CN111373526A - 用于允许恢复电源模块的管芯的互连部的系统及方法 - Google Patents
用于允许恢复电源模块的管芯的互连部的系统及方法 Download PDFInfo
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Abstract
本发明涉及一种用于允许恢复电源模块的管芯的互连部的系统,互连部的第一端子固定在管芯上并且互连部的第二端子连接到电路。系统包括:位于互连部的第一端子附近的至少一种材料,该材料具有预定熔化温度,用于在预定时间段期间将管芯的温度控制在所述预定熔化温度的装置。本发明还涉及方法。
Description
技术领域
本发明总体上涉及一种用于允许恢复电源模块的管芯的互连部的方法及系统。
背景技术
安装在电器中的电源模块由于它们由各自具有不同特性的各种层状材料组成而经历损耗。
电源模块在运行期间必须支持较大的温度漂移。运行固有的损耗表现为诸如焊料层或布线接合之类的各种界面层中裂纹的增加。
为了防止损耗,用更好的匹配材料来设计电源模块,但是这种解决方案通常会遭受电气性能不良和制造成本更高的困扰。此外,由于这些附加的制造成本,设计适应最严苛使用场景的电源模块是不切实际的,从而导致越繁重的应用电源模块寿命越低。
发明内容
本发明旨在允许恢复电源模块的管芯的至少一个互连部。
为此,本发明涉及一种用于允许恢复电源模块的管芯的互连部的系统,所述互连部的第一端子固定在管芯上并且互连部的第二端子连接到电路,其特征在于,该系统包括:
-位于所述互连部的所述第一端子附近的至少一种材料,该材料具有预定熔化温度,
-用于在预定时间段期间将所述管芯的温度控制在所述预定熔化温度的装置。
本发明还涉及一种用于允许恢复电源模块的管芯的互连部的方法,所述互连部的第一端子固定在管芯上并且所述互连部的第二端子连接到电路,其特征在于,至少一种材料位于所述互连部的所述第一端子附近,所述材料具有预定熔化温度,并且该方法包括以下步骤:在预定时间段期间将所述管芯的温度控制在所述预定熔化温度。
因此,电源模块的管芯的互连部可以通过管芯的控制信号(例如到栅极的控制信号)来恢复,从而降低了解决方案的成本。能够在现场引起恢复状态,从而减少了维护所损失的时间,能够在电源模块中可靠地引起恢复过程,从而允许电源模块完成其任务达更长的持续时间。
根据特定特征,所述管芯和位于所述第一端子附近的所述至少一种材料由固体材料复原。
因此,在电源模块的正常操作期间,位于第一端子附近的材料不会相互作用。
根据特定特征,位于所述第一端子附近的材料是锡和铅-铋合金。
因此,锡和铅-铋合金在管芯正常工作期间是固态的,并且引起液相的温度低于管芯的最大安全工作结温度。因此,可以仅由管芯本身产生热量,而不会损坏管芯并且没有外部热源。
根据一个特定的特征,熔化温度等于150℃并且预定时间段为30分钟。
因此,熔化温度处于管芯的安全工作区域中,并且在维护间隔期间在没有外部热源的情况下使用仅由管芯本身产生的热量来实现熔化温度。
根据特定特征,用于控制管芯的温度的装置以从热电偶获得管芯的温度。
因此,能够使用低成本和广泛使用的传感器来控制温度。
根据特定特征,用于控制管芯的温度的装置从管芯的温度敏感电参数获得管芯的温度。
因此,可以在没有任何额外的热传感器的情况下控制管芯的温度然后控制互连部的温度,从而减少了所提出的实施方式所必需的部件数量。
根据特定特征,管芯的温度敏感电参数是管芯的栅极-发射极电压值。
因此,从用于控制温度的装置无法直接得到管芯的互连部中或者栅极控制和栅极-发射极电压值中的变化。
通过阅读下面的示例性实施方式的描述,本发明的特征将变得更加清楚,所述描述是参照附图进行的。
附图说明
[图1]
图1表示其中实施本发明的电源模块的实施例。
[图2a]
图2a表示根据本发明包括能够修复的裂纹的互连部的区域的放大图。
[图2b]
图2b表示根据本发明包括能够修复的裂纹的互连部的区域的放大图。
[图3]
图3表示根据本发明的包括电源模块和驱动器的系统。
[图4]
图4表示用于实施本发明的栅极电压控制器的架构的实施例。
[图5]
图5表示根据本发明使用的电压调整器。
[图6]
图6表示根据本发明的控制器的架构的实施例。
[图7]
图7表示根据本发明的用于控制焊料层的加热状态以实施愈合过程的算法。
[图8]
图8是使用温度热电偶反馈的控制回路的实施例。
[图9]
图9是使用温度敏感电参数反馈的控制回路的实施例。
具体实施方式
图1表示其中实施本发明的电源模块的实施例。
电源模块包括将管芯Di连接到外部组件的互连部110a和110b,例如铜层。
使用焊料130将管芯Di固定在直接铜接合(DCB)基板140、150、160的铜层140上,陶瓷150固定在铜底板160上,铜底板160固定在冷却板上。
根据本发明,对于一个互连部,电源模块还至少包括例如锡和铅-铋合金的愈合剂100a和100b,愈合剂100a和100b具有在给定温度下变成液体的低熔化温度。
愈合剂围绕互连部,并且可以渗入互连部110a中存在的裂纹120,如图2a和图2b所示。
例如环氧树脂或硅基封装胶之类的固态材料170复原管芯、愈合剂100和DCB。
图2a和图2b表示根据本发明包括能够修复的裂纹的互连部的区域的放大图。
图2a表示电源模块的在图1中标记为120的区域,该区域包括裂纹Cr和如图2b所示在互连部110a处通过毛细运动渗入裂纹Cr中的愈合剂100a。通过周期性施加热应力并随之变形,进一步促进了渗入。变型必须是针对其电迁移特性而专门选择的合金,诸如Al-4Cu,从而通过正常整流中的高电流和根据本发明维持的高温促进的金属元素迁移来修复裂纹的边缘。
此外,电源模块本身内的互连部也可以由自愈材料制成,例如形状记忆合金,其中仅需要高温来激活愈合过程。
图3表示根据本发明的包括电源模块和驱动器的系统。
根据本发明,通过向管芯的栅极施加电压,在电源模块的至少一个管芯Di内产生高损耗状态。
对于电压驱动的半导体管芯,即IGBT或MOSFET,管芯的漏电流使管芯成为不完善的隔离器,同时阻断电压。如果管芯正在阻断电压,则管芯中耗散的功率与漏电流和阻断电压有关。在这种情况下,管芯处于高损耗状态。
高损耗状态是由于受控的栅极电压和电流反馈控制环路所致,这使得电压驱动管芯中的漏电流受到控制,从而也可以控制管芯中的有功热量。
本发明在电源模块运行的同时控制加热状态,以激活电源模块中的恢复状态。
在半桥配置中,当一个管芯处于导通状态时,第二管芯处于截止状态并阻断电压。因此,在截止状态下,当管芯正在阻断电压时,耗散的功率直接受漏电流或在IGBT的情况下从集电极流向发射极的电流的影响。调整栅极电压刚好超过阈值电压,以在沟道中感应出小电流,从而以线性模式控制管芯:
Ic=k*(Vgs-VTh)2
其中k与管芯的跨导有关,Vgs是施加的栅极电压,Ic是集电极电流,VTh是管芯的阈值电压。
因此,假设电源模块具有温度依从恢复状态,通过控制DC操作点附近的栅极电压gs,控制电源模块中产生的热量,使得电源模块能够达到所需温度。在电源模块中产生给定量的电力的情况下,壳体温度升高,直到去除电力。因此,由于电源模块需要以特定温度持续超过最少时间才能激活恢复过程(例如150℃持续30分钟),在管芯截止状态期间对电源模块中集电极电流的控制能够允许由热机械疲劳引起的裂纹愈合。
在图3的实施例中,电源模块由分别由栅极电压控制器301和302驱动的两个管芯D1和D2组成。
栅极电压控制器301接收信号PWM1并将其提供给管芯D1。PWM1信号是在正常操作期间要施加到管芯D1的信号。栅极电压控制器301接收使能恢复过程的修复使能信号ENR1。例如,修复使能信号ENR1周期性地(例如,每年在给定时间(例如30分钟)期间)使能修复过程。
栅极电压控制器301接收控制信号CTRL1。
栅极电压控制器302接收信号PWM2并将其提供给管芯D2。PWM2信号是在正常操作期间要施加到管芯D2的信号。栅极电压控制器302接收使能恢复过程的修复使能信号ENR2。例如,修复使能信号ENR2周期性地(例如,每年在给定时间(例如30分钟)期间)使能修复过程。
栅极电压控制器301接收控制信号CTRL2。
分流电阻Rs用于监测集电极电流。
图4表示用于实施本发明的栅极电压控制器的架构的实施例。
栅极电压控制器包括放大信号PWMi的放大器Ampi,其中,i=1或2。
放大器Ampi由负电源VSS和正电源VCC通过调整器Regi供电。
当修复使能信号ENRi有效时,信号CTRLi施加到调整器Regi。
图5表示根据本发明使用的电压调整器。
可控的dc调整器用于调整所施加的栅极电压。
为了处理反馈信息并提供用于可控电压调整器的基准,使用控制器,如图6所示。例如通过分流电阻Rs测量的集电器电流用作基准来调制所施加的栅极电压,从而将电源模块中的功率耗散控制在特定水平以引起愈合状态。取决于电源模块中修复材料的特性,可能需要使温度保持恒定,在这种情况下,能够将嵌入电源模块的热电偶用于调整目的,或者能够采用热敏电参数(例如,某个电流Ic的Vg)。
电压调整器Regi由一个放大器Amp50i、两个电阻R50和R51以及两个晶体管T50和T51组成。放大器Amp50i的负输入连接到电阻器R50的第一端子和电阻器R51的第一端子。电阻器R50的第二端子连接到晶体管T50的发射极和图4的放大器Ampi。电阻器R50的第二端子连接到晶体管T51的发射极和电源VCC的基准。
电源VCC的正端子连接到晶体管T50的集电极。
放大器Amp50i的输出连接到晶体管T51的基极,并且晶体管T51的集电极连接到晶体管T50的基极。
图6表示根据本发明的控制器的架构的实施例。
控制器10具有例如基于通过总线601和由如图7所公开的程序控制的处理器600连接在一起的组件的架构。
总线601将处理器600链接到只读存储器ROM 602、随机存取存储器RAM 603和输入输出I/O IF接口605。
存储器603包含旨在接收变量和与图7中公开的算法有关的程序的指令的寄存器。
处理器600通过输入输出I/O IF 605接收集电极电流Ic、由温度传感器感测到的温度或热敏参数反馈(如栅极到发射极的电压值Vge),并提供信号PWM1、PMW2、ENR1、ENR2、CTRL1和CTRL2。
例如通过分流电阻Rs测量到的集电极电流用作基准来调制所施加的栅极电压,使得将电源模块中的功率耗散控制在特定水平以诱导愈合状态。取决于电源模块中修复材料的特性,可能需要使温度保持恒定,在这种情况下,能够将嵌入电源模块的热电偶用于调整目的,或者能够采用基于热敏电参数(例如,某电流Ic的Vg)的方法。
只读存储器或可能的闪存602包含与图7中公开的算法有关的程序的指令,当控制器10通电时,所述指令被传送至随机存取存储器603。
控制器10可以通过由诸如PC(个人计算机)、DSP(数字信号处理器)或微控制器之类的可编程计算机器执行一组指令或者编程以软件来实现;或者通过机器或诸如FPGA(现场可编程门阵列)或ASIC(专用集成电路)之类的专用组件以硬件实现。
换句话说,控制器10包括使得控制器10能够执行与如图7中公开的算法有关的程序的电路或包括电路的设备。
图7表示用于控制焊料层的加热状态以实施根据本发明的愈合过程的算法。
在实施例中公开了本算法,其中该算法由控制器10的处理器600执行。
在步骤S700,修复使能信号ENR1和ENR2处于低逻辑电平,即,恢复过程被禁用。
在下一步骤S701,处理器600将信号PWM1设置为低电平,并且将信号PWM2设置为高电平。
在下一步骤S702,处理器600将修复使能信号ENR1设置为高电平,即,开始对管芯D1的恢复过程。
在步骤S703,处理器600控制将参照图8或图9公开的加热状态控制回路。
考虑到温度反馈参数的使用,用于调整集电极电流的控制回路可以有两种实施方式。对于第一种方法,使用热电偶来提供壳体温度,控制如图8所示。对于第二种方法,栅极到发射极的电压用作热敏电参数来测量温度,控制如图9所示。
在给定的持续时间期间调整温度,例如在30分钟期间150℃。
在步骤S704,处理器600检查给定的持续时间是否完成。如果给定的持续时间完成,则处理器600移至步骤S705。否则,处理器600返回到步骤S703。
在步骤S705,处理器600将修复使能信号ENR1设置为低电平,即,对管芯D1中断恢复过程。
此后,处理器600对管芯D2执行本算法。
图8是使用热电偶温度反馈的控制回路的实施例。
模块800将由温度传感器感测到的温度减去与愈合剂100的熔化温度相对应的基准温度Tcref。
其中,Vce是集电极到发射极的电压,Ic是集电极电流,Rth是电源模块的热阻,并且P是功率耗散。
由减法器802从基准电流Ic,ref减去测量到的集电极电流Ic,以获得差分电流模块803是将模块802提供的差分电流转换为栅极偏置电压CRTLi的比例积分器,假设在略高于数据手册阈值电压的DC栅极偏置电压Vbias操作,栅极偏置电压CRTLi能够由比例(Kp2)和积分(Ki2)关系来定义。再次,需要假设基于采样频率存在某个增益C',K'是由半导体类型的物理特性和所需误差补偿的大小限定的某个常数。
信号CTRLi被提供给电压调整器Regi,该电压调整器Regi将栅极到发射极电压Vge提供给管芯。
图9是使用温度敏感电参数的控制回路的实施例。
基于热敏电参数的方法使用栅极-发射极电压值Vge,其是针对一定电流和一定温度而定义的,作为如下式所示的间接温度测量值:
基于温度敏感电参数的方法要求在设备制造后立即执行校准阶段。
在此校准阶段,功率管芯被加热到Tcref,通过管芯集电极-发射极与栅极-集电极端子短路,外部电流源注入校准电流Ic,cal值(例如,0.5A)。然后,测量栅极-发射极的电压值并将其定义为Vgcal。如上面提到的公式所示,该电压还被用作间接测量管芯温度的设置点。
在恢复过程的操作期间,由减法器901从基准电流Iref减去测量到的集电极电流Ic,以获得差分电流模块902是将模块901提供的差分电流转换为栅极偏置电压CRTLi的比例积分器,假设在略高于数据手册阈值电压的DC栅极偏置电压Vbias操作,栅极偏置电压CRTLi能够由比例(Kp2)和积分(Ki2)关系来限定。
电压CRTLi被提供给电压调整器Regi,并且栅极电压控制器30it将栅极到发射极电压Vge提供给管芯Di。
在第一时刻,信号“Ttrigger”为高(HIGH),基准电流Iref由块900设置为等于预定电流Ic,cal。稳态电压Vgref以时间常数te(由电时间常数给出的数百微秒)采样。
在Ttrigger的下降沿期间,由采样保持电路905对栅极电压Vgref采样并保持。由减法器906从采样保持电路905的输出值中减去Vgcal值,并且减法器906的结果被提供给比例积分器907,比例积分器907产生信号Ic,pwr。比例积分器907将减法器906提供的差分电压转换成可由比例(Kp3)和积分(Ki3)关系限定的电流Ic,pwr。再次,需要假设基于采样频率存在某些增益C″,1/(te+tt)是由半导体类型的物理特性和所需误差补偿的大小限定的某个常数。
当信号“Ttrigger”低时,基准电流Iref由块900设置为等于先前计算出的电流Ic,pwr,并根据预定的恢复时间在例如几分钟的时间tt期间保持。
Claims (8)
1.一种用于允许恢复电源模块的管芯的互连部的系统,所述互连部的第一端子固定在所述管芯上并且所述互连部的第二端子连接到电路,其特征在于,该系统包括:
-位于所述互连部的所述第一端子附近的至少一种材料,该材料具有预定熔化温度,
-用于在预定时间段期间将所述管芯的温度控制在所述预定熔化温度的装置。
2.根据权利要求1所述的系统,其特征在于,所述管芯和位于所述第一端子附近的所述至少一种材料由固体材料复原。
3.根据权利要求1或2所述的系统,其特征在于,位于所述第一端子附近的材料是锡和铅-铋合金。
4.根据权利要求3所述的系统,其特征在于,所述熔化温度等于150℃并且所述预定时间段为30分钟。
5.根据权利要求1至4中的任一项所述的系统,其特征在于,用于控制所述管芯的温度的所述装置从热电偶获得所述管芯的温度。
6.根据权利要求1至4中的任一项所述的系统,其特征在于,用于控制所述管芯的温度的所述装置从所述管芯的温度敏感电参数获得所述管芯的温度。
7.根据权利要求6所述的系统,其特征在于,所述管芯的温度敏感电参数是所述管芯的栅极-发射极电压值。
8.一种用于允许恢复电源模块的管芯的互连部的方法,其特征在于,所述互连部的第一端子固定在所述管芯上并且所述互连部的第二端子连接到电路,其特征在于,至少一种材料位于所述互连部的所述第一端子附近,所述材料具有预定熔化温度,并且该方法包括以下步骤:在预定时间段期间将所述管芯的温度控制在所述预定熔化温度。
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