CN102648520B - 用于车辆的电力模块 - Google Patents

用于车辆的电力模块 Download PDF

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CN102648520B
CN102648520B CN201080055495.8A CN201080055495A CN102648520B CN 102648520 B CN102648520 B CN 102648520B CN 201080055495 A CN201080055495 A CN 201080055495A CN 102648520 B CN102648520 B CN 102648520B
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sheet
module
power module
electronic unit
face
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CN102648520A (zh
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J-M.莫雷尔
K.L.坦
L.维维特
S.迪梅利
S.托姆林
H.洛林
P.达布斯
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Valeo Comfort and Driving Assistance SAS
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Valeo Etudes Electroniques SAS
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Abstract

本发明涉及一种电力模块（10），优选地用于车辆，特别是电动车辆，其特征在于，所述模块包括两个垂直相邻的半导体片（12、14），每一个片具有连接到热沉基板（24、26）的第一表面（20、22）和与第一表面隔开的第二表面（28、30），至少一个电子部件（38a-44b）布置在所述第二表面上，模块布置为使得片的第二表面布置为彼此相对。

Description

用于车辆的电力模块
技术领域
本发明涉及设计为用于车辆的电力模块，特别是用于包括电马达的混合动力车辆。
背景技术
电力模块是包括半导体片的电子模块，所述半导体片承载电子部件，高电流在所述电子部件中流动。这特别是当电力模块意图用于混合动力车辆中应用时的情况，其中使用的电流为200Amp的量级。
由于高强度电流设计为在电力模块中流动，显著量的热由电力模块产生。因此非常重要的是，将热量消散到模块的周边，以便避免电子部件的过热和模块的故障。
在现有技术中，已知电力模块包括半导体片，所述半导体片包括连接面和用于散热的相反的面，电子部件设置在所述连接面上，所述用于散热的面电连接到允许热被消散的基板。但是，当高强度电流（在混合动力车辆中是必然的）正流动在混合动力车辆中时，这样的模块不消散足够的热以能够正确地运转。
电力模块也从现有技术中已知，特别是从文献EP 1 381 115，包括封装半导体片的壳体，半导体片包括第一连接面和第二相反的面，电子部件设置在第一连接面上，第二相反面直接接触用于散热的基板。壳体还包括弹簧，所述弹簧连接到连接面并在该面和用于控制并调节温度的装置之间提供电联接。
这样的电力模块因此具有允许热从半导体片的两个面消散的结构，更高的电流于是能够在电力模块中流动。
但是，这样的电力模块具有特定的架构，该架构较庞大并包括较多数量的部件，这些部件还是特定部件。
发明内容
本发明的目的特别是提供一种电力模块，该电力模块允许热量的显著消散，使得高强度电流可以在模块中流动而不损害部件，同时具有简单的设计。
为此，本发明的一个主题是电力模块，优选地用于车辆，特别是电动车辆，所述电力模块包括两个叠置的半导体片，每一个片包括第一面和第二面，所述第一面形成散热面并设计为连接到散热基板，所述第二面不同于第一面，形成连接面并且至少一个电子部件设置在所述第二面上，该模块被构造为使得片的第二面面对彼此布置。
相应地，来自模块的热可以以非常高效的方式从模块的两个面消散，这是由于，设计为用于散热的两个面中的任一个都不承载电子部件，允许散热的基板可以与整个散热面直接接触。
此外，半导体片的部件可以经由常规方式连接，且模块的组装不呈现任何特别的困难。具体地，不需要特定元件，以便将每一个半导体片连接到半导体片中的另一个。类似地，由于每一个片的散热面不承载任何部件，该面与基板的连接可以以简单的方式在不借助特定部件的情况下实现。
因此，这样的模块，尽管具有简单的设计以及为此是经济的，允许热从模块的两个面消散以及允许在电力模块中流动的电流的强度显著地增加而没有损坏该模块的风险。
本发明还包括来自以下列表的一个或多个特征：
-所述至少一个电子部件或所述电子部件的至少一个从二极管或晶体管之间选择，
-每一个片的第二面包括至少一个连接器，所述模块包括至少一个连接元件，所述连接元件用于将一个片的连接器或电子部件连接到另一个片的连接器或电子部件。因此在两个半导体片上包括单个电路，各部件在半导体片上的分布允许散热被优化。
-所述至少一个连接元件或所述连接元件的至少一个包括带状电缆。这样的带状电缆用于电力连接并允许电力在各部件之间的传输被优化。具体地，将带状电缆制成为波浪形，以便呈现交替反向的弓形部，第一类型的弓形部的至少一个峰电连接到一个片的第二面，第二类型的弓形部的至少一个峰电连接到另一个片的第二面，这允许连接器和/或电子部件之间的路径被最小化，以及因而，限制了当电流在带状电缆中流动时的热量损失。
-每一个片在其相对端的至少两个处包括间隔支撑元件，模块构造为使得所述间隔支撑元件相接触以及使得在片的两个面之间留有空间。以该方式，模块的设计变得便利，在两个面之间留有的空间允许电子部件和连接元件更容易地插入到片上。此外，由于间隔支撑元件，形成在片之间的空间的厚度能够被精确地控制，并且避免模块由于片之间的距离太小而造成的过热，
-间隔支撑元件包括用于将片锁定在它们的相对位置的装置，特别地包括具有互补形状的邻接表面。由于这样的装置，两个片可以相对于彼此更精确地定位，因此简化了模块的组装过程。因此减少了制造所述模块的成本。有利地，这些装置可以包括互补的匹配表面，这是由于定位装置在该情况下可廉价制造。
-至少一个片具有由塑料材料制成的框架，该框架优选地包括间隔支撑元件。因此，模块可以是紧凑的并与电子部件邻接，所述电子部件由于塑料框架而被机械地保护免于潜在的外部侵害。
-模块可以还包括用于固定间隔支撑元件和/或框架的装置，其中，这些装置可以是螺钉固定装置，所述框架或间隔支撑元件于是具有用于接收固定螺钉的相对的孔。
本发明的另一主题是根据本发明的电力模块的和用于散热的两个基板的组件，每一个基板分别电连接到其中一个片的第一面，优选地与其中一个片的第一面直接接触。基板可以经由传导表面连接到模块，特别是金属化表面，所述表面通过常规方法形成，诸如银膏烧结或珠焊。
本发明的另一主题是用于组装电力模块的方法，包括以下操作：
-模块包括两个半导体片，至少一个电子部件设置在每一个片的一个面上，所述面称为连接面，
-片被叠置为使得连接面面对彼此布置。
这样的方法允许根据本发明的模块被制造。如本领域技术人员将理解的，连接面对应于模块的第二面。
根据本发明的方法可以还包括以下步骤：
-至少一个连接元件，优选地为带状电缆，位于一个片的连接面上，和
-所述片被叠置，使得连接元件将片的第二面的至少一个连接器或布置在所述面上的电子部件电连接到另一个片的第二面上的连接器或布置在所述面上的电子部件。
附图说明
在阅读以下仅作为示例和参考附图给出的描述将更好地理解本发明，在附图中：
图1是根据本发明的一个实施例的电力模块的分解透视图，
图2是包括图1中的电力模块的组件的示意性横截面图，
图3是图1和2中的电力模块的电路的电气图的视图。
具体实施方式
在图中，示出了根据本发明的电力模块10。如可在图1和2中看到的，这样的模块10包括两个半导体片12和14，分别标识为下片12和上片14。这些片12、14包括导电电路，塑料材料模制到该导电电路上。框架16、18还围绕每一个片12、14。该框架由塑料材料制成，并且还模制到片的导电电路上。
框架16、18布置为一个在另一个顶部上，并形成间隔支撑元件，允许片12和14布置为使得它们被叠置，如可以在图2中特别看到的。框架的形状匹配为在两个叠置的片之间留有空间17，空间的厚度由框架16、18的尺寸和形状确定。
如可以还在图2中看到的，分别在框架的上端和下端处，框架具有互补的形状，这些形状的面形成邻接表面13、15，允许框架16、18相对于彼此更高效和更容易地定位。
模块还包括用于将两个框架相对于彼此固定的装置19，如可以在图1中看到的。这些装置包括叠置的孔，布置在框架16、18的每一个角处，诸如螺钉这样的固定元件用于接合到所述孔中。
每一个片12、14包括第一面20、22，所述第一面20、22设计为与散热基板24、26接触，如可以在图2中看到的。该面相应地在其整个表面上覆盖有电绝缘但导热的膜，所述膜允许热量的消散，同时使模块安全。这些面形成模块的外表面。
每一个片12、14还包括与第一面相反的第二面28、30，所述第二面28、30设计为接收电子部件并称为连接面。模块被构造为使得，两个片12、14的面28、30彼此相对并界定定位在两个片之间的空间17。
每一个片包括在其连接面上的电力连接器，分别是在下片12上的电源连接器32和接地连接器34以及在上片14上的相连接器36。其还包括控制和检测连接器37。如可在图1中看到的，模块包括凸耳39a，用金属制成并从模块突出。这些凸耳允许模块的电力连接器电连接到位于模块之外的其他元件，并且允许将所述其它元件集成到更综合的电路中。模块还包括销39b，用于将控制连接器连接到外部电路。
电子部件38a、38b、40a、40b、42a、42b、44a、44b还布置在片12、14的连接面28、30上。每一个片12、14特别包括两个IGBT晶体管和两个二极管，所述IGBT晶体管分别为用于片12的38a、40a和用于片14的42a、44a，所述二极管分别为用于片12的38b、40b和用于片14的42b、44b。这些部件钎焊到每一个片12、14的连接面28、30上。
连接元件46、48还安装在连接面上，用于将连接器和/或电子部件连接在一起。连接元件包括电力带状电缆46和控制线48。
两个带状电缆46特别地布置在片的每一个电子部件38a-44b上，用于将所述电子部件连接到另一片的电力连接器上。带状电缆46更具体地成波浪形，以便呈现交替反向的弓形部，第一类型的弓形部的峰电连接到部件，第二类型的弓形部的峰在插置有金属元件41的情况下电连接到另一片的电力连接器。例如，如可在图2中看到的，带状电缆46将片12的晶体管38a电连接到片14的相连接器36。另一带状电缆将片14的晶体管42a电连接到片12的接地连接器34。
模块还包括控制线48，每一个控制线将晶体管38a-44a连接到控制连接器37。
图3更具体地示出了在该实施例的该示例中的电子部件。这是常规的半桥式电路，包括多个晶体管38a、40a和42a、44a，每一个晶体管分别与二极管38b、40b和42b、44b并联连接。安装到片12的连接面28上的两个晶体管-二极管对安装在电源连接器32和相连接器36之间，而安装到片14的连接面30上的另外两个对安装在相连接器36和接地连接器34之间。片12的晶体管38a、40a与片14的晶体管42a、44a一起通过控制和检测连接器37以相同的方式受控，晶体管的倍增首要允许在每一个晶体管中流动的电流和被模块消散的热量被分配。
在该电路中，晶体管38a-44a操作为开关，所述开关交替地断开和闭合。二极管38b-44b形成续流二极管，其允许当控制命令被发送到晶体管以用作断开开关时电路中的过压受到限制。这样的构造允许在输出处提供正负交替的电压。在输入处，其通常连接到车辆的电池，以及在输出处，通常连接到车辆的电马达。
这样的模块允许热量的高效消散，这是由于其面中的两个可以连接到允许散热的基板。此外，其具有简单的设计并且不需要使用特定的连接元件。而且，这样的模块占据非常小的空间。
现在将描述诸如之前所述的模块的制造方法。首先，将导电电路放置在模具中，将塑料材料模制到模具上，以这样的方式来获得两个半导体片12和14，每一个半导体片被框架16、18围绕。
接下来，将各电子部件38a、38b、40a、40b、42a、42b、44a、44b放置到相应的片12和14上，并且将各部件钎焊到片12和14的合适的导电电路上。之后，将控制线48和带状电缆46放置到如上所述的片上，并且控制线48和带状电缆46通过超声焊接电连接到连接器和/或电部件。
随后，将金属元件41定位在片12的带状电缆46的峰处和定位到该片的设计为接收上片14的带状电缆的下弓形部的峰的连接器上。之后将片14安装在片12上，使得两个片12和14通过邻接表面13、15而叠置。
每一个带状电缆46随后被钎焊到其至今还未连接到的片。每一个片的散热面20、22随后覆盖有电绝缘但导热的膜，以便避免电通过并非凸耳和销39a、39b的其它渠道传导至模块外部。
随后将树脂注射到形成在两个片12、14之间的空间17中，以便保护部件免于外部元件的损坏。
两个片12、14随后通过螺钉附连元件而固定在一起。
可以之后使片12、14每一个经由其第一面20、22组装到允许散热的基板24、26，且这些基板可以固定到模块，从而它们直接接触片的散热面20、22。因此获得根据本发明的一个实施例的组件。
将注意到，本发明不限于之前描述的实施例。
首先，放置到片上的电子部件不限于所述部件。为了形成半桥式电路，可以优选地设想，将单个晶体管-二极管对放置到每一个片上。可以还设想，将其他类型的电路集成到这样的电力模块中。
类似地，连接元件不限于已经描述的连接元件。例如，模块不必包括电力带状电缆。可以等同地每部件包括更多个电力带状电缆。
此外，模块的形状不限于已经描述的模块的形状。模块不需包括围绕模块的框架或允许片相对于彼此正确定位的邻接表面。模块可以等同地通过并非螺钉附连装置的装置而固定。
模块的外表面不必在它们的整个表面上与散热基板直接接触。此外，模块的两个片使用与用于将模块组装到基板的装置相同的装置而被组装。
此外，将注意到，本方法不必限于之前描述的方法。例如，本方法的一些步骤可以颠倒。

Claims (13)

1.一种电力模块(10)，其特征在于，所述模块包括两个叠置的半导体片(12、14)，每一个片包括设计为连接到散热基板(24、26)的第一面(20、22)和不同于第一面的第二面(28、30)，至少一个电子部件(38a-44b)布置在所述第二面上，模块被构造为使得片的第二面面对彼此布置，且
其中，每一个片包括框架(16、18)，所述框架在片的相对端的至少两个处包括间隔支撑元件(16、18)，且
模块构造为使得所述间隔支撑元件相接触以及使得在片的两个面之间留有空间(17)，以及
所述框架(16、18)模制到片的导电电路上。
2.如权利要求1所述的电力模块，其中，每一个片的第二面包括至少一个连接器(32、34、36、37)，所述模块包括至少一个连接元件(46、48)，所述连接元件用于将一个片的连接器或电子部件(38a-44b)连接到另一个片的连接器或电子部件。
3.如前一项权利要求所述的电力模块，其中，所述至少一个连接元件或所述连接元件的至少一个包括带状电缆(46)。
4.如前一项权利要求所述的电力模块，其中，将带状电缆(46)制成为波浪形，以便呈现交替反向的弓形部，第一类型的弓形部的至少一个峰电连接到一个片(12)的第二面(28)，第二类型的弓形部的至少一个峰电连接到另一个片(14)的第二面(30)。
5.如前述权利要求中的任一项所述的电力模块，其中，间隔支撑元件包括用于将片锁定在它们的相对位置的装置。
6.如权利要求1所述的电力模块，其中，所述电力模块用于车辆。
7.如权利要求6所述的电力模块，其中，所述车辆是电动车辆。
8.如权利要求5所述的电力模块，其中，所述用于将片锁定在它们的相对位置的装置包括具有互补形状的匹配表面(13、15)。
9.一种组件，包括如前述权利要求中的任一项所述的电力模块(10)和两个散热基板(24、26)，每一个基板分别电连接到其中一个片的第一面。
10.如权利要求9所述的组件，其中，每一个基板与其中一个片的第一面直接接触。
11.一种用于电力模块(10)的组装方法，其特征在于，其包括以下操作：
-提供两个半导体片(12、14)，每一个片被框架(16、18)围绕，所述框架模制到片(12、14)的导电电路上；
-至少一个电子部件(38a-44b)放置到每一个片的一个面上，所述面称为连接面(28、30)，
-通过将框架(16、18)布置为一个在另一个顶部上，片(12、14)被叠置为使得连接面对着彼此布置，所述框架形成间隔支撑元件。
12.如前一项权利要求所述的方法，其中，至少一个连接元件设置在其中一个片(12、14)的连接面(28、30)上，并且片(12、14)被叠置为使得连接元件将片的连接面的至少一个连接器(32、34、36)或布置在所述面上的电子部件(38a-44b)电连接到另一个片的连接面的连接器或设置在所述面上的电子部件。
13.如权利要求12所述的方法，其中，所述连接元件是带状电缆(46)。
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CN102648520A (zh) 2012-08-22
US20120235290A1 (en) 2012-09-20
US8916963B2 (en) 2014-12-23
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