Power inverter for a vehicle

Patent metadata

Field	Value
Publication number	US-9538691-B2
Application number	US-201514687380-A
Country	US
Kind code	B2
Filing date	Apr 15, 2015
Priority date	Apr 15, 2015
Publication date	Jan 3, 2017
Grant date	Jan 3, 2017

Abstract

A power inverter includes a plurality of power modules stacked in an array. A plurality of coolant chambers are interleaved with the modules. Each of the chambers includes an inlet and an outlet interconnected by a coolant path configured to circulate coolant within the chamber. Fins project into the coolant path and are configured to alter shape based on a temperature of the coolant to alter a turbulence associated with the coolant.

First claim

What is claimed is:

1. A power inverter comprising:
power modules each including opposing major sides that each define a pocket recessed therein, and being arranged in a stack such that pockets adjacent to each other cooperate to form coolant chambers interleaved with the modules; and
flow guide assemblies each disposed within one of the coolant chambers and including fins configured to alter shape based on a temperature of the coolant to alter a turbulence associated with the coolant.

2. The power inverter of claim 1 further including a plurality of housings each received within one of the chambers and defining a cavity for receiving one of the flow guide assemblies therein.

3. The power inverter of claim 1 wherein each of the flow guide assemblies further includes a barrier defining an inlet side of the coolant chamber and an outlet side of the coolant chamber.

4. The power inverter of claim 3 wherein each of the coolant chambers defines a return region between the inlet and outlets sides, and wherein the fins are arranged to form U-shaped coolant flow paths.

5. The power inverter of claim 1 wherein each of the coolant chambers includes an inlet and an outlet disposed on a same side.

6. The power inverter of claim 1 further comprising a manifold extending along a length of the stack and in fluid communication with each of the coolant chambers.

7. The power inverter of claim 6 wherein each of the modules defines an opening and the manifold is disposed within each of the openings.

8. A power inverter comprising:
a plurality of power modules each including a power stage having opposing major sides and minor sides connecting between the major sides, the minor sides being surrounded by a frame that extends past both of the major sides such that the frame and the power stage cooperate to define pockets that are each recessed into a side of the power module, wherein the power modules are arranged in a stack such that frames adjacent to each other are in contact with each other, and pockets adjacent to each other cooperate to form coolant chambers that are interleaved with the power modules; and
fins disposed in each of the coolant chamber and projecting into a coolant path of each of the chambers, the fins being configured to alter shape based on a temperature of the coolant to alter a turbulence associated with the coolant.

9. The power inverter of claim 8 wherein the fins are further configured to have a first shape for a first range of temperatures of the coolant and a second shape for a second range of temperatures of the coolant.

10. The power inverter of claim 8 wherein the fins are made of bimetal material configured to mechanically displace in response to a change in the temperature.

11. The power inverter of claim 8 wherein the fins are made of shape-memory alloy configured to mechanically displace in response to a change in the temperature.

12. The power inverter of claim 8 further comprising a manifold extending along a length of the stack and being in fluid communication with each of the coolant chambers.

13. The power inverter of claim 12 wherein each of the power modules includes an opening defined by one of the minor sides and the frame, where each of the openings receives a portion of the manifold therein.

14. The power inverter of claim 8 wherein each of the coolant chambers is defined by a housing received between power modules that are adjacent to each other and wherein the fins are attached to an interior surface of the housing and project laterally therefrom.

15. The power inverter of claim 14 wherein each of the housings includes an inlet and an outlet disposed on a same side of the chamber.

16. 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 that extends past both of the major sides and cooperates with the major sides to define pockets on each side of the power module, the power modules being arranged in a stack such that pockets adjacent to each other cooperate to form cavities that are interleaved with the power modules, wherein each of the power modules further includes a manifold opening defined by one of the minor sides and the frame, the power modules being stacked such that the manifold openings are in alignment with each other and cooperate to define a manifold slot along a length of the stack;
a manifold received in the manifold slot and extending through each of the manifold openings; and
a plurality of flow guide assemblies each disposed in one of the cavities and in fluid communication with the manifold.

17. The power inverter of claim 16 wherein each of the flow guide assemblies further includes a housing have opposing major sides that are each in contact with a corresponding one of the major sides of one of the power stages.

18. The power inverter of claim 17 wherein each of the flow guide assemblies further includes fins extending between the opposing major sides of the housing.

19. The power inverter of claim 18 wherein the fins are configured to alter shape based on a temperature of coolant circulating through the housing.

20. The power inverter of claim 18 wherein the fins are made of bimetal material configured to mechanically displace in response to a change in temperature.

Assignees

• Ford Global Tech Llc

Inventors

• Kikuchi Jun
• Lei Guangyin
• Su Ming
• Wang Tienli
• Jih Edward Chan-Jiun
• Degner Michael W

Classifications

• H05K7/2089 Primary

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

• H05K7/20927 Primary

  Liquid coolant without phase change · CPC title

• H05K7/20272

  Accessories for moving fluid, for expanding fluid, for connecting fluid conduits, for distributing fluid, for removing gas or for preventing leakage, e.g. pumps, tanks or manifolds · CPC title

• H02M7/003 Primary

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