FR3113440A1 - ELECTRICAL DEVICE WITH WATER-BOX COOLING AND ELECTRICAL SYSTEM COMPRISING SUCH DEVICE - Google Patents

Abstract

This device comprises: - a main body (302) comprising a coolant inlet connector (304) and an outlet connector (306), a coolant flow channel having upper openings, and first and second power electronics module receiving locations (324, 326), each covering at least a respective upper opening and having a same first receiving configuration; and - a first power electronic module (110) compatible with the first reception configuration to be received interchangeably in the first and second slots (324, 326). It further comprises: - an intermediate part (502) compatible with the first reception configuration to be received interchangeably in the first and second locations (324, 326) and having a third location (506) for receiving an electronic module of power having a second receive configuration, different from the first; and - a second power electronic module (112) incompatible with the first reception configuration but compatible with the second reception configuration. Figure for abstract: Fig. 5

Description

ELECTRICAL DEVICE WITH WATER BOX COOLING AND ELECTRICAL SYSTEM COMPRISING SUCH DEVICE

The present invention relates to an electrical device with water box cooling and an electrical system comprising such a device.

The Japanese patent published under the number JP 5 698 310 B2 describes an electrical device with water box cooling, designed to cool two electronic power modules. This device comprises a main body comprising an inlet connector and a water outlet connector. The main body further has a water flow channel extending between the inlet and outlet connectors. The flow channel has two parts, called upper, extending on an upper face of the main body and made by four recesses and a part, called lower, extending on a lower face of the main body and made by a single recess . The lower part is connected to the upper parts by openings provided through the main body. This device thus comprises a lower cover for closing the lower part of the flow channel (and more precisely the recess which forms it) and the two power electronic modules are designed to respectively cover the upper parts of the flow channel (and more precisely the recesses that form them). The entire flow path, lower cover and power electronic modules then form a closed coolant flow channel connecting the inlet connector to the outlet connector.

A disadvantage of this known device is that it is provided for two identical power electronic modules. However, it may happen that two different modules must be used, which means reviewing the entire design of the water box.

It may thus be desirable to provide an electrical device with water box cooling which makes it possible to overcome at least some of the aforementioned problems and constraints.

• un corps principal comprenant :
  • un connecteur d’entrée et un connecteur de sortie d’un liquide de refroidissement, conçus pour être respectivement connectés à une conduite d’entrée et à une conduite de sortie du liquide de refroidissement,
  • un canal d’écoulement du liquide de refroidissement s’étendant entre les connecteurs d’entrée et de sortie et présentant des ouvertures supérieures, et
  • des premier et deuxième emplacements de réception de module électronique de puissance, recouvrant chacun au moins une ouverture supérieure respective et ayant une même première configuration de réception ; et
• un premier module électronique de puissance compatible avec la première configuration de réception pour être reçu de manière interchangeable dans les premier et deuxième emplacements ;

caractérisé en ce qu’il comporte en outre :

• une pièce intermédiaire compatible avec la première configuration de réception pour être reçu de manière interchangeable dans les premier et deuxième emplacements et présentant un troisième emplacement de réception de module électronique de puissance ayant une deuxième configuration de réception, différente de la première ; et
• un deuxième module électronique de puissance incompatible avec la première configuration de réception mais compatible avec la deuxième configuration de réception.

An electrical device with water box cooling is therefore proposed, comprising:

• a main body comprising:
  • a coolant inlet connector and an outlet connector, designed to be respectively connected to a coolant inlet pipe and to a coolant outlet pipe,
  • a coolant flow channel extending between the inlet and outlet connectors and having upper openings, and
  • first and second electronic power module reception slots, each covering at least one respective upper opening and having the same first reception configuration; And
• a first power electronic module compatible with the first reception configuration to be received interchangeably in the first and second slots;

characterized in that it further comprises:

• an intermediate part compatible with the first reception configuration to be received interchangeably in the first and second slots and having a third power electronic module reception slot having a second reception configuration, different from the first; And
• a second electronic power module incompatible with the first reception configuration but compatible with the second reception configuration.

Thus, it is possible to continue to use an already existing main body but provided for two identical power electronic modules, with two different power electronic modules, or at least compatible with different reception configurations.

Optionally, the first reception configuration comprises a first screwing diagram, the second reception configuration comprises a second screwing diagram, different from the first, each of the first electronic power module and of the intermediate part has the first screwing diagram and the second electronic power module has the second tightening diagram.

Also optionally, the second electronic power module has a base plate.

Also optionally, the base plate of the second electronic power module is too small to cover the upper opening or openings of the first receiving location and the upper opening or openings of the second receiving location.

Also optionally, the base plate of the second electronic power module is not suitable for being in contact with the coolant.

Also optionally, the second electronic power module comprises a substrate, power components fixed on the substrate itself fixed on the base plate and an electrically insulating casing at least partially encasing the substrate, entirely the power components and partially the base plate so as to leave at least a part of an underside of the exposed base plate.

Also optionally, the first electronic power module comprises a substrate, power components fixed on the substrate, a base plate on which the substrate is fixed and an electrically insulating casing at least partially encasing the substrate, entirely the components of power and partially the base plate so as to leave at least part of an underside of the exposed base plate.

Also optionally, each power electronic module implements a voltage converter.

Also optionally, the power components comprise semiconductor switches of switching arms of the voltage converters.

• une source de tension continue ;
• une machine électrique tournante ;
• un dispositif électrique à refroidissement par boîte à eau selon l’invention, les convertisseurs de tension étant connectés chacun, d’une part, à la source de tension continue et, d’autre part, à la machine électrique tournante ; et
• un dispositif de commande conçu pour, sélectivement, commander le premier convertisseur de tension en onduleur, en laissant le deuxième convertisseur de tension inactif, pour fournir de l’énergie électrique à la machine électrique tournante à partir de la source de tension continue et commander le deuxième convertisseur de tension en redresseur, en laissant le premier convertisseur de tension inactif, pour fournir de l’énergie électrique à la source de tension continue à partir de la machine électrique tournante.

An electrical system is also proposed comprising:

• a DC voltage source;
• a rotating electric machine;
• an electrical device with water box cooling according to the invention, the voltage converters each being connected, on the one hand, to the DC voltage source and, on the other hand, to the rotating electrical machine; And
• a control device arranged to selectively control the first voltage converter into an inverter, leaving the second voltage converter inactive, to supply electrical energy to the rotating electrical machine from the DC voltage source and control the second voltage converter into a rectifier, leaving the first voltage converter inactive, to supply electrical energy to the DC voltage source from the rotating electrical machine.

The invention will be better understood with the aid of the following description, given solely by way of example and made with reference to the appended drawings in which:

FIG. 1 is a schematic view of an electrical system comprising an electrical device with water box cooling according to the invention,

FIG. 2 is a sectional view of two electronic power modules of the device of FIG. 1,

FIG. 3 is a simplified three-dimensional view of a heat sink of the device of FIG. 1, seen from above,

figure 4 is a simplified three-dimensional view of the heat sink of figure 3, seen from below,

FIG. 5 is a view similar to that of FIG. 3, with the two electronic power modules of FIG. 2 and an intermediate piece mounted on the heat sink,

FIG. 6 is a sectional view of a digital simulation of the heat sink, of the two power electronic modules and of the intermediate part, and

FIG. 7 is a top view of a digital simulation of a variant of the invention.

With reference to FIG. 1, an example 100 of an electrical system implementing the invention will now be described. The electrical system 100 is for example intended to be implemented in a motor vehicle (not shown).

The electrical system 100 firstly comprises a DC voltage source 102 comprising a positive terminal and a negative terminal, the latter being generally connected to an electrical ground, such as a chassis of the motor vehicle. The DC voltage source 102 is designed to provide an input voltage denoted E.

The electrical system 100 further comprises a rotating electrical machine 104 comprising stator phases. For example, the rotating electrical machine 104 is part of an alternator-starter coupled to a heat engine (not shown) of the motor vehicle. The rotating electrical machine 104 is thus designed to operate alternately in motor mode in which it assists the heat engine and in alternator mode in which it transforms part of the mechanical energy generated by the heat engine into electrical energy to recharge the voltage source carry on 102.

The heat engine could be omitted. In this case, the rotating electrical machine 104 could be of high power and capable of serving as an alternator. Still in the case of the absence of a heat engine, the rotating electric machine 104 could alternatively be used solely for the electric drive of the vehicle. In this case, the electrical system 100 could comprise an alternator separate from the rotating electrical machine 104. Thus, the electrical motricity and the power recovery would be decoupled from each other. Alternatively, the electric machine could be used both to drive the wheels of the vehicle and to transform the mechanical energy generated during the braking of the vehicle into electrical energy.

The electrical system 100 further comprises two voltage converters 106, 108 each connected, on the one hand, to the terminals of the DC voltage source 102 and, on the other hand, to the rotating electrical machine 104.

Each voltage converter 106, 108 comprises switching arms respectively associated with the stator phases. Each switch arm has a high side switch connected to the positive terminal of DC voltage source 102 and a low side switch connected to the negative terminal of DC voltage source 102. The high side switch and the low side switch are further connected to each other at a midpoint connected to the associated stator phase.

The electrical system 100 further includes a controller 109, designed to control each switch arm to switch between two configurations. In the first, called high configuration, the high side switch is closed and the low side switch is open so that the input voltage E is applied to the associated stator phase. In the second, known as the low configuration, the high side switch is open and the low side switch is closed so that zero voltage is applied to the associated stator phase.

Each voltage converter 106, 108 is intended to be controlled to cause each arm to switch between these two configurations. In the example described, the voltage converter 106 is controlled as an inverter so as to supply electrical energy to the rotating electrical machine 104 when it is desired that it operates in motor mode. In this case, inverter 108 is not used. In addition, the voltage converter 108 is controlled as a rectifier to supply electrical energy to the DC voltage source 102 (for example, to recharge it) when it is desired that the rotating electrical machine 104 operates in alternator mode. In this case, inverter 106 is not used.

The use of two voltage converters is advantageous because the electrical power transferred is generally not the same in one direction and in the other. It is thus possible to provide a voltage converter suitable for high power in the direction of the highest electrical power transferred and a voltage converter suitable for low power in the direction of the lowest electrical power transferred.

In the case where the electric motricity and the power recovery are decoupled from each other, one of the voltage converters could be used to drive the rotating electric machine 104, while the other voltage converter could be used to drive the alternator.

The two voltage converters 106, 108 can be used together to control the electric machine 104, either in a motor mode to drive the vehicle for example, or in an alternator mode.

The switches are semiconductor switches comprising for example transistors. The switches are for example insulated gate field effect transistors (from the English “Metal Oxide Semiconductor Field Effect Transistor” or MOSFET) or else for example insulated gate bipolar transistors (from the English “Insulated Gate Bipolar Transistor or IGBT).

The voltage converters 106, 108 are respectively integrated in two electronic power modules 110, 112 cooled by a heat sink 114.

Referring to Figure 2, in the example described, each power electronic module 110, 112 comprises for example a base plate 202 on which a substrate 204 is fixed, for example by a bonding layer 206 providing mechanical fixing as well than high thermal conductivity. The substrate 204 is for example a directly bonded copper substrate (from the English "Direct Bonded Copper" or DBC), that is to say for example a ceramic substrate flanked by copper on both sides. Exothermic power components 208 comprising the semiconductor switches are fixed on the substrate 204, for example by a bonding layer 210 ensuring, like the bonding layer 206, a mechanical fixing as well as a high thermal conductivity. Each power electronic module 110, 112 further comprises an electrically insulating casing 212 enclosing (that is to say in which are embedded) at least partially the substrate 204, entirely the power components 208, and partially the base plate 202 so as to leave at least part of an underside of the base plate 202 visible. Thus, these elements are encapsulated so that the electronic power module 110, 112 forms an integral block. The box 212 is for example produced by overmolding and comprises for example epoxy resin, or else by a plastic belt filled with electrical insulating gel.

It will be appreciated that, in the example described, the second power electronics module 112 is smaller than the first power electronics module 110. In particular, its base plate is smaller than that of the first power electronics module 110. In addition, holes 214 for passing screws are provided in the base plate 202, these holes 214 being organized according to different screwing patterns, that is to say these holes 214 are positioned relative to each other. differently for the first electronic power module 110 and the second electronic power module 112.

In the rest of the description, the elements of the device 100 will be described spatially with reference to an orthogonal reference frame comprising a vertical direction V and two horizontal directions, one longitudinal L and the other transverse T.

Referring to Figure 3, the heat sink 114 first comprises a main body 302 comprising an input connector 304 and an output connector 306 of a cooling liquid, such as water. These inlet 304 and outlet 306 connectors are designed to be respectively connected to a coolant inlet pipe and an outlet pipe (not shown).

The main body 302 further comprises a coolant flow channel 308, open laterally upwards in the example described. In general, the channel 308 connects the input connector 304 to the output connector 306 and is for example formed at least in part by one or more recesses made in an upper face of the main body 302 and optionally additionally by one or more recesses made in an underside of the main body 302.

More specifically, in the example described, the main body 302 comprises a substantially horizontal rectangular plate 314 having an upper face 315 in which recesses 316a-d are made, four in the example described, arranged in a square: two pairs of recesses following each other in the longitudinal direction L, the recesses 316a, 316d of the first pair being called proximal and the recesses 316b, 316c of the next pair being called distal. The recesses of each pair are side by side in the transverse direction T and respectively called right and left. Recesses 316a-d define upper openings through which channel 308 is opened laterally.

The input 304 and output 306 connectors are located on the same proximal transverse side of the plate 314. The input connector 304 leads to the right proximal recess 316a and the output connector 306 leads to the left proximal recess 316d. The recesses 316a-d are bounded by outer edges 317a-d and separated from each other by support bosses 318, 320 comprising, in the example described, a longitudinal support boss 318 and a transverse support boss 320. The longitudinal support boss 318 has a distal end 318' located away from the distal edge 317c so as to leave an opening 322 between the right distal recess 316b and the left distal recess 316c.

Thus, in the example described, the channel 308 is generally U-shaped with two longitudinal sections and a transverse end section.

Referring to Figure 4, in the example described, two lower recesses 402a, b are formed in a lower face 404 of the plate 314. They are for example located opposite the transverse support boss 320 and side by side in the transverse direction, so as to be respectively called left and right. The main body 302 further comprises through openings 406a-d, through the plate 314 in the example described, connecting the lower recesses 402a, b to at least some of the upper recesses 316a-d. In the example described, the lower left recess 402a is connected to the upper left recesses 316c,d respectively by the left through openings 406c,d, while the lower right recess 402b is connected to the right upper recesses 316a,b by the through openings 406a,b respectively.

The heat sink 114 further includes a bottom cover 408 designed to close the lower recess(es), the two lower recesses 402a,b in the example described.

Returning to Figure 3, it is apparent that, in the example described, the channel 308 is U-shaped and that the coolant is intended to successively pass through: the upper recess 316a, the lower recess 402b, the upper recess 316b, upper recess 316c, lower recess 402a and upper recess 316d.

Furthermore, the main body 302 further comprises first and second slots 324, 326 for receiving the power electronic module. Receiving locations 324, 326 cover upper recesses 316a-d, and thus the upper openings they define. Specifically, each location 324, 326 covers a respective portion of the upper recesses 316a-d. In the example described, the receiving location 324 covers the upper recesses 316a,d, while the receiving location 326 covers the upper recesses 316b,c. Furthermore, the reception locations 324, 326 have the same first reception configuration. A reception configuration comprises for example a geometry and an arrangement of reception surfaces on which the electronic power module must rest (in the example described, these surfaces extend over part of the bosses 318, 320 and the edges 317a, b,d for the first reception location 324, and part of the bosses 318, 320 and the edges 317b,c,d for the second reception location 326) and/or a screw pattern, i.e. for example the relative positions of several holes 328 screw passage, tapped or not, for example provided through the receiving surfaces.

The first power electronic module 110 is compatible with the first reception configuration to be received interchangeably in the first and second reception slots 324, 326. On the contrary, the second power electronic module 112 is incompatible with the first configuration of reception, but compatible with a second reception configuration, different from the first. For example, base plate 202 of the second module 112 is too small to entirely cover the upper recesses 316a,d or 316b,c. For example again, the second module 112 has a screwing diagram, that is to say for example the relative positions of the screw passage holes 214, tapped or not, different from the screwing diagram of the first reception configuration. For example again, the base plate 202 of the second module 112 is not suitable for being in contact with the coolant, for example because it corrodes on contact with the coolant.

Referring to Figure 5, the first electronic power module 110 is received in one of the reception slots 324, 326, the first reception slot 324 in the example described.

In order to be able to use the second power electronic module 112, there is provided an intermediate part 502 compatible with the first reception configuration to be received interchangeably in the first and second slots 324, 326. In the example described, the part intermediate part 502 is received in the second slot 326. The intermediate piece 502 then has, on an upper face 504 in the example described, a third slot 506 for receiving the power electronic module having the second reception configuration, in order to receive the second electronic power module 112. This reception location 506 has for example holes 508 for receiving screws according to the screwing diagram of the second reception configuration with which the second electronic power module 112 is compatible. Thus, the holes 508 of the intermediate piece 502 are arranged opposite the holes 214 of the base plate 202 of the second electronic power module 112.

Referring to Figure 7, in one embodiment of the invention, the electronic power modules 110, 112 each comprise several parts 110a-c, 112a-c (three in the example described) next to each other , implementing the switching arms respectively. The housing 212 is common for the three parts and made in one piece.

To improve cooling, it is possible to provide, for the channel 308, several transverse sections 702a-f between the two longitudinal sections 704a,b, for example in addition to the end transverse section 706.

In the example described, for each part 110a-c, 112a-c of the electronic power modules 110, 112, a transverse section is provided and passes under this part.

These transverse sections are for example made by providing openings in the longitudinal boss 318 of Figure 3.

According to the above, an electrical device with water box cooling such as those described above allows the use of a heat sink initially provided for two identical power electronic modules.

It will also be noted that the invention is not limited to the embodiments described above. It will indeed appear to those skilled in the art that various modifications can be made to the embodiments described above, in the light of the teaching which has just been disclosed to them.

In the detailed presentation of the invention which is made above, the terms used must not be interpreted as limiting the invention to the embodiments set out in the present description, but must be interpreted to include therein all the equivalents whose provision is within the reach of those skilled in the art by applying their general knowledge to the implementation of the teaching which has just been disclosed to them.

Claims (10)

Electrical device with water box cooling, comprising:

• a main body (302) comprising:
  • a coolant inlet connector (304) and an outlet connector (306), adapted to be respectively connected to a coolant inlet pipe and to a coolant outlet pipe,
  • a coolant flow channel (308) extending between the inlet (304) and outlet (306) connectors and having upper openings, and
  • first and second power electronic module reception locations (324, 326), each covering at least one respective upper opening and having the same first reception configuration; And
• a first power electronics module (110) compatible with the first reception configuration to be received interchangeably in the first and second slots (324, 326);

characterized in that it further comprises:

• an intermediate part (502) compatible with the first reception configuration to be received interchangeably in the first and second slots (324, 326) and having a third power electronic module reception slot (506) having a second configuration of reception, different from the first; And
• a second electronic power module (112) incompatible with the first reception configuration but compatible with the second reception configuration.

Device according to Claim 1, in which the first reception configuration comprises a first screwing scheme, in which the second reception configuration comprises a second screwing scheme, different from the first, in which each of the first electronic power module (110) and of the intermediate part (502) presents the first tightening diagram and in which the second electronic power module (112) presents the second tightening diagram. Device according to Claim 1 or 2, in which the second electronic power module (112) has a base plate (202). Device according to claim 3, in which the base plate (202) of the second power electronic module (112) is too small to cover the upper opening or openings of the first reception location (324) and the upper opening or openings of the second receiving location (326). Device according to Claim 3 or 4, in which the base plate (202) of the second electronic power module (112) is not adapted to be in contact with the cooling liquid. Device according to any one of Claims 3 to 5, in which the second electronic power module (112) comprises a substrate (204), power components (208) fixed to the substrate (204) itself fixed to the base plate (202) and an electrically insulating case (212) at least partially enclosing the substrate (204), completely the power components (208) and partially the base plate (202) so as to leave at least a part of 'an underside of the base plate (202) visible. Device according to any one of Claims 1 to 6, in which the first electronic power module (110) comprises a substrate (204), power components (208) fixed to the substrate (204), a base plate ( 202) on which the substrate (204) is fixed and an electrically insulating casing (212) at least partially encasing the substrate (204), entirely the power components (208) and partially the base plate (202) so as to leave at least a portion of an underside of the exposed base plate (202). Device according to claims 6 and 7 taken together, in which each power electronic module (110, 112) implements a voltage converter (106, 108). Device according to claim 8, in which the power components (208) comprise semiconductor switches of switching arms of the voltage converters (106, 108). Electrical system (100) comprising:

• a DC voltage source (102);
• a rotating electrical machine (104);
• a water-box-cooled electrical device according to claim 8 or 9, the voltage converters (106, 108) each being connected, on the one hand, to the DC voltage source (102) and, on the other hand, to the rotating electrical machine (104); And
• a control device (109) adapted to selectively control the first voltage converter (106) into an inverter, leaving the second voltage converter (108) inactive, to supply electrical energy to the rotating electrical machine (104 ) from the DC voltage source (102) and controlling the second voltage converter (108) into a rectifier, leaving the first voltage converter (106) inactive, to supply electrical energy to the DC voltage source (102) from the rotating electric machine (104).