CN107097658B - 用于车辆的电力逆变器的电力模块组件 - Google Patents

用于车辆的电力逆变器的电力模块组件 Download PDF

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CN107097658B
CN107097658B CN201710090461.6A CN201710090461A CN107097658B CN 107097658 B CN107097658 B CN 107097658B CN 201710090461 A CN201710090461 A CN 201710090461A CN 107097658 B CN107097658 B CN 107097658B
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power module
cards
end caps
module assembly
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CN107097658A (zh
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塞尔达尔·哈基·约纳克
文森特·斯卡斯基
沙雷斯·斯坎特·柯扎雷卡尔
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Ford Global Technologies LLC
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
    • B60L53/20—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by converters located in the vehicle
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/20—Modifications to facilitate cooling, ventilating, or heating
    • H05K7/2089—Modifications to facilitate cooling, ventilating, or heating for power electronics, e.g. for inverters for controlling motor
    • H05K7/20927—Liquid coolant without phase change
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K6/00—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00
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    • B60K6/22—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by apparatus, components or means specially adapted for HEVs
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    • B60K6/36—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by apparatus, components or means specially adapted for HEVs characterised by the transmission gearings
    • B60K6/365—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by apparatus, components or means specially adapted for HEVs characterised by the transmission gearings with the gears having orbital motion
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K6/00—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00
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Abstract

本公开涉及用于车辆的电力逆变器的电力模块组件。一种电力模块组件包括相对的端盖和成行的卡，所述端盖共同具有冷却剂端口，所述卡中的每个具有限定横跨所述卡延伸的突起的主侧。侧面板在所述端盖之间延伸，使得所述侧面板与所述行限定通道，所述通道与所述冷却剂端口流体连通并且被构造为使冷却剂直接经过所述卡进行输送。所述侧面板限定容纳所述突起的槽。

Description

用于车辆的电力逆变器的电力模块组件
技术领域
本公开涉及用于机动车辆的电力逆变器的电力模块组件。
背景技术
诸如电池电动车辆(BEV)、插电式混合动力电动车辆(PHEV)和全混合动力电动车辆(FHEV)的车辆包含用作一个或更多个电机的能量源的牵引电池组件。牵引电池包括用于帮助管理车辆性能和操作的部件和系统。电力逆变器电连接在电池与电机之间，以将来自电池的直流电转换为与电机兼容的交流电。电力逆变器还可用作整流器，以将来自电机的交流电转换为与电池兼容的直流电。
发明内容
根据一个实施例，一种电力模块组件包括相对的端盖和成行的卡，所述端盖共同具有冷却剂端口，所述卡中的每个具有限定横跨所述卡延伸的突起的主侧。侧面板在所述端盖之间延伸，使得所述侧面板与所述行限定通道，所述通道与所述冷却剂端口流体连通，并且被构造为使冷却剂直接经过所述卡进行输送。所述侧面板限定容纳所述突起的槽。
根据本发明的一个实施例，所述卡中的每个还包括限定横跨所述卡延伸的另一突起的另一主侧，并且所述电力模块组件还包括另一侧面板，所述另一侧面板在所述端盖之间延伸并且限定容纳所述另一突起的槽。
根据本发明的一个实施例，所述另一侧面板和所述行限定与所述冷却剂端口流体连通的另一通道。
根据本发明的一个实施例，所述卡中的每个还包括限定横跨所述卡延伸的另一突起的另一主侧，并且所述电力模块组件还包括中间分隔件，所述中间分隔件在所述端盖之间延伸并且具有限定容纳所述另一突起的槽的第一侧。
根据本发明的一个实施例，所述电力模块组件还包括：另一侧面板，在所述端盖之间延伸并且限定槽；另一行卡，所述卡中的每个具有第一主侧和第二主侧，所述第一主侧限定横跨所述卡延伸并且设置于在所述中间分隔件的第二侧中限定的槽内的第三突起，所述第二主侧具有横跨所述卡延伸并且设置在所述另一侧面板的槽内的第四突起。
根据本发明的一个实施例，冷却剂端口是在所述端盖中的一个中限定的入口端口和在所述端盖中的另一个中限定的出口端口。
根据本发明的一个实施例，所述冷却剂端口是均限定在所述端盖中的一个中的入口端口和出口端口。
根据另一实施例，一种电力模块组件包括卡模块，所述卡模块具有间隔开的侧面板和设置在所述卡模块中的卡，所述侧面板限定冷却剂室。所述电力模块组件还包括相对的端盖，所述端盖中的每个具有限定腔的壁，所述腔容纳所述卡模块的一端使得所述壁的内表面与所述侧面板的外表面接合。所述端盖中的一个限定端口，所述端口与所述冷却剂室流体连通以使冷却剂经过所述卡进行输送。
根据本发明的一个实施例，所述端盖中的每个的内表面限定容纳所述侧面板中的一个的一部分的第一凹陷以及容纳所述侧面板中的另一个的一部分的第二凹陷。
根据本发明的一个实施例，所述卡中的至少一些卡布置在第一行中，使得第一行中的每个卡的主侧面对所述侧面板中的一个，其中，所述侧面板中的所述一个具有凸沿，所述凸沿从所述侧面板中的所述一个延伸并且与第一行中的每个卡的主侧接合，以在第一行与所述侧面板中的所述一个之间限定冷却剂通道。
根据本发明的一个实施例，所述凸沿限定横跨所述侧面板纵向延伸的槽，其中，第一行中的每个卡的主侧限定被容纳在所述槽内的突起。
根据本发明的一个实施例，所述卡被布置在大致平行的第一行与第二行中，其中，中间分隔件设置在第一行与第二行之间以产生冷却剂通道，所述冷却剂通道被限定在第一行与第二行之间并且与所述端口流体连通。
根据本发明的一个实施例，所述中间分隔件具有第一侧并具有第二侧，第一侧限定容纳第一行中的每个卡的一部分的槽，第二侧与第一侧相对并且容纳第二行中的每个卡的一部分。
根据本发明的一个实施例，所述端盖中的另一个限定另一端口，所述另一端口与所述冷却剂室流体连通。
根据又一实施例，一种用于车辆的电力逆变器的电力模块组件包括壳体，所述壳体具有在相对的端盖之间延伸的面板。所述面板具有限定沿着面板的纵向方向延伸的第一连接特征的内侧。所述壳体还具有至少部分地由所述内侧和所述端盖限定的腔。所述端盖中的至少一个限定冷却剂端口。卡的阵列设置在所述腔内，并且所述卡中的每个具有相对的主侧以及在相对的主侧之间延伸的副侧。所述卡中的至少一个卡限定第二连接特征，第二连接特征横跨所述至少一个卡的主侧中的一个延伸并且与第一连接特征接合，以连接所述至少一个卡和所述面板。与所述冷却剂端口流体连通的冷却剂通道被限定在所述至少一个卡与所述面板之间，并且被构造为使冷却剂直接经过所述至少一个卡进行输送。
附图说明
图1是示例性混合动力车辆的示意图。
图2是可变电压转换器和电力逆变器的示意图。
图3是车辆电力逆变器的示意图。
图4是电力模块组件的分解图。
图5是图4中的电力模块组件的俯视图。
图6是沿着剖切线6-6的截面图。
图7是图4中的电力模块组件的端部的截面形式的侧视图。
图8是另一电力模块组件的透视图。
图9是连接特征的截面形式的放大透视图。
图10是另一连接特征的截面形式的放大透视图。
图11是示例性的卡的俯视图。
图12是图11中示出的卡的分解图。
具体实施方式
在此描述本公开的实施例。然而，应当理解的是，所公开的实施例仅为示例，其它实施例可采取多种替代形式。附图无需按比例绘制；可夸大或最小化一些特征以示出特定组件的细节。因此，此处所公开的具体结构和功能细节不应被解释为限制，而仅仅作为教导本领域技术人员以多种形式利用本发明的代表性基础。如本领域普通技术人员将理解的，参照任一附图示出和描述的各个特征可与一个或更多个其它附图中示出的特征组合以产生未明确示出或描述的实施例。示出的特征的组合提供用于典型应用的代表性实施例。然而，与本公开的教导一致的特征的多种组合和变型可被期望用于特定的应用或实施方式。
在图1中描述了PHEV的示例，并且该PHEV总体上被称为车辆16。车辆16包括传动装置12，并且车辆16在内燃发动机20的选择性的帮助下由至少一个电机18推进。电机18可以是在图1中被描绘为“马达”18的交流(AC)电动马达。电机18接收电力并提供扭矩以推进车辆。电机18还用作发电机，以通过再生制动将机械能转换为电能。
传动装置12可以是动力分流式构造(power-split configuration)。传动装置12包括第一电机18和第二电机24。第二电机24可以是在图1中被描绘为“发电机”24的AC电动马达。与第一电机18类似，第二电机24接收电力并提供输出扭矩。第二电机24还用作发电机，以将机械能转换为电能并优化通过传动装置12的动力流。在其它实施例中，传动装置不具有动力分流式构造。
传动装置12可包括行星齿轮单元26，行星齿轮单元26包括中心齿轮28、行星架30和齿圈32。中心齿轮28连接到第二电机24的输出轴，以接收发电机扭矩。行星架30连接到发动机20的输出轴，以接收发动机扭矩。行星齿轮单元26将发电机扭矩与发动机扭矩组合，并围绕齿圈32提供组合的输出扭矩。行星齿轮单元26用作无级变速器，而不具有任何固定传动比或“阶梯”传动比。
传动装置12还可包括单向离合器(O.W.C)和发电机制动器33。O.W.C连接到发动机20的输出轴，以仅允许输出轴沿着一个方向旋转。O.W.C防止传动装置12反向驱动发动机20。发电机制动器33连接到第二电机24的输出轴。发电机制动器33可被启用而进行“制动”或者防止第二电机24的输出轴和中心齿轮28的旋转。可选地，O.W.C和发电机制动器33可被去除并由针对发动机20和第二电机24的控制策略来代替。
传动装置12还可包括具有中间齿轮的中间轴，所述中间齿轮包括第一齿轮34、第二齿轮36和第三齿轮38。行星输出齿轮40连接到齿圈32。行星输出齿轮40与第一齿轮34啮合，以在行星齿轮单元26与中间轴之间传递扭矩。输出齿轮42连接到第一电机18的输出轴。输出齿轮42与第二齿轮36啮合，以在第一电机18与中间轴之间传递扭矩。传动装置输出齿轮44连接到驱动轴46。驱动轴46经差速器50连接到一对驱动轮48。传动装置输出齿轮44与第三齿轮38啮合，以在传动装置12与驱动轮48之间传递扭矩。
车辆16包括用于储存电能的能量储存装置，诸如牵引电池52。电池52是能够输出电力以操作第一电机18和第二电机24的高电压电池。当第一电机18和第二电机24作为发电机运转时，电池52还从第一电机18和第二电机24接收电力。电池52是由多个电池模块(未示出)组成的电池组，其中，每个电池模块包括多个电池单元(未示出)。车辆16的其它实施例预期可补充或取代电池52的不同类型的能量储存装置，诸如，电容器和燃料电池(未示出)。高电压总线将电池52电连接至第一电机18和第二电机24。
车辆包括用于控制电池52的电池能量控制模块(BECM)54。BECM 54接收指示车辆状况和电池状况(诸如，电池温度、电压和电流)的输入。BECM 54计算并估计电池参数，诸如，电池荷电状态和电池功率容量。BECM 54向其它车辆系统和控制器提供指示电池荷电状态(BSOC)和电池功率容量(Pcap)的输出(BSOC，Pcap)。
车辆16包括DC-DC转换器或可变电压转换器(VVC)10和逆变器56。VVC 10和逆变器56电连接在牵引电池52与第一电机18之间以及牵引电池52与第二电机24之间。VVC 10“增压”或增大由电池52提供的电力的电压电位(voltage potential)。根据一个或更多个实施例，VVC 10还“降压”或减小由电池52提供的电力的电压电位。逆变器56将(通过VVC 10)由电池52供应的DC电力转换为AC电力用于操作电机18和24。逆变器56还将由电机18和24提供的AC电力整流为DC电力用于给牵引电池52充电。传动装置12的其它实施例包括多个逆变器(未示出)，诸如，电机18和24中的每个电机都关联有一个逆变器。VVC 10包括电感器组件14。
传动装置12包括用于控制电机18和24、VVC 10以及逆变器56的传动装置控制模块(TCM)58。TCM 58被配置为监测电机18和24的位置、转速和功率消耗等。TCM 58还监测VVC10和逆变器56内的多个位置处的电参数(例如，电压和电流)。TCM 58将与该信息对应的输出信号提供给其它车辆系统。
车辆16包括车辆系统控制器(VSC)60，VSC 60与其它车辆系统和控制器进行通信，以用于协调它们的功能。尽管示出为单个控制器，但是VSC 60可包括多个控制器，所述多个控制器可用于根据整个车辆控制逻辑或软件来控制多个车辆系统。
车辆控制器(包括VSC 60和TCM 58)通常包括彼此协作以执行一系列操作的任意数量的微处理器、ASIC、IC、存储器(例如，闪存、ROM、RAM、EPROM和/或EEPROM)以及软件代码。控制器还包括预定数据或“查找表”，所述预定数据或“查找表”是基于计算和测试数据的并被存储在存储器中。VSC 60通过使用通用总线协议(诸如，CAN和LIN)的一个或更多个有线或无线车辆连接而与其它车辆系统和控制器(例如，BECM 54和TCM 58)通信。VSC 60接收表示传动装置12的当前位置(例如，驻车挡、倒车挡、空挡或前进挡)的输入(PRND)。VSC60还接收表示加速踏板位置的输入(APP)。VSC 60向TCM 58提供表示期望的车轮扭矩、期望的发动机转速和发电机制动器命令的输出，并且向BECM 54提供接触器控制。
车辆16包括用于控制发动机20的发动机控制模块(ECM)64。VSC 60向ECM 64提供输出(期望的发动机扭矩)，所述输出是基于包括APP的若干输入信号的并且与驾驶员对车辆推进的请求相对应。
如果车辆16为PHEV，则电池52可经由充电端口66周期性地从外部电源或电网接收AC电能。车辆16还包括从充电端口66接收AC电能的车载充电器68。充电器68是AC/DC转换器，所述AC/DC转换器将接收到的AC电能转换为适合于给电池52充电的DC电能。进而，充电器68在再充电期间将DC电能供应给电池52。尽管以PHEV 16的背景进行示出和描述，但是应该理解的是，可在其它类型的电动车辆(诸如，HEV或BEV)上实施逆变器56。
参照图2，示出了VVC 10和电力逆变器56的电力模块组件57的电路图。VVC 10可包括一个或更多个卡(card)，所述卡至少具有用于提升输入电压(Vbat)以提供输出电压(Vdc)的第一开关单元70和第二开关单元72。第一开关单元70可包括并联连接到第一二极管76的第一晶体管74，但是它们的极性对调(反并联(anti-parallel))。在一个实施例中，开关70可以是逆导绝缘栅双极型晶体管(RCIGBT)。第二开关单元72可包括反并联连接到第二二极管80的第二晶体管78。晶体管74和78中的每个都可以是任意类型的可控开关(例如，绝缘栅双极型晶体管(IGBT)或场效应晶体管(FET))。另外，晶体管74和78中的每个都可由TCM 58单独控制。电感器组件14被描绘为串联连接在牵引电池52与开关单元70和72之间的输入电感器。当供应电流时，电感器14产生磁通。当流过电感器14的电流变化时，产生随时间变化的磁场并感应出电压。VVC 10的其它实施例包括替代的电路配置。
电力模块组件57可包括堆叠在组件中的多个卡(也称为电力模块)。每个卡可包括一个或更多个半桥82，半桥82具有连接至来自电池的正极DC节点的正极DC引线84以及连接至来自电池的负极DC节点的负极DC引线86。半桥82中的每个还可包括第一开关单元88和第二开关单元90。第一开关单元88可包括反并联连接至第一二极管94的第一晶体管92。第二开关单元90可包括反并联连接至第二二极管98的第二晶体管96。第一晶体管92和第二晶体管96可以是IGBT或FET。第一开关单元88和第二开关单元90可与开关单元70和72类似。半桥82中的每个的第一开关单元和第二开关单元将电池的DC电力转换为AC引线100处的单相AC输出。AC引线100中的每个电连接至马达18或发电机24。
参照图3，车辆电力逆变器102可安装在车辆部件104(诸如，车身结构、车架构件或动力传动系统部件)上。电力逆变器102可包括电力模块组件106，电力模块组件106与栅极驱动板108、电容器组110以及控制板112电连接。电力模块组件106可包括多个卡(也被称作电力模块)，每个卡具有封装在其中的一个或更多个半桥。
图4至图10以及相关的讨论描述了示例性电力模块组件。参照图4至图7，示例性电力模块组件120包括卡模块122，卡模块122被一对相对的端盖124夹住。卡模块122包括多个卡126，卡126中的每个包括第一主侧132、第二主侧134以及在第一主侧132和第二主侧134之间延伸的副侧136。第一主侧132包括上连接特征138和下连接特征140。第二主侧134包括上连接特征142和下连接特征144。示出的连接特征中的每个是沿着相应的主侧在副侧之间延伸的突起。在其它实施例中，连接特征可以是槽或使卡能够被组装到卡模块122的另一部件的任何其它特征。卡126中的每个还包括从副侧136延伸的端子146和信号引脚148。
卡126可被布置成具有第一行128和第二行130的阵列。行可以大致彼此平行。在此使用的术语“大致”应该被解释或理解为意味着沿着它们的长度不交叉或者相对于彼此成小于或等于三度的角度。每行中的卡126可在副侧136接触的情况下端对端地布置。行相对于彼此定位成使得第一行128中的卡的主侧面对第二行130中的卡的主侧。应该理解的是，示出的卡的二乘二布置不是限制性的，并且卡可以以很多不同的构造进行布置。例如，卡模块122可仅包括单行的卡，或者可包括三行或更多行的卡。每行还可包括多于或少于两个的卡。
卡模块122还包括在端盖124之间延伸的第一侧面板150和第二侧面板152。侧面板可以是大致平行的。第一侧面板150包括外侧154和内侧156。卡126的第一行128可相对于第一侧面板150大致平行地布置，其中，卡126的第二主侧134面对第一侧面板150的内侧156。上凸沿160和下凸沿168分别从内侧156朝着卡126的第一行128向内突出。上凸沿160包括与上连接特征142配合的连接特征162，下凸沿168包括与下连接特征144配合的连接特征170。在示出的实施例中，连接特征162和170是沿着各自的凸沿延伸的槽。槽162容纳第一行128中的卡的上突起142，槽170容纳第一行128中的卡的下突起144。
第二侧面板152包括外侧176和内侧178。卡126的第二行130可相对于第二侧面板152大致平行地布置，其中，卡126的主侧132面对第二侧面板152的内侧178。侧面板150和152可被成形为使内表面更靠近相应的一行卡放置。上凸沿182和下凸沿186分别从内侧178朝着卡126的第二行130向内突出。上凸沿182包括与上连接特征138配合的连接特征184，下凸沿186包括与下连接特征140配合的连接特征188。在示出的实施例中，连接特征184和188是沿着各自的凸沿延伸的槽。槽184容纳第二行130中的卡的上突起138，槽188容纳第二行130中的卡的下突起140。
卡模块122还可包括上中间分隔件198和下中间分隔件200，上中间分隔件198和下中间分隔件200分别在端盖124之间延伸。分隔件198和200可与侧面板150和152大致平行。上分隔件198包括面向卡的第一行128的第一纵向侧202以及面向卡的第二行130的第二纵向侧206。第一纵向侧202包括与上连接特征138接合的连接特征204。例如，第一纵向侧202限定容纳第一行128中的卡的突起138的槽204。第二纵向侧206包括与上连接特征142接合的连接特征208。例如，第二纵向侧限定容纳第二行130中的卡的突起142的槽208。
下中间分隔件200可包括面向卡的第一行128的第一纵向侧212以及面向卡的第二行130的第二纵向侧216。第一纵向侧212包括与下连接特征140接合的连接特征214。例如，第一纵向侧212限定容纳第一行128中的卡的突起140的槽214。第二纵向侧216包括与下连接特征144接合的连接特征218。例如，第二纵向侧限定容纳第二行130中的卡的突起144的槽218。
可通过首先将卡模块122进行组装并且随后将卡模块的第一端222插入到端盖124中的一个中和将卡模块的第二端224插入到端盖124中的另一个中来形成电力模块120。端盖124中的每个包括壁226，壁226具有限定腔230的内表面228。卡模块122的端部可被容纳到腔230内，使得侧面板150的外侧154和侧面板152的外侧176与壁226的内表面228接合。端盖124中的每个还包括分别容纳第一侧面板150的凸耳(tab)172中的一个或者第二侧面板152的凸耳194中的一个的凹陷234。
第一侧面板150和第二侧面板152与端盖124配合以限定电力模块组件120的壳体238。壳体238限定具有多个冷却剂通道242的冷却剂室240，所述多个冷却剂通道242使冷却剂直接经过卡126的主侧进行输送。端盖124中的每个可限定用于使冷却剂循环进入或离开冷却剂室240的一个或更多个冷却剂端口232。例如，端盖中的一个可限定入口端口，端盖中的另一个可限定出口端口。在一些实施例中，入口端口和出口端口被限定在同一个端盖中。冷却剂端口232可连接到冷却剂管线244，冷却剂管线244连接到车辆的热管理系统。
在示出的实施例中，在第一侧面板150的内侧156与卡的第一行128之间限定第一通道242a。第一行128中的卡126的第二主侧134与通过第一通道242a的冷却剂直接接触。在卡的第一行128与卡的第二行130之间限定第二通道242b。中间分隔件198和200确保在第一行与第二行之间保持有一定间隙。第一行128中的卡126的主侧132以及第二行130中的卡126的主侧134与通过第二通道242b的冷却剂直接接触。在第二侧面板152的内侧178与卡的第二行130之间限定第三通道242c。第二行130中的卡126的主侧132与通过第三通道242c的冷却剂直接接触。
与冷却板和冷却翅片的设计相比，使液体冷却剂与卡126直接接触通过消除冷却板顶部或翅片的热阻来减小冷却系统的热阻。与传统的设计相比，这在卡与冷却剂之间产生了更高效的热传递。
壳体238需要是水密的，以防止冷却剂从电力模块组件120中泄漏出去。各个部件的连接特征可配合以形成密封表面。例如，突起142与槽162形成第一冷却剂通道242a的上密封表面。槽与突起之间的连接可通过设置在槽中的垫圈进行密封，或者可通过粘合剂或产生塑性焊接的溶剂粘合来进行密封。其它配合表面可被类似地密封。也可在相邻的卡126的配合的副侧上应用垫圈或密封剂。在示出的实施例中，通过O形圈246在卡模块122的端部与相应的端盖124之间产生密封。可选地，可在侧面板150和152与壁226之间应用密封剂或溶剂粘合。还可沿着行的顶部248和底部250设置灌封材料，以使卡与侧面板、分隔件和端盖进一步密封。
参照图8，另一电力模块组件260包括具有多个卡264的卡模块262。卡264可具有主侧266和副侧268。如上面参照其它实施例所描述的，可在主侧266上提供连接特征270(例如，突起)。卡264可被布置在第一行272和第二行274中，其中，每行具有两个卡。(注意：出于说明的目的，未示出第四个卡)。然而，应理解的是，卡可被布置成多于或少于两行，并且每行可包括多于或少于两个的卡。邻近卡的第一行272设置第一侧面板276，邻近卡的第二行274设置第二侧面板278。中间分隔件290设置在卡的第一行272与卡的第二行274之间。中间分隔件290包括上部292、下部294以及在上部与下部之间延伸的腹板(web)296。中间分隔件290可包括与连接特征270配合的一个或更多个连接特征298(例如，槽)。如上面参照其它实施例所描述的，第一侧面板276和第二侧面板278还可包括与卡的连接特征配合的连接特征。
如上所述，卡模块262被第一端盖280和第二端盖282夹住。第一端盖280可包括入口端口284和出口端口286，第二端盖282可包括膨胀端口(expansion port)288。在其它实施例中，可以以不同的方式布置端口。与电力模块120(其使冷却剂直线通过模块循环)不同，电力模块260具有U形冷却剂回路，在所述U形冷却剂回路中，冷却剂循环进入和离开同一端盖。例如，卡模块262包括在第一侧面板276与中间分隔件290之间限定的第一冷却剂室(不可见)和在中间分隔件290与第二侧面板278之间限定的第二冷却剂室302。卡的第一行272设置在第一冷却剂室内并且与第一冷却剂室内的冷却剂直接接触，卡的第二行274设置在第二冷却剂室302内并且与第二冷却剂室内的冷却剂直接接触。第二冷却剂室302可包括在分隔件290与卡的第二行274之间限定的第一通道304以及在卡的第二行274与第二侧面板278之间限定的第二通道306。第一冷却剂室可类似地包括多个通道。在操作中，冷却剂可从入口端口284循环通过第一冷却剂室并且到达第二端盖282。第二端盖282可包括用于将冷却剂重新引导到第二冷却剂室302中、返回第一端盖280并从出口端口286离开的特征。入口端口284和出口端口286可偏移(例如，左或右)中间分隔件290，以将端口放置为与相应的冷却剂室流体连通。电力模块260可包括如上面参照其它实施例所描述的密封手段。
卡模块262以及端盖280和282可包括用于将模块262连接到端盖的连接特征308和310。这些特征308和310可单独使用或者与其它手段(例如，粘合剂、溶剂粘合或本领域已知的技术)配合使用以固定端盖和卡模块。
参照图9，示出了连接特征308的放大视图。侧面板278包括外表面318，在外表面318上设置有卡合部320。端盖282包括侧壁312，侧壁312具有限定插槽316的U形部件314。卡合部320插入到插槽316中以便将端盖282卡在卡模块262上。卡合部320包括当部件被连接时被容纳在插槽316内的柄部(shaft)322以及当卡合部320穿过插槽316进行安装时设置在部件314的后侧上的头部334。头部334包括与部件314的壁配合以阻止卡合部320从插槽316中拔出的倒钩部(barb)336。
参照图10，示出了连接特征310的放大视图。端盖282包括具有止动部(detent)340的顶部338。止动部340与在中间分隔件290的顶部342中限定的凹窝(dimple)344配合，以将端盖282固定到卡模块262。应理解的是，根据设计参数，电力模块260可仅包括连接特征308和310中的一种、连接特征308和310中的两种或者不包括连接特征308和310。
图11和图12以及关联的文本描述了用于电力模块组件(诸如，电力模块组件120或电力模块组件260)的示例性的卡(或电力模块)350。卡350可包括夹住多个开关单元356的第一基板352和第二基板354。第一基板352包括外面板358、内面板360和设置在内面板与外面板之间的介电层362。外面板358限定卡的外主侧，内面板360限定基板的内主侧，面板和介电层的薄边共同限定卡的副侧的一部分。例如，面板和介电层通过高温氧化工艺粘合在一起。内面板360和外面板358可以是诸如铜、铝、银或金的金属。在一个实施例中，外面板358是未图案化的铜，内面板360是图案化的铜。术语“图案化”指的是面板已经被蚀刻以限定电路。介电层362可以是陶瓷。示例性的陶瓷包括氧化铝、氮化铝和氮化硅。在一些实施例中，陶瓷可以是掺杂过的。第二基板354也包括外面板364、内面板366和介电层368。内面板和外面板以及介电层的材料可与上面关于第一基板352所描述的材料类似。
卡350包括一个或更多个开关单元356(也被称为芯片或裸片(die))，诸如图12示出的实施例中示出的六个开关单元。每个开关单元356包括晶体管370和二极管372。晶体管370可以是但不限于IGBT或FET。每个开关单元356电连接到内面板360和内面板366中的一个或两者。卡350包括多个垫片(shim)378，垫片378将开关单元356电连接到内面板中的一个并且起到分隔功能。模塑化合物(mold compound)380对卡350的内部部件进行封装。
卡350还包括多个端子376和信号引脚374。例如，卡350可包括正极DC端子382、负极DC端子384、发电机AC端子386以及马达AC端子388。DC端子382和384与电容器组和牵引电池电连接。AC端子386和388电连接到关联的电机。信号引脚374电连接到栅极驱动板。端子和引脚可通过图案化的内面板来形成，或者可以是附连到开关单元356的单独的部件。
尽管上文描述了示例性实施例，但是这些实施例并不意在描述了权利要求所涵盖的所有可能的形式。在说明书中使用的词语是描述性词语而非限制性词语，应该理解的是，可在不脱离本公开的精神和范围的情况下进行各种改变。如前所述，各个实施例的特征可被组合，以形成本发明的可能未被明确描述或示出的进一步的实施例。尽管各个实施例可能已被描述为提供优点或者在一个或更多个期望的特性方面优于其它实施例或现有技术的实施方式，但是本领域普通技术人员应该认识到，可对一个或更多个特征或特性进行折衷，以实现期望的整体系统属性，期望的整体系统属性取决于具体的应用和实施方式。这些属性可包括但不限于成本、强度、耐久性、生命周期成本、可销售性、外观、包装、尺寸、维护保养方便性、重量、可制造性、装配容易性等。因此，被描述为在一个或更多个特性方面不如其它实施例或现有技术的实施方式合意的实施例并不在本公开的范围之外，并且可被期望用于特定的应用。

Claims (10)

1.一种用于车辆的电力逆变器的电力模块组件，所述电力模块组件包括：
壳体，包括面板，所述面板在相对的端盖之间延伸并且具有限定沿着所述面板的纵向方向延伸的第一连接特征的内侧，其中，所述壳体还包括至少部分地由所述内侧和所述端盖限定的腔，并且所述端盖中的至少一个限定冷却剂端口；
卡的阵列，设置在所述腔内，并且所述卡中的每个具有相对的主侧以及在所述相对的主侧之间延伸的副侧，其中，所述卡中的至少一个卡限定第二连接特征，所述第二连接特征横跨所述至少一个卡的主侧中的一个延伸并且与第一连接特征接合以连接所述至少一个卡和所述面板，并且其中，与所述冷却剂端口流体连通的冷却剂通道被限定在所述至少一个卡与所述面板之间，并且被构造为使冷却剂直接经过所述至少一个卡进行输送。
2.如权利要求1所述的电力模块组件，其中，第一连接特征是槽，并且第二连接特征是设置在所述槽内的突起。
3.如权利要求1所述的电力模块组件，其中，第一连接特征是突起，并且第二连接特征是容纳所述突起的槽。
4.如权利要求1所述的电力模块组件，其中，所述至少一个卡还限定横跨所述主侧中的另一个延伸的第三连接特征，所述电力模块组件还包括中间分隔件，所述中间分隔件在所述端盖之间延伸并且限定第四连接特征，第四连接特征与第三连接特征接合以连接所述至少一个卡和所述中间分隔件。
5.如权利要求4所述的电力模块组件，其中，第三连接特征是突起，第四连接特征是容纳所述突起的槽。
6.如权利要求1所述的电力模块组件，其中，所述端盖中的另一个限定第二冷却剂端口。
7.一种电力模块组件，包括：
相对的端盖，共同具有冷却剂端口；
成行的卡，所述卡中的每个具有主侧，所述主侧限定横跨所述卡延伸的突起；
侧面板，在所述端盖之间延伸使得所述侧面板与所述行限定通道，所述通道与所述冷却剂端口流体连通并且被构造为使冷却剂直接经过所述卡进行输送，其中，所述侧面板限定容纳所述突起的槽。
8.如权利要求7所述的电力模块组件，其中，所述卡中的每个还包括另一主侧，所述另一主侧限定横跨所述卡延伸的另一突起，并且所述电力模块组件还包括另一侧面板，所述另一侧面板在所述端盖之间延伸并且限定容纳所述另一突起的槽。
9.一种电力模块组件，包括：
卡模块，包括间隔开的侧面板和设置在所述卡模块中的卡，所述侧面板限定冷却剂室；
相对的端盖，所述端盖中的每个包括限定腔的壁，所述腔容纳所述卡模块的一端使得所述壁的内表面与所述侧面板的外表面接合，所述端盖中的一个限定端口，所述端口与所述冷却剂室流体连通以使冷却剂直接经过所述卡进行输送。
10.如权利要求9所述的电力模块组件，其中，所述端盖中的每个的内表面限定容纳所述侧面板中的一个的一部分的第一凹陷和容纳所述侧面板中的另一个的一部分的第二凹陷。
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