This application claims priority to German Application No. DE 10 2023 202 462.4, filed on Mar. 21, 2023, the entirety of which is hereby fully incorporated by reference herein.
The present disclosure relates to the field of electromobility, in particular of electronic modules for an electric drive.
The use of electronic modules, such as power electronics modules, in motor vehicles has increased significantly in recent decades. On the one hand, this is due to the need to improve fuel economy and vehicle performance, and, on the other hand, is due to advances in semiconductor technology. The main component of such an electronic module, also known as power electronics, are an electronic control unit (ECU), which is connected to or forms part of the vehicle control unit(s) and receives control signals and/or information based on, for example, driving behavior or signals from other control units, and a DC/AC inverter, which is used to supply electrical machines such as electric motors or generators with a multi-phase alternating current (AC). This involves converting a direct current generated by a DC energy source, such as a battery or accumulator, into a multi-phase alternating current. For this purpose, the inverters comprise a large number of electronic components with which bridge circuits (such as half bridges) are realized, for example semiconductor power switches, which are also referred to as power semiconductors. In addition, a DC/DC converter may also be present in the power electronics.
Since one aim is to make electrically powered vehicles as light as possible, for example to enable the longest possible range, one aim of the present disclosure is to provide a reduction in weight in the region of the inverter and its components.
This object is achieved by the features as disclosed herein. Advantageous embodiments are also disclosed herein.
What is proposed is a base plate of a single-phase or multi-phase module of an inverter of an electric drive of an at least partially electrically driven vehicle, wherein the base plate is formed from at least two sub-assemblies, of which a first sub-assembly is formed as a base structure of lightweight construction, and a second sub-assembly is formed as at least one heat-conducting element which is integrated into the base structure and has one or more receiving regions for fastening in each case a semiconductor package on an upper side and a cooling structure on an underside, opposite the upper side, wherein the cooling structure is arranged at least in the region of the receiving region(s).
In one embodiment, the heat-conducting element(s) are formed as a continuous structure, or as a plurality of individual structures arranged next to each other.
In one embodiment, the base structure is formed from aluminum or a plastic with a predetermined specific density, and the heat-conducting element(s) are formed from copper or aluminum.
In one embodiment, the heat-conducting element(s) and the base structure are connected to each other by an integrally bonded or frictional connection and in a gas-tight manner.
In one embodiment, the heat-conducting element(s) and the base structure are interconnected by butt joints or by lap joints.
In one embodiment, the base structure has, in the region in which a heat-conducting element is provided, an undercut on at least two opposing regions as connection region, wherein the heat-conducting element has supports corresponding to the undercuts as connection region in such a way that it bears against the undercuts of the base structure after assembly from an underside of the base plate, and the supports and the undercuts are connected to each other.
In one embodiment, the base structure has, in the region in which a heat-conducting element is provided, a support on at least two opposing regions as a connection region, wherein the heat-conducting element has undercuts corresponding to the supports as a connection region in such a way that it rests on the supports of the base structure after assembly from an upper side of the base plate, and the undercuts and the supports are connected to each other.
In one embodiment, the base structure and the heat-conducting element are connected by a tongue-and-groove connection as connection regions, wherein either the base structure has a groove and the heat-conducting element has a tongue, or wherein the base structure has a tongue and the heat-conducting element has a groove.
In one embodiment, the connection regions of heat-conducting element and base structure are formed in such a way that the region of the connection regions of a heat-conducting element on the underside of the base plate extends from the cooling structure in a predetermined length in the direction of the base structure.
In one embodiment, the heat-conducting element or elements are formed in such a way that they are flush with the base structure or protrude beyond the base structure by a predetermined height.
Furthermore, a single-phase module or a multi-phase module is proposed, comprising the base plate, as well as at least one half-bridge arranged on the base plate and per phase, which half-bridge is formed from two semiconductor packages fixed on two heat-conducting elements arranged opposite each other, or which is formed as a single semiconductor package fixed on a single heat-conducting element, and DC and AC busbars arranged stacked on the half-bridge(s) and electrically contacted with the associated current terminals.
Power electronics for operating a three-phase electric motor of a vehicle are also proposed, wherein the power electronics have an inverter which is formed from a multi-phase module or, per phase, from a single-phase module, as well as at least one ECU which is connected to the electric motor for open-loop and closed-loop control thereof and to the inverter.
Furthermore, an electric drive for a vehicle is proposed, comprising a three-phase electric motor and an accumulator, as well as the power electronics connected to both.
Furthermore, a vehicle is proposed comprising the electric drive, which is formed as an electric axle drive.
Further features and advantages of the present disclosure will become apparent from the following description of exemplary embodiments of the present disclosure, with reference to the figures in the drawing, which shows details according to the present disclosure, and from the claims. The individual features can be realized individually or in any combination in a variant of the present disclosure.
Preferred embodiments of the present disclosure are explained in greater detail below with reference to the appended figures.
In the following figure descriptions, like elements or functions are provided with like reference signs.
Current single-phase modules 1, as shown in
Currently, base plates 2, also known as cooling plates, are embodied with a large surface area, as shown in
In order to make inverters (DC/AC inverters) in the vehicle lighter, it is proposed to change the structure of the base plate 2, as described below. The aim here is to provide the best possible cooling of the semiconductors 40 (power semiconductors) of the semiconductor packages 1 placed on the base plate 2, more precisely in the receiving regions 22 provided for this purpose (arranged in the housing 43), while still achieving a lower weight than previously possible.
This is achieved by dividing the base plate 2 into two interconnected sub-assemblies, as shown in
For example, half bridges are installed in an inverter, each of which half-bridges has a high-side switch and a low-side switch that are arranged on one or more corresponding heat-conducting elements 21, in particular opposite each other, as shown in
The second sub-assembly, i.e., the heat-conducting element(s) 21, are substantially manufactured as inlets for the semiconductor packages 4 and are designed in different ways. These inlets have an optimized cooling structure 23, e.g., via pinfins, as shown in
In the proposed concept, the connection of the materials of the two sub-assemblies poses a challenge. The connection between the base structure 20 and the heat-conducting element(s) 21 (only the plural is used below) must (depending on the specific application) withstand the respective temperature, pressure and tightness requirements, as well as take into account the manufacturing process and the successive steps involved. The two sub-assemblies are therefore connected by an integrally bonded, gas-tight connection, e.g. by welding, soldering, gluing, or also by a frictional connection if this can be made gas-tight.
As shown in the embodiment in
As shown in the embodiment in
The two sub-assemblies can also be joined, for example, by inserting the heat-conducting elements 21 into a mold and then overmolding or encapsulating them with the base structure 20 if the material is an injection-moldable or castable material. This is a possible manufacturing option in the embodiment shown in
As in the embodiments shown in
In the embodiment shown in
In the embodiment shown in
In the embodiment shown in
The joining processes described can be supported by coatings or surface structuring (ordered or unordered) of the joining surfaces.
As already described in conjunction with the individual figures, the size of the edge regions of the heat-conducting elements 21 can be varied depending on the stipulated requirements. By increasing the size of the support, for example, more solder can be applied to the connection. The heat transfer can be increased by making the cooling medium side (underside U) wider (extension in the X direction).
The distances, materials and shape of the heat-conducting elements 21 must be selected accordingly in order to maintain the specified clearances between the busbars (HV level), arranged above the base structure 20, and the base structure 20 (GND level). In one embodiment, the heat-conducting elements 21 are formed in such a way that they are flush with the base structure 20. In an alternative embodiment, the heat-conducting elements 21 are formed in such a way that they protrude above the base structure 20 by a predetermined height H.
Furthermore, suitable shapes may be arranged on or formed in the base structure 20 to stiffen the base structure 20, such as a ribbed structure.
The proposed base plate 2 is preferably used in single-phase modules 1, which are used in an inverter, as a carrier and cooling plate in order to be connected to a housing of the inverter on its underside U, which is provided with the cooling structure 23, and in order to carry further components of the inverter, such as AC and DC busbars, as well as printed circuit boards and other components, on its upper side O (more precisely the semiconductor packages 4 arranged thereon). Single-phase modules 1 are modules that each represent one phase of an inverter and can be connected together to form a multi-phase module. The base plate 2 can, of course, also be used for multi-phase modules in which several phases of the inverter are realized on a base plate 2.
As already described, the base plate 2 serves as a carrier plate. Here, regions on which no semiconductor packages 4 to be cooled are arranged are formed in lightweight construction from a material that is sufficiently stable for the respective application, such as aluminum or plastic. Furthermore, it must have good thermal conductivity in the regions where the semiconductor packages 4 are arranged in order to be able to cool the semiconductors 40 provided therein. For this purpose, this part of the base plate 2 is formed as a heat-conducting element 21 and is made of a material such as copper. This provides sufficient heat dissipation of the semiconductor packages 4. The base plate 2 advantageously provides ground potential GND.
The semiconductor packages 4 are generally arranged opposite each other so that two of them form a half-bridge, wherein one semiconductor package 4 serves as a high-side switch and the other as a low-side switch, each of which can have power semiconductors, e.g., MOSFETs, IGBTs, etc., connected in parallel with each other. One or more half-bridges can be provided per phase. DC and AC busbars are arranged above the half-bridges and electrically contacted with the associated current terminals of the half bridges. Semiconductor package 4 refers to one or more encapsulated (located in a housing) power semiconductors (chips) that serve as high-side or low-side switches, including (non-encapsulated) connection legs for electrical or signal contacting. The term semiconductor package 4 also refers to a half-bridge module in which the high-side and low-side switches are already installed together in a housing.
Furthermore, a single-phase module 1 with a base plate 2 and at least two opposing semiconductor packages 4, which form a half-bridge, is proposed. In each case, one of the semiconductor packages 4 is formed as a high-side switch and the other as a low-side switch. Furthermore, a multi-phase module is proposed which differs from the single-phase module 1 only in that the base plate 2 is not used for only one phase of the inverter, but several, in particular three, phases are provided on a single base plate 2. Thus, for example, a three-phase module can be produced with only one base plate 2 instead of arranging three single-phase modules 1 together (next to each other).
The number of half bridges depends here on the required power of the inverter and the semiconductor packages 4 used.
The base plate is advantageously used in power electronics, preferably used in an electric drive of a vehicle comprising a three-phase electric motor and an accumulator. The power electronics have an inverter with several phases and are connected to the electric motor and accumulator in order to generate direct current from the accumulator into alternating current that can be used for the electric motor by the inverter in order to drive the electric motor. An ECU, i.e., an electronic control unit, is provided to control the inverter. The ECU is connected to the electric motor for its open-loop and closed-loop control and to the inverter. In particular, the electric motor is an electric axle drive in this case.
Advantageously, a vehicle, e.g., a passenger car or a commercial vehicle, has at least one such drive. The vehicle is in particular a commercial vehicle such as a truck or a bus, or a passenger car. The power electronics module (i.e., the power electronics) comprises a DC/AC inverter with the structure described. It may also comprise an AC/DC rectifier, a DC/DC converter, a transformer and/or another electrical converter or a part of such a converter, or may be a part thereof. In particular, the power electronics module is used to power an electric machine, for example an electric motor and/or a generator. A DC/AC inverter is preferably used to generate a multi-phase alternating current from a direct current generated by a DC voltage from an energy source, such as a battery.
Number | Date | Country | Kind |
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10 2023 202 462.4 | Mar 2023 | DE | national |