Power module for operating an electric vehicle drive with an intermediate circuit capacitor

Abstract

A power module (10) for operating an electric vehicle drive includes a current input configured for supplying an input current. The current input includes multiple contact elements (182, 184). Multiple circuit-breakers (142, 144) are configured for generating an output current based on the supplied input current. A current output (192) is configured for outputting the output current at a consumer. A substrate (12) includes a metal layer (122-130) and an insulating layer (121) connected to the metal layer (122-130). The multiple circuit-breakers (142, 144) are arranged on the metal layer (122-130). The multiple contact elements (182, 184) are also arranged on the metal layer (122-130) such that the multiple contact elements (182, 184) extend perpendicular to a surface of the substrate (12).

Claims

1. A power module (10) for operating an electric vehicle drive, comprising: a current input configured for supplying an input current, the current input comprising a plurality of contact elements (182, 184) with a first subset (182) of the contact elements (182, 184); a plurality of circuit-breakers (142, 144) configured for generating an output current based on the supplied input current, the circuit-breakers (142, 144) subdivided into a plurality of groups with a first group and a second group; a current output (192) configured for outputting the output current at a consumer; and a substrate (12) comprising a metal layer (122-130) and an insulating layer (121) connected to the metal layer (122-130), the metal layer (122-130) comprising a plurality of discrete zones (122-130) with a first zone and a second zone that are spaced apart from each other on the substrate (12), wherein each of the groups of the circuit-breakers (142, 144) is associated with a respective one of the discrete zones (122-130) of the metal layer, the circuit-breakers (142, 144) of the first group (142) are arranged on the metal layer (122-130) at the first zone (122), the circuit-breakers (142, 144) of the second group (144) are arranged on the metal layer (122-130) at the second zone (124), the contact elements (182, 184) are arranged on the metal layer (122-130) such that the contact elements (182, 184) extend perpendicular to a surface of the substrate (12), and the first subset (182) of the contact elements (182, 184) is arranged in the metal layer (122-130) at the first zone (122).

2. The power module (10) of claim 1, wherein a second subset (184) of the contact elements (182, 184) is arranged in the metal layer (122-130) at the third zone (126) of the metal layer (122-130) that is spaced apart from the first and second zones (122, 124).

3. The power module (10) of claim 1, wherein the current output (192) is electrically coupled with the metal layer (122-130) at the second zone (124).

4. The power module (10) of claim 1, wherein an electrical resistor (162, 164) is connected between a gate electrode of at least one of the circuit-breakers (142, 144) and a control unit (136) for activating the gate electrode.

5. The power module (10) of claim 1, further comprising a plurality of resistors (162, 164), each of the resistors (162, 164) connected between a respective one of a plurality of gate electrodes and a control unit (136) for activating the gate electrodes, each of the gate electrodes associated with a respective one of the circuit-breakers (142, 144).

6. The power module (10) of claim 5, wherein the circuit-breakers (142, 144) are associated with a current phase.

7. The power module (10) of claim 2, wherein the current input is a direct current input, the first subset (182) of the contact elements (182, 184) are a positive pole of the direct current input, the second subset (184) of the contact elements (182, 184) are a negative pole of the direct current input, and the current output (192) is an alternating current output.

8. The power module (10) of claim 1, wherein the circuit-breakers (142, 144) of the first group (142) are high-side switches, and the circuit-breakers (142, 144) of the second group (144) are low-side switches.

9. The power module (10) of claim 8, the first group (142) comprises six circuit-breakers, and the second group (144) comprises six circuit-breakers.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments are now described by way of example and with reference to the attached drawings, wherein:

(2) FIG. 1 shows a schematic of a power module according to one example embodiment; and

(3) FIG. 2 shows a schematic of an electrical circuit of the example power module from FIG. 1.

(4) In the figures, identical reference characters refer to identical or functionally identical referenced parts. The particular relevant referenced parts are labeled in the individual figures.

DETAILED DESCRIPTION

(5) Reference will now be made to embodiments of the invention, one or more examples of which are shown in the drawings. Each embodiment is provided by way of explanation of the invention, and not as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be combined with another embodiment to yield still another embodiment. It is intended that the present invention include these and other modifications and variations to the embodiments described herein.

(6) FIG. 1 shows a schematic of a power module 10 according to one example embodiment. The power module 10 includes a plurality of circuit-breakers 142, 144, which are arranged on a metal layer 122, 124, respectively. The metal layer 122, 124 is part of a substrate 12, which additionally includes an insulating layer 121, on which the metal layer 122, 124, 126 is arranged. The metal layer has a first zone 122, in which a first circuit-breaker group of the circuit-breakers 142 is arranged. The metal layer has a second zone 124, in which a second circuit-breaker group of the circuit-breakers 144 is arranged. The metal layer has a third zone 126. A fourth zone 128 of the metal layer is arranged between the first zone 122 and the second zone 124. Multiple first impedances 162, which preferably include electrical resistors, are arranged in the fourth zone 128. A fifth zone 130 of the metal layer is arranged between the second zone 124 and the third zone 126. Multiple second impedances 164, which preferably include electrical resistors, are arranged in the fifth zone 130. The zones 122-130 of the metal layer are spatially separated from one another, in order to allow for electrical insulation.

(7) The substrate 12 can include a direct bonded copper (DCB) insulating substrate and, in addition to the (first) metal layer 122-130 and the insulating layer 121, can also include a second metal layer (not shown), which is arranged at a side of the insulating layer 121 opposite the first metal layer 122-130. The second metal layer can be connected to a heat sink, for example, made of aluminum, in order to allow for a heat dissipation from the circuit-breakers 142, 144 and from further heat-generating components (for example, an intermediate circuit capacitor) of the power module 10.

(8) In addition to the first circuit-breaker group, two contact elements 182 of a current input of the power module 10 are also arranged in the first zone 122 of the metal layer. Preferably, the contact elements 182 are a positive pole of a DC current input. Moreover, two contact elements 184 of the current input of the power module 10 are arranged in the third zone 126 of the metal layer. Preferably, the contact elements 184 are a negative pole of the DC current input. In addition to the second circuit-breaker group, a current output 192, preferably an AC current output, is arranged in the second zone 124.

(9) Preferably, the circuit-breakers 142 of the first circuit-breaker group are high-side switches, wherein the circuit-breakers 144 of the second circuit-breaker group are preferably low-side switches. In FIG. 1, six high-side switches 142 and six low-side switches 144 are shown, which, together, form a half-bridge, which is associated with a current phase of the multiphase alternating current in the case of an inverter.

(10) In the power module 10 in FIG. 1, only one half-bridge is shown, by way of example. This is not limiting for the present invention. Generally speaking, the components shown in FIG. 1 can form a sub-module of the power module 10, wherein the power module 10 can include three or a further number of such sub-modules, wherein each sub-module is associated with a current phase of the multiphase inverter.

(11) The connection between the metal layer and the circuit-breakers 142, 144, the contact elements 182, 184, the impedances or electrical resistors 162, 164, as well as the current output 192 is an electrical connection, in order to allow for a power and/or signal line.

(12) According to example aspects of the invention, the contact elements 182, 184 extend essentially perpendicular to a surface of the substrate 12 (pointing out of the plane of the drawing in FIG. 1). In this way, the length of the electrical line between the positive electrode of the power supply, for example, a battery, and the power module 10 can be reduced on the current input-side. In addition, a busbar for the current input-side contacting can be dispensed with. This measure therefore facilitates a reduction of the leakage inductance in the power module 10 as well as a simplified design. As a result, the circuit-breakers 142, 144 are subjected, to a lesser extent, to a risk of blowing, which is due to high voltage peaks present at the circuit-breakers 142, 144 caused by the short switching times in combination with the leakage inductance. The functionability of the power module 10 is therefore increased.

(13) According to example aspects of the invention, the contact elements 182 are also arranged in the same zone as the first circuit-breaker group of circuit-breakers 142, namely in the first zone 122 of the metal layer. As a result, the length of the electrical line between the circuit-breakers 142 and the contact elements 182 of the current input is minimized, which reduces the leakage inductance in the power module 10. This also yields a power module 10, in which the circuit-breakers 142, 144 are subjected, to a lesser extent, to a risk of blowing and, associated therewith, the performance is increased.

(14) FIG. 2 diagrammatically shows an electrical circuit related to a portion of the power module 1 from FIG. 1. In the electrical circuit, the circuit-breakers 142 of the first circuit-breaker group and the circuit-breakers 144 of the second circuit-breaker group are shown. The circuit-breakers 142 are connected to one another in parallel within the first circuit-breaker group. The circuit-breakers 144 are also connected to one another in parallel within the second circuit-breaker group. The first circuit-breaker group and the second circuit-breaker group are connected to one another in series.

(15) The first impedances 162 and the second impedances 164 designed as electrical resistors, by way of example, are also shown in FIG. 2. The first impedances or electrical resistors 162 are each connected at a first end to a gate electrode of the particular circuit-breaker 142 of the first circuit-breaker group and, at a second end opposite the first end, to a gate control unit 136 via a further electrical resistor 132 and a buffer 134. The second impedances or electrical resistors 164 are each connected at a first end to a gate electrode of the particular circuit-breaker 144 of the second circuit-breaker group and, at a second end opposite the first end, to a further gate control unit 136 via an additional further electrical resistor 132 and an additional buffer 134. The gate control unit 136 is utilized for activating the gate electrodes of the individual circuit-breakers 142, 144 and can include one or multiple integrated circuit(s). The electrical or signal connection between the first electrical resistances 162 and the circuit-breakers 142 of the first zone 122 and between the second electrical resistances 164 and the circuit-breakers 144 of the second zone 124 can be implemented by wire bonding or lead frame.

(16) Due to the utilization of the impedances or electrical resistors 162, 164, the stability of the control signals communicated between the gate electrodes of the circuit-breakers 142, 144 and the gate control unit 136 is increased. This facilitates a low-noise signal line for the gate activation and, thereby, an improved performance of the power module 10.

(17) Modifications and variations can be made to the embodiments illustrated or described herein without departing from the scope and spirit of the invention as set forth in the appended claims. In the claims, reference characters corresponding to elements recited in the detailed description and the drawings may be recited. Such reference characters are enclosed within parentheses and are provided as an aid for reference to example embodiments described in the detailed description and the drawings. Such reference characters are provided for convenience only and have no effect on the scope of the claims. In particular, such reference characters are not intended to limit the claims to the particular example embodiments described in the detailed description and the drawings.

REFERENCE CHARACTERS

(18) 10 power module 12 substrate 121 insulating layer 122-130 metal layer 122 first zone 124 second zone 126 third zone 128 fourth zone 130 fifth zone 132 resistance 134 buffer 136 gate control unit 142, 144 circuit-breaker 162 first impedance 164 second impedance 182, 184 current input (contact element) 192 current output