U.S. patent application number 15/162669 was filed with the patent office on 2017-11-30 for power-module assembly.
The applicant listed for this patent is Ford Global Technologies, LLC. Invention is credited to Chingchi CHEN, Michael W. DEGNER, Edward Chan-Jiun JIH, Guangyin LEI.
Application Number | 20170346412 15/162669 |
Document ID | / |
Family ID | 60269417 |
Filed Date | 2017-11-30 |
United States Patent
Application |
20170346412 |
Kind Code |
A1 |
LEI; Guangyin ; et
al. |
November 30, 2017 |
POWER-MODULE ASSEMBLY
Abstract
A power inverter includes a plurality of power modules each
having a power stage encased in a frame that defines an opening.
The power modules are stacked in an array with the power stages
being spaced apart to define coolant chambers interleaved with the
power stages. The openings cooperate to form a manifold cavity
extending along a length of the stack and in fluid communication
with the chambers. A manifold insert is disposed in the cavity and
extends through the openings.
Inventors: |
LEI; Guangyin; (Dearborn
Heights, MI) ; DEGNER; Michael W.; (Novi, MI)
; CHEN; Chingchi; (Ann Arbor, MI) ; JIH; Edward
Chan-Jiun; (Troy, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ford Global Technologies, LLC |
Dearborn |
MI |
US |
|
|
Family ID: |
60269417 |
Appl. No.: |
15/162669 |
Filed: |
May 24, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B60Y 2400/61 20130101;
Y10S 903/951 20130101; Y02T 10/64 20130101; Y10S 903/906 20130101;
B60K 6/365 20130101; B60L 2240/545 20130101; B60L 58/26 20190201;
H05K 7/20927 20130101; Y02T 90/16 20130101; H05K 7/2089 20130101;
Y10S 903/93 20130101; B60K 6/40 20130101; B60K 11/02 20130101; B60L
15/007 20130101; Y02T 10/70 20130101; Y10S 903/913 20130101; B60K
6/445 20130101; B60Y 2200/92 20130101; B60K 6/383 20130101; H02M
7/003 20130101; B60L 3/0046 20130101; B60L 50/61 20190201; Y02T
10/62 20130101; B60K 2001/003 20130101; H02P 27/06 20130101; Y10S
903/91 20130101; B60K 6/26 20130101 |
International
Class: |
H02M 7/00 20060101
H02M007/00; B60K 6/383 20071001 B60K006/383; B60K 6/40 20071001
B60K006/40; B60K 6/26 20071001 B60K006/26; B60L 15/00 20060101
B60L015/00; H05K 7/20 20060101 H05K007/20; H02P 27/06 20060101
H02P027/06; B60K 6/365 20071001 B60K006/365; B60K 6/445 20071001
B60K006/445 |
Claims
1. A power inverter comprising: power modules each including a
power stage encased in a frame defining an opening, the modules
being stacked in an array with the power stages spaced to define
coolant chambers interleaved with the power stages, and the
openings cooperating to form a manifold cavity extending along a
length of the stack and in fluid communication with the chambers;
and a manifold insert disposed in the cavity and extending through
the openings.
2. The power inverter of claim 1, wherein the manifold insert
defines a plurality of apertures permitting fluid to flow from the
manifold cavity and into the coolant chambers.
3. The power inverter of claim 1, wherein at least one of the
frames defines a connection feature that engages the manifold
insert to secure the insert in the manifold cavity.
4. The power inverter of claim 3, wherein the connection feature
defines a slot that receives a portion of the insert therein.
5. The power inverter of claim 1 further comprising an endplate
disposed against one end of the stack and defining an inlet port
opening into the manifold cavity, wherein a planar wall of the
insert is disposed between the inlet port and the coolant
chambers.
6. The power inverter of claim 1, wherein each of the frames
further includes a partitioning wall extending between opposing
walls of the opening to divide the opening into a pair of openings,
wherein the partitioning walls cooperate to form a supply cavity
and a return cavity.
7. The power inverter of claim 1, wherein the manifold insert
further includes a first planar surface facing the coolant chambers
and a second planar surface that is substantially perpendicular to
the first surface.
8. A power-module assembly comprising: a power-stage housing
encasing power stages arranged in a stack with coolant chambers
interleaved therebetween; a manifold defining a cavity and disposed
against the housing such that the chambers are in fluid
communication with the cavity; and a manifold insert disposed in
the cavity and including a wall extending along a length of the
cavity and defining apertures arranged to permit coolant flow from
the cavity and into the chambers.
9. The power-module assembly of claim 8, wherein the housing
defines slots in a side facing the manifold, and wherein each of
the slots opens into one of the coolant chambers.
10. The power-module assembly of claim 8, wherein the wall includes
a planar surface that faces the coolant chambers and the apertures
are defined in the planar surface.
11. The power-module assembly of claim 8, wherein a wall of the
cavity defines a connection feature that engages the manifold
insert to secure the insert in the cavity.
12. The power-module assembly of claim 11, wherein the connection
feature defines a slot that receives a portion of the insert
therein.
13. The power-module assembly of claim 8, wherein the insert
includes a plurality of flow guides that each extend into one of
the coolant chambers.
14. The power-module assembly of claim 13, wherein the wall and the
flow guides are substantially perpendicular to each other.
15. The power-module assembly of claim 8, wherein the housing
defines partitioning walls each disposed in a corresponding one of
the coolant chambers, wherein each of the partitioning walls
extends between power stages adjacent to each other to divide the
coolant chambers into an inlet portion and an outlet portion.
16. The power-module assembly of claim 8, wherein each of the power
stages includes a half-bridge switching arrangement.
17. A power-module assembly comprising: a power-stage assembly
including power stages encased in a housing and arranged in a stack
such that power stages adjacent to each other define coolant
chambers interleaved with the stack, wherein a bottom of the
housing defines slots each aligned with one of the coolant
chambers; a manifold including a bottom and sidewalls cooperating
to define a manifold cavity recessed into a top of the manifold,
wherein the top is disposed against the bottom of the housing such
that the manifold cavity is in fluid communication with the coolant
chambers via the slots, and inlet and outlet ports are defined in
at least one of the sidewalls permitting coolant to enter and exit
the manifold cavity; and a manifold insert disposed in the manifold
cavity and including a horizontal wall extending along a length of
the cavity and vertically aligned between a top of the inlet port
and the top of the manifold, wherein the insert defines apertures
arranged to permit coolant flow from the manifold cavity and into
the chambers.
18. The power-module assembly of claim 17, wherein the manifold
insert includes a vertical wall extending along the length of the
manifold cavity between the inlet and outlet ports to divide the
manifold cavity into a supply cavity and a return cavity.
19. The power-module assembly of claim 17, wherein at least one of
the bottom and sidewalls defines a connection feature that engages
the manifold insert to secure the insert in the cavity.
20. The power-module assembly of claim 19, wherein the connection
feature defines a slot that receives a portion of the insert
therein.
Description
TECHNICAL FIELD
[0001] The present disclosure relates to power-module assemblies
for an electric drivetrain of an automobile.
BACKGROUND
[0002] Vehicles such as battery-electric vehicles (BEVs), plug-in
hybrid electric vehicles (PHEVs) and fully hybrid-electric vehicles
(FHEVs) contain a traction battery assembly to act as an energy
source for one or more electric machines. The traction battery
includes components and systems to assist in managing vehicle
performance and operations. A power inverter is electrically
connected between the battery and the electric machines to convert
direct current coming from the battery into alternating current
compatible with the electric machines. The power inverter may also
act as a rectifier to convert alternating current from the electric
machines to direct current compatible with the battery.
SUMMARY
[0003] According to one embodiment, a power inverter includes a
plurality of power modules each having a power stage encased in a
frame that defines an opening. The power modules are stacked in an
array with the power stages being spaced apart to define coolant
chambers interleaved with the power stages. The openings cooperate
to form a manifold cavity extending along a length of the stack and
in fluid communication with the chambers. A manifold insert is
disposed in the cavity and extends through the openings.
[0004] According to another embodiment, a power-module assembly
includes a power-stage housing that encases power stages arranged
in a stack with coolant chambers interleaved therebetween. The
assembly also includes a manifold that defines a cavity and is
disposed against the housing such that the chambers are in fluid
communication with the cavity. A manifold insert is disposed in the
cavity and includes a wall extending along a length of the cavity.
The wall defines apertures arranged to permit coolant flow from the
cavity and into the chambers.
[0005] According to yet another embodiment, a power-module assembly
includes a power-stage assembly having power stages encased in a
housing and arranged in a stack such that power stages adjacent to
each other define coolant chambers interleaved with the stack. A
bottom of the housing defines slots each aligned with one of the
coolant chambers. The power-module assembly further includes a
manifold having a bottom and sidewalls cooperating to define a
manifold cavity recessed into a top of the manifold. The top is
disposed against the bottom of the housing such that the manifold
cavity is in fluid communication with the coolant chambers via the
slots. Inlet and outlet ports are defined in at least one of the
sidewalls permitting coolant to enter and exit the manifold cavity.
The power-module assembly also includes a manifold insert disposed
in the manifold cavity and having a horizontal wall extending along
a length of the cavity and vertically aligned between a top of the
inlet port and the top of the manifold. The insert defines
apertures arranged to permit coolant flow from the manifold cavity
and into the chambers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a schematic diagram of an example hybrid
vehicle.
[0007] FIG. 2 is a schematic diagram of a variable-voltage
converter and a power inverter.
[0008] FIG. 3 is a perspective view of a power inverter.
[0009] FIG. 4 is an exploded perspective view of a power-module
assembly.
[0010] FIG. 5 is a front view of the power-module assembly of FIG.
4 with the front endplate removed for illustrative purposes.
[0011] FIG. 6 is a side view of the power-module assembly of FIG.
4.
[0012] FIG. 7 is a perspective view of a manifold insert according
to another embodiment.
[0013] FIG. 8 is a front view of another power-module assembly
having the insert of FIG. 7; the front endplate is removed for
illustrative purposes.
[0014] FIG. 9 is a perspective view of a manifold insert according
to yet another embodiment.
[0015] FIG. 10 is a front view of yet another power-module assembly
having the insert of FIG. 9; the front endplate is removed for
illustrative purposes.
[0016] FIG. 11 is an exploded perspective view of a power-module
assembly according to an over-molded embodiment.
[0017] FIG. 12 is a bottom perspective view of the power-stage
assembly for the power-module assembly shown in FIG. 11.
DETAILED DESCRIPTION
[0018] Embodiments of the present disclosure are described herein.
It is to be understood, however, that the disclosed embodiments are
merely examples and other embodiments can take various and
alternative forms. The figures are not necessarily to scale; some
features could be exaggerated or minimized to show details of
particular components. Therefore, specific structural and
functional details disclosed herein are not to be interpreted as
limiting, but merely as a representative basis for teaching one
skilled in the art to variously employ the present invention. As
those of ordinary skill in the art will understand, various
features illustrated and described with reference to any one of the
figures can be combined with features illustrated in one or more
other figures to produce embodiments that are not explicitly
illustrated or described. The combinations of features illustrated
provide representative embodiments for typical applications.
Various combinations and modifications of the features consistent
with the teachings of this disclosure, however, could be desired
for particular applications or implementations.
[0019] An example of a PHEV is depicted in FIG. 1 and referred to
generally as a vehicle 16. The vehicle 16 includes a transmission
12 and is propelled by at least one electric machine 18 with
assistance from an internal combustion engine 20. The electric
machine 18 may be an alternating current (AC) electric motor
depicted as "motor" 18 in FIG. 1. The electric machine 18 receives
electrical power and provides torque for vehicle propulsion. The
electric machine 18 also functions as a generator for converting
mechanical power into electrical power through regenerative
braking.
[0020] The transmission 12 may be a power-split configuration. The
transmission 12 includes the first electric machine 18 and a second
electric machine 24. The second electric machine 24 may be an AC
electric motor depicted as "generator" 24 in FIG. 1. Like the first
electric machine 18, the second electric machine 24 receives
electrical power and provides output torque. The second electric
machine 24 also functions as a generator for converting mechanical
power into electrical power and optimizing power flow through the
transmission 12. In other embodiments, the transmission does not
have a power-split configuration.
[0021] The transmission 12 may include a planetary gear unit 26,
which includes a sun gear 28, a planet carrier 30, and a ring gear
32. The sun gear 28 is connected to an output shaft of the second
electric machine 24 for receiving generator torque. The planet
carrier 30 is connected to an output shaft of the engine 20 for
receiving engine torque. The planetary gear unit 26 combines the
generator torque and the engine torque and provides a combined
output torque about the ring gear 32. The planetary gear unit 26
functions as a continuously variable transmission, without any
fixed or "step" ratios.
[0022] The transmission 12 may also include a one-way clutch
(O.W.C.) and a generator brake 33. The O.W.C. is coupled to the
output shaft of the engine 20 to only allow the output shaft to
rotate in one direction. The O.W.C. prevents the transmission 12
from back-driving the engine 20. The generator brake 33 is coupled
to the output shaft of the second electric machine 24. The
generator brake 33 may be activated to "brake" or prevent rotation
of the output shaft of the second electric machine 24 and of the
sun gear 28. Alternatively, the O.W.C. and the generator brake 33
may be eliminated and replaced by control strategies for the engine
20 and the second electric machine 24.
[0023] The transmission 12 may further include a countershaft
having intermediate gears including a first gear 34, a second gear
36 and a third gear 38. A planetary output gear 40 is connected to
the ring gear 32. The planetary output gear 40 meshes with the
first gear 34 for transferring torque between the planetary gear
unit 26 and the countershaft. An output gear 42 is connected to an
output shaft of the first electric machine 18. The output gear 42
meshes with the second gear 36 for transferring torque between the
first electric machine 18 and the countershaft. A transmission
output gear 44 is connected to a driveshaft 46. The driveshaft 46
is coupled to a pair of driven wheels 48 through a differential 50.
The transmission output gear 44 meshes with the third gear 38 for
transferring torque between the transmission 12 and the driven
wheels 48.
[0024] The vehicle 16 includes an energy storage device, such as a
traction battery 52 for storing electrical energy. The battery 52
is a high-voltage battery that is capable of outputting electrical
power to operate the first electric machine 18 and the second
electric machine 24. The battery 52 also receives electrical power
from the first electric machine 18 and the second electric machine
24 when they are operating as generators. The battery 52 is a
battery pack made up of several battery modules (not shown), where
each battery module contains a plurality of battery cells (not
shown). Other embodiments of the vehicle 16 contemplate different
types of energy storage devices, such as capacitors and fuel cells
(not shown) that supplement or replace the battery 52. A
high-voltage bus electrically connects the battery 52 to the first
electric machine 18 and to the second electric machine 24.
[0025] The vehicle includes a battery energy control module (BECM)
54 for controlling the battery 52. The BECM 54 receives input that
is indicative of vehicle conditions and battery conditions, such as
battery temperature, voltage and current. The BECM 54 calculates
and estimates battery parameters, such as battery state of charge
and the battery power capability. The BECM 54 provides output
(BSOC, P.sub.cap) that is indicative of a battery state of charge
(BSOC) and a battery power capability (P.sub.cap) to other vehicle
systems and controllers.
[0026] The vehicle 16 includes a DC-DC converter or
variable-voltage converter (VVC) 10 and an inverter 56. The VVC 10
and the inverter 56 are electrically connected between the traction
battery 52 and the first electric machine 18, and between the
battery 52 and the second electric machine 24. The VVC 10 "boosts"
or increases the voltage potential of the electrical power provided
by the battery 52. The VVC 10 also "bucks" or decreases the voltage
potential of the electrical power provided to the battery 52,
according to one or more embodiments. The inverter 56 inverts the
DC power supplied by the main battery 52 (through the VVC 10) to AC
power for operating the electric machines 18, 24. The inverter 56
also rectifies AC power provided by the electric machines 18, 24,
to DC for charging the traction battery 52. Other embodiments of
the transmission 12 include multiple inverters (not shown), such as
one invertor associated with each electric machine 18, 24. The VVC
10 includes an inductor assembly 14.
[0027] The transmission 12 includes a transmission control module
(TCM) 58 for controlling the electric machines 18, 24, the VVC 10
and the inverter 56. The TCM 58 is configured to monitor, among
other things, the position, speed, and power consumption of the
electric machines 18, 24. The TCM 58 also monitors electrical
parameters (e.g., voltage and current) at various locations within
the VVC 10 and the inverter 56. The TCM 58 provides output signals
corresponding to this information to other vehicle systems.
[0028] The vehicle 16 includes a vehicle system controller (VSC) 60
that communicates with other vehicle systems and controllers for
coordinating their function. Although it is shown as a single
controller, the VSC 60 may include multiple controllers that may be
used to control multiple vehicle systems according to an overall
vehicle control logic, or software.
[0029] The vehicle controllers, including the VSC 60 and the TCM 58
generally includes any number of microprocessors, ASICs, ICs,
memory (e.g., FLASH, ROM, RAM, EPROM and/or EEPROM) and software
code to co-act with one another to perform a series of operations.
The controllers also include predetermined data, or "look up
tables" that are based on calculations and test data and stored
within the memory. The VSC 60 communicates with other vehicle
systems and controllers (e.g., the BECM 54 and the TCM 58) over one
or more wired or wireless vehicle connections using common bus
protocols (e.g., CAN and LIN). The VSC 60 receives input (PRND)
that represents a current position of the transmission 12 (e.g.,
park, reverse, neutral or drive). The VSC 60 also receives input
(APP) that represents an accelerator pedal position. The VSC 60
provides output that represents a desired wheel torque, desired
engine speed, and generator brake command to the TCM 58; and
contactor control to the BECM 54.
[0030] The vehicle 16 includes an engine control module (ECM) 64
for controlling the engine 20. The VSC 60 provides output (desired
engine torque) to the ECM 64 that is based on a number of input
signals including APP, and corresponds to a driver's request for
vehicle propulsion.
[0031] If the vehicle 16 is a PHEV, the battery 52 may periodically
receive AC energy from an external power supply or grid, via a
charge port 66. The vehicle 16 also includes an on-board charger
68, which receives the AC energy from the charge port 66. The
charger 68 is an AC/DC converter which converts the received AC
energy into DC energy suitable for charging the battery 52. In
turn, the charger 68 supplies the DC energy to the battery 52
during recharging. Although illustrated and described in the
context of a PHEV 16, it is understood that the inverter 56 may be
implemented on other types of electric vehicles, such as a HEV or a
BEV.
[0032] Referring to FIG. 2, an electrical schematic of the VVC 10
and the inverter 56 is shown. The VVC 10 may include a one or more
power stages having a transistor-based switching arrangement, such
as a half bridge. Each power stage includes a first switching unit
70 and a second switching unit 72 for boosting the input voltage
(V.sub.bat) to provide output voltage (V.sub.dc). The first
switching unit 70 may include a first transistor 74 connected in
parallel to a first diode 76, but with their polarities switched
(anti-parallel). The second switching unit 72 may include a second
transistor 78 connected anti-parallel to a second diode 80. Each
transistor 74, 78 may be any type of controllable switch (e.g., an
insulated gate bipolar transistor (IGBT) or field-effect transistor
(FET)). Additionally, each transistor 74, 78 may be individually
controlled by the TCM 58. The inductor assembly 14 is depicted as
an input inductor that is connected in series between the traction
battery 52 and the switching units 70, 72. The inductor 14
generates magnetic flux when a current is supplied. When the
current flowing through the inductor 14 changes, a time-varying
magnetic field is created, and a voltage is induced. Other
embodiments of the VVC 10 include alternative circuit
configurations.
[0033] The inverter 56 may include a plurality of power stages
having a transistor-based switching arrangement, such as a
half-bridge that are stacked in an assembly. Each of the half
bridges may include a positive DC lead 84 that is coupled to a
positive DC node from the battery and a negative DC lead 86 that is
coupled to a negative DC node from the battery. Each of the half
bridges 82 may also include a first switching unit 88 and a second
switching unit 90. The first switching unit 88 may include a first
transistor 92 connected in parallel to a first diode 94. The second
switching unit 90 may include a second transistor 96 connected in
parallel to a second diode 98. The first and second transistors 88,
96 may be IGBTs or FETs. The first and second switching units 88,
90 of the each of the half-bridges 82 convert the DC power of the
battery into a single phase AC output at the AC lead 100. Each of
the AC leads 100 are electrically connected to the motor 18 or
generator 24.
[0034] In the illustrated embodiment, the VVC 10 includes two power
stages and the inverter includes 9 power stages (three for the
generator 24 and six for the motor 18). In other embodiments, the
VVC 10 includes one power stage and the inverter includes six power
stages (three for the generator 24 and three for the motor 18). The
VVC power stages and the inverter power stages may be identical
components and generally referred to as power stages 82. Both the
VVC power stages and the inverter power stages may be arranged in a
common stack.
[0035] Referring to FIG. 3, the vehicle power inverter 56 may be
mounted on a vehicle component 111, such as a body structure, frame
member, or powertrain component. The power inverter 56 may include
a power-module assembly 112 that is electrically connected with a
gate drive board 114, a capacitor bank 116, and a control board
118. The power-module assembly 112 may include a plurality of power
modules stacked in an array and each having one or more half
bridges packaged in a power stage.
[0036] FIGS. 4 to 12 and the related discussion describe example
power-module assemblies and their individual components. The
power-module assemblies may be of a power inverter such as power
inverter 56 described above or may be another type of power
electronics. Referring to FIG. 4, an example power-module assembly
120 includes a plurality of power modules 122 stacked an array.
Each power module includes opposing major sides 162 and minor sides
164 extending therebetween. The power modules 122 are stacked such
that the major sides 162 of adjacent power modules are disposed
against each other. The power-module assembly 120 includes a first
power module 124 defining one end of the stack and a last power
module 126 defining the other end of the stack. A first endplate
128 is disposed against the first module 124, and a second endplate
130 is disposed against the last module 126. The endplates
cooperate to sandwich the stack and may provide compression to help
hold the stack together. The power-module assembly 120 may be
secured together by adhesive, bracketry, or fasteners extending
through the assembly. The power modules 122 may all be a same power
module, or the power-modules assembly 120 may include two or more
sets of power modules that are at least slightly different. In the
example power-module assembly 120, all of the power modules 122 are
the same.
[0037] Each of the power modules 122 includes a power stage 132
that contains the semiconductor devices. Each power stage 132 may
include a half bridge. The power stages 132 are encased by a frame
160 of the power module 122. In the illustrated embodiment, the
frame 160 is a hollow rectangular body including a left side 154, a
right side 152, a top 150, and a bottom 151 cooperating to define
an exterior 166, an interior 168, a front surface 170, and a back
surface 172. The frame 160 may have a different shape in other
embodiments.
[0038] Each of the power stages 132 may include opposing major
sides 134, opposing minor sides 136, a top 138, and a bottom 140.
The edges of the power stage 132 are embedded in the interior
surface 168. The power stage 132 may include a positive DC power
terminal 142, a negative DC power terminal 144, an AC power
terminal 146, and signal pins 148 that are electrically connected
with the semiconductor devices of the power stage 132. The location
of the terminals and signal pins may vary by embodiment and are not
limited to the configuration shown. In this example, the signal
pins 148 may extend from the top 150, terminals 142 and 144 may
extend from the right side 152, and the terminal 146 may extend
from the left side 154. Each of the power stages 132 may include a
first plate 156 that defines the outer surface of one of the major
sides 134 and a second plate (not visible) that defines the other
of the major sides 134. The plates may be metallic, plastic,
composite, or a combination thereof. The semiconductor devices of
the power stage 132 may be filled with an epoxy or other material
to electrically isolate the semiconductor devices from the plates
and other components.
[0039] Each of the frames 160 also defines a manifold opening 174
adjacent to the power stage 132. The opening 174 may be defined by
the cooperation of the interior 168 of the left side 154, the right
side 152, and the bottom 151. The top of the opening 174 may be
defined by a cross member 176. In embodiments where the cross
member 176 is not present, the bottom 140 of the power stage 132
defines the top of the opening 174.
[0040] The frame 160 is thick enough to extend past the outer
plates 156 of the power stage 132 in the longitudinal direction of
the stack. The extended region of the frame 160 and the plates 156
define a pair of pockets 178 recessed into the major sides 162 of
the power module 122.
[0041] As is best shown in FIGS. 5 and 6, the individual power
modules 122 are arranged in a stack with the front and back
surfaces 170, 172 of adjacent frames 160 being disposed against
each other. When stacked, the pockets 178 of adjacent power modules
122 cooperate to define coolant chambers 180 interleaved with the
modules 122. The endplates may also define pockets that cooperate
with the pockets of the power modules to define some of the coolant
chambers 180. For example, the first endplate 128 cooperates with
the first module 124 to define an outer coolant chamber, and the
second endplate 130 cooperates with last module 126 to define
another outer coolant chamber. The outer coolant chambers may have
a smaller volume than the interior coolant chambers, or the
endplates may have a recessed area to provide outer coolant
chambers having a same or similar volume as the interior coolant
chambers. Alternatively, the outer coolant chambers may be omitted.
For example, each of the endplates 128, 130 may include a
protruding face that is received within the outer pocket of the
first and last modules 124, 126 to fill the pocket. Each of the
coolant chambers 180 may be bounded on all sides by features of the
frame 160 and power stage 132 or may only be bounded on five sides
and may have an open bottom side. Each of the coolant chambers 180
may include a vertical partitioning wall 184 that extends upwardly
from the cross member 176 to partially divide the coolant chamber
180 creating a U-shaped flow path. The partitioning wall 184, the
cross member 176 may be integrally formed with the frame. The
partitioning wall 184 and the cross member 176 are not included in
all embodiments. Each of the coolant chambers 180 may include fins
(not shown) or other features disposed therein to guide fluid
circulating within the chamber.
[0042] The openings 174 of each power module cooperate to define a
manifold cavity 182 extending along a length of the stack. The ends
of the manifold cavity 182 are bounded by the endplates and the
longitudinal sides are bounded by the plurality of power modules
122. The manifold cavity 182 is in fluid communication with each of
the coolant chambers 180. For example, the cross members 176 may
define openings 190 allowing fluid to flow from the manifold cavity
182 and into the chambers 180. The first endplate 128 includes an
inlet port 186 and an outlet port 188 that each open into the
manifold cavity 182. In other embodiments, the inlet port may be
located in different endplate than the outlet port.
[0043] The coolant chambers 180 may be connected to the manifold
such the chambers are arranged in parallel flow paths. The parallel
flow provides a more uniform temperature gradient along the length
of the stack because the coolant within the supply chamber of the
manifold is relatively uniform. Coolant chambers arranged in series
may have a relatively large temperature gradient, where coolant at
the exit end of the stack is much hotter than at the entrance end
of the stack. In some embodiments, series cooling may be
advantageous. As such, series cooling is not outside the scope of
this disclosure.
[0044] Referring back to FIGS. 4 and 5, a manifold insert 192 is
disposed within the manifold cavity 182 to more precisely control
the flow of coolant to the coolant chambers 180. The manifold
insert may take on a variety of different shapes and feature
depending upon the precise flow characteristics needed to
effectively cool (or heat) the power-module assembly 120. The
specific features of illustrated insert 192 are not to be construed
as limiting and several other design alternatives will be presented
below. These alternatives, however, are also not limiting. The
manifold insert 192 may extend along a length of the manifold
cavity 182 with a first end of the manifold abutting the first
endplate 128 and a second end of the insert abutting the second
endplate 130. The insert 192 may include a vertical wall 194
extending between a bottom 220 of the manifold cavity 182 and a top
222 of the cavity to divide the cavity 182 into a supply side 224
and a return side 226. The insert 192 also includes a lower
horizontal wall 196 that is oriented substantially perpendicular to
the vertical wall 194. Used herein, "substantially perpendicular"
means the angle between the substantially perpendicular components
is between 80 and 100 degrees, inclusive. The wall 196 includes a
pair of opposing planar surface 206 oriented to face the top and
bottom of the cavity, respectively, and edges 208 that are disposed
against the interior 168 of the left and right frame walls,
respectively. Apertures 204 are defined in the wall 196 to permit
fluid to flow therethrough. The lower wall 196 may be positioned
such that it is above a top of the inlet and outlet ports 186,
188.
[0045] Insert 192 may also include an upper horizontal wall 200
that also includes planar surfaces (oriented similar to surfaces
206) and edges that engage with the interior 168. The upper
horizontal wall 200 may define a plurality of apertures 210. The
apertures 210 may be much smaller than the apertures 204, and may
be greater in number. The insert 192 may also include an
intermediate horizontal wall 198. The intermediate wall 198 may
only extend partially across the cavity. The intermediate wall 198
may be useful in creating turbulence to increase the cooling
effectiveness of the system. The edges of the intermediate wall 198
may not extend as far from the vertical wall 194 as the other walls
196, 200. An array of flaps 202 may be disposed across the upper
edge of the vertical wall 194. The flaps 202 are spaced apart to
create a plurality of slots 205 to allow fluid to flow between the
flaps 202. An upper planar surface 203 of the flaps 202 engages
with the cross members 176. The flaps 202 are arranged such that
the slots 205 are aligned with the openings 190 to permit fluid to
flow into the coolant chambers 180.
[0046] At least some of the frames 160 may include at least one
connection feature 214 to secure the insert 192 within the manifold
cavity 182. The connection feature 214 may be integrally formed
with the frames and extend from select interior surfaces 168. In
the illustrated embodiment, three connection features are shown. A
first connection feature 214 is disposed on the bottom 151 and
includes a pair of projections 216 defining a slot 218 that
receives an edge portion of the vertical wall 194. A second
connection feature and a third connection feature may be disposed
on the right and left walls 152, 154 respectively. Each of these
features includes a single projection 219 that cooperates with the
cross member 176 to define a slot. The projections 219 may engage
with the upper horizontal wall 200, and the cross members 176 may
each engage with a corresponding flap 202. An adhesive or similar
material may be used to permanently bond the connection features
and the insert.
[0047] Referring to FIGS. 7 and 8, an insert 230 according to
another embodiment is illustrated within a power-module assembly
232 that is similar to the power-module assembly 120. The frame 234
of this assembly is similar to that of frame 160 except that frame
234 includes a partitioning wall 236 that extends between the
bottom of the power stage 238 and the bottom 240 of the manifold
cavity 242 dividing the cavity into supply and return sides 239,
241. The partitioning wall 236 may be integrally formed with the
frame 234. The frame 234 may include connection features 244 that
secure the insert 230 within the manifold cavity 242. In this
embodiment, the insert 230 is a pair of planar inserts 246 that are
each inserted into one of the sides of the manifold cavity 242.
Each insert 246 may include opposing planar surfaces 248 and
apertures 250 extending between the planar surfaces. The inserts
are arranged in the cavity such that one of the planar surfaces
faces the power stages, and such that the inserts are disposed
between a top of the inlet and outlet ports and a bottom of the
power stages.
[0048] Referring to FIGS. 9 and 10, another insert 260--that may be
inserted into manifold cavity 261, for example--includes a vertical
wall 262 having an upper edge 264 and a lower edge 266. The upper
edge 264 engages with a top 276 of the manifold cavity 261, and the
lower edge 266 engages with a bottom 278 of the manifold cavity. A
first horizontal wall 268 extends from the right side of the
vertical wall 262, and a second horizontal wall 270 extends from
the left side. Each of the horizontal walls 268, 270 define
apertures 272 that allow coolant to circulate between the coolant
chambers and the manifold cavity. The horizontal walls 268, 270 may
be positioned such that at least a portion of the vertical wall 262
extends above an upper planar surface 274 of the horizontal
walls.
[0049] Referring to FIGS. 11 and 12, another power-module assembly
300 is illustrated. Unlike assembly 120, which includes a plurality
of modular power modules 122 assembled into a stack, assembly 300
includes a plurality of power stages 302 that that are molded into
a housing 306 to form a power-stage assembly 304, which may be a
single piece. The power stages 302 are arranged in a spaced apart
relationship relative to each other creating coolant chambers 308
that are interleaved with the power stages. The housing 306
includes a bottom 310 that defines slots 312 in alignment with the
coolant chambers 308. The slots 312 allow coolant to circulate into
and out of the chambers 308.
[0050] The assembly 300 also includes a manifold 314 that includes
a bottom 316 and a plurality of sidewalls 318 extending from the
bottom to define a manifold cavity 320. The manifold 314 also
includes an inlet port 324 and an outlet port 326 that open into
the manifold. The ports may be located in a same sidewall or may be
located in different sidewalls.
[0051] An insert 330 is disposed within the manifold cavity 320 to
control the coolant flow. The manifold insert may take on a variety
of different shapes such as those shown in FIG. 11 or any of the
preceding figures. The specific features of illustrated insert 330
are not to be construed as limiting.
[0052] The manifold insert 330 may extend along a length of the
manifold cavity 320 with a first end of the manifold abutting the
front wall and a second end of the insert abutting the back wall.
The insert 330 may include a vertical wall 344 extending between a
bottom 316 of the manifold cavity 320 and a top 322 of the cavity
to divide the cavity 320 into a supply side and a return side. The
insert 330 also includes a lower horizontal wall 346 that is
oriented substantially perpendicular to the vertical wall 344. The
wall 346 includes a pair of opposing planar surface 350 oriented to
face the top and bottom of the cavity, respectively, and edges 352
that are disposed against the sidewalls 318. The apertures 348 are
defined in the wall 346 to permit fluid to flow therethrough. The
lower wall 346 may be positioned such that it is above a top of the
inlet and outlet ports 324, 326.
[0053] Insert 330 may also include an upper horizontal wall 354
that also includes planar surfaces (oriented similar to surfaces
350) and edges that engage with the sidewalls 318. The upper
horizontal wall 354 may define a plurality of apertures 358. The
apertures 358 may be much smaller than the apertures 348, and may
be greater in number. The insert 330 may also include an
intermediate horizontal wall 355. The intermediate wall 355 may
only extend partially across the cavity. The intermediate wall 355
may be useful in creating turbulence to increase the cooling
effectiveness of the system. The edges of the intermediate wall 355
may not extend to the sidewalls 318. An array of flaps 360 may be
disposed across the upper edge of the vertical wall 344. The flaps
360 are spaced apart to create a plurality of slots 364 allowing
fluid to flow between the flaps 360. An upper planar surface 366 of
the flaps 360 engages with the bottom 310. The flaps 360 are
arranged such that the slots 364 are aligned with the slots 312 to
permit fluid to flow into the coolant chambers 308. The insert 330
may also include a plurality of flow guides 362 extending upwardly
from the top of the vertical wall 344. The flow guides 362 are
spaced apart from each other corresponding to the spacing of the
coolant chambers 308. The flow guides 362 may extend upwardly
between the flaps 360. The flow guides 362 are disposed in the
coolant chambers 308 to partition the coolant chambers 308 into an
inlet side and an outlet side. In some embodiments the flow guides
are omitted and the housing 306 may define the partitioning walls
in order to divide the coolant chambers. While not illustrated, the
manifold 314 may include one or more connection features (such as
those previously described) to secure the insert 330 within the
cavity 320. The insert 330 may also be secured within the cavity
using adhesive or other bonding means.
[0054] The assembly 300 may be assembled by first manufacturing the
power stage assembly 304, the manifold 314, and the insert 330.
Next, the insert 330 may be disposed within the manifold cavity
320. Then, the top 322 of the manifold 314 is disposed against the
bottom 310 of the housing 306 with the flow guides 362 extending
into the coolant chambers 308.
[0055] The illustrated embodiments show the manifold-insert
apertures as being round. But, it is to be understood that the
aperture could have any shape suitable to permit coolant flow
therethrough. The specific sizes of the aperture illustrated are
not limiting and the size of the apertures may vary in different
embodiments.
[0056] While example embodiments are described above, it is not
intended that these embodiments describe all possible forms
encompassed by the claims. The words used in the specification are
words of description rather than limitation, and it is understood
that various changes can be made without departing from the spirit
and scope of the disclosure. As previously described, the features
of various embodiments can be combined to form further embodiments
of the invention that may not be explicitly described or
illustrated. While various embodiments could have been described as
providing advantages or being preferred over other embodiments or
prior art implementations with respect to one or more desired
characteristics, those of ordinary skill in the art recognize that
one or more features or characteristics can be compromised to
achieve desired overall system attributes, which depend on the
specific application and implementation. These attributes can
include, but are not limited to cost, strength, durability, life
cycle cost, marketability, appearance, packaging, size,
serviceability, weight, manufacturability, ease of assembly, etc.
As such, embodiments described as less desirable than other
embodiments or prior art implementations with respect to one or
more characteristics are not outside the scope of the disclosure
and can be desirable for particular applications.
* * * * *