at least part of the magnetic core being set within the insulation cavity or the connecting bridge; the first winding being electrically connected to the first power device, and the second winding being electrically connected to the second power device; wherein the first direction, the second direction, and the third direction are perpendicular to each other.

2 . The power module according to claim 1 , wherein the at least part of the magnetic core is set within the insulation cavity, and a part of the winding is set within the connecting bridge.

3 . The power module according to claim 2 , wherein the magnetic core is provided with an opening along the first direction, and part of the connecting bridge is penetrated into the opening of the magnetic core.

4 . The power module according to claim 2 , wherein one of the first winding and the second winding is directly wound on the magnetic core, and the other of the first winding and the second winding comprises a first part and a second part connected electrically, the first part is located on one side of the protrusion portion away from the insulation cavity, and the second part is located within the connecting bridge.

5 . The power module according to claim 4 , wherein the first part is integrally-formed with the second part, and a through-hole is set within the connecting bridge, and the second part is located within the through-hole; or
wherein the second part is integrally-formed with the connecting bridge, an end of the second part is located outside the connecting bridge, and an end of the first part is electrically connected to the end of the second part.

6 . The power module according to claim 3 , wherein the magnetic core comprises a first vertical pillar and a second vertical pillar extending along the third direction, as well as a first transverse pillar and a second transverse pillar extending along the second direction, the first vertical pillar, the first transverse pillar, the second vertical pillar, and second transverse pillar are connected head-to-tail in sequence, and the first transverse pillar is located within the insulation cavity.

7 . The power module according to claim 1 , wherein the at least part of the magnetic core is set within the connecting bridge.

8 . The power module according to claim 7 , wherein the magnetic core comprises a first unit and a second unit, the first unit is located on one side of the protrusion portion away from the insulation cavity, and the second unit is penetrated into the connecting bridge.

9 . The power module according to claim 8 , wherein the first winding is wound on the first unit, the second winding is wound on the connecting bridge, the first winding is set within the first accommodating space, and the second winding is set within the second accommodating space; or
wherein the second winding is wound on the first unit, the first winding is wound on the connecting bridge, the first winding is set within the first accommodating space, and the second winding is set within the second accommodating space.

10 . The power module according to claim 7 , wherein the connecting bridge is provided with a through-hole along the first direction, and the at least part of the magnetic core is penetrated into the through-hole.

11 . The power module according to claim 7 , wherein the at least part of the magnetic core is integrally-formed with the connecting bridge.

12 . The power module according to claim 7 , wherein one of the first winding and the second winding is directly wound on the magnetic core located within the connecting bridge, and the other of the first winding and the second winding is wound on the connecting bridge.

13 . The power module according to claim 1 , wherein the insulating board comprises multiple protrusion portions and multiple connecting bridges, and along the first direction, the multiple protrusion portions and the multiple connecting bridges form multiple insulation cavities; the power module comprises multiple transformers, the multiple transformers correspond to the multiple insulation cavities, and the multiple transformers are connected in series or parallel.

14 . The power module according to claim 1 , wherein along the third direction, a distance between the connecting bridge and the flat plate portion is zero, and the protrusion portion is set to be protuberant, at one side thereof, towards the first accommodating space or the second accommodating space; or
wherein along the third direction, a distance between the protrusion portion and the flat plate portion is zero, and the connecting bridge is set to be protuberant, at one side thereof, towards the first accommodating space or the second accommodating space.

15 . The power module according to claim 1 , wherein a surface of the insulating board is provided with a semi conductive layer;
wherein a material of the semi conductive layer comprises a graphene or a carbon black.

16 . The power module according to claim 1 , wherein along the second direction, both ends of the insulation cavity are provided with openings.

17 . The power module according to claim 1 , further comprising a cover plate, the cover plate covers the second accommodating space along the third direction, and the second power device comprises a high-voltage power device;
wherein sides of the first side plate and the second side plate located within the second accommodating space are of double-layer structures.

18 . The power module according to claim 2 , wherein the magnetic core is provided with an opening along the third direction, and part of the connecting bridge or the protrusion portion is penetrated into the opening of the magnetic core;
wherein the insulating board comprises multiple protrusion portions and multiple connecting bridges, and the multiple protrusion portions and the multiple connecting bridges form at least two insulation cavities; the magnetic core comprises a first longitudinal pillar and a second longitudinal pillar extending along the first direction, as well as a first transverse pillar and a second transverse pillar extending along the second direction, the first longitudinal pillar, the first transverse pillar, the second longitudinal pillar, and the second transverse pillar are connected head-to-tail in sequence, and the first transverse pillar and the second transverse pillar are penetrated into different insulation cavities respectively.

19 . The power module according to claim 18 , wherein the winding comprises two first windings and two second windings, the two first windings are woun

Assignees

• Delta Electronics Shanghai Co

Inventors

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

Classifications

• H01F27/266

  Fastening or mounting the core on casing or support (on coil H01F27/30) · CPC title

• H01F27/24

  Magnetic cores · CPC title

• H01F27/306 Primary

  Fastening or mounting coils or windings on core, casing or other support · CPC title

• H01F27/28

  Coils; Windings; Conductive connections · CPC title

• H01F27/02

  Casings · CPC title