Power module and method for manufacturing the same
First Claim
1. A power module comprising:
- one or more main body units, each of the body units respectively having a semiconductor element, a control terminal connected to the semiconductor element, a power terminal through which a current corresponding to an electrical signal to the control terminal flows, and a heat dissipation layer;
one or more cooling units disposed to exchange heat with the heat dissipation layer and cool the main body units;
a busbar connected to the power terminal of each of the main body units;
a casing in which at least a contact part with the busbar is insulating; and
a metal member which supports the casing;
wherein the metal member contacts the casing, thereby forming a box with one side opened,at least the main body units and the busbar are disposed inside the box,in each of the main body units, the control terminal and the power terminal are disposed to extend to the one side from the semiconductor element, andan insulating sealant fills the inside of the box, thereby sealing the main body units and the busbar,the metal member has one or more pockets which are recessed towards another side opposite the one side and which accommodate the main body units,the cooling units and the main body units, accommodated in the pockets, are arranged alternately and separated by the metal member, andthe cooling units exchange heat with the main body units via the pockets.
1 Assignment
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Accused Products
Abstract
A power module or the like is provided in which lower inductance and miniaturization are achieved. The power module includes: main body units (11 to 13), cooling units (21 to 24) which cool the main body units (11 to 13), busbars (51, 52) connected to power terminals (1i, 1j) of the main body units (11 to 13), a casing (W) in which at least contact parts with the busbars (51, 52) are insulative, and a metal member (30) which supports the casing (W). The metal member (30) tightly contacts the casing (W), thereby forming a box with one side opened. At least the main body units (11 to 13) and the busbars (51, 52) are arranged inside the box. An insulating sealant is provided to fill the inside of the box.
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Citations
14 Claims
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1. A power module comprising:
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one or more main body units, each of the body units respectively having a semiconductor element, a control terminal connected to the semiconductor element, a power terminal through which a current corresponding to an electrical signal to the control terminal flows, and a heat dissipation layer; one or more cooling units disposed to exchange heat with the heat dissipation layer and cool the main body units; a busbar connected to the power terminal of each of the main body units; a casing in which at least a contact part with the busbar is insulating; and a metal member which supports the casing; wherein the metal member contacts the casing, thereby forming a box with one side opened, at least the main body units and the busbar are disposed inside the box, in each of the main body units, the control terminal and the power terminal are disposed to extend to the one side from the semiconductor element, and an insulating sealant fills the inside of the box, thereby sealing the main body units and the busbar, the metal member has one or more pockets which are recessed towards another side opposite the one side and which accommodate the main body units, the cooling units and the main body units, accommodated in the pockets, are arranged alternately and separated by the metal member, and the cooling units exchange heat with the main body units via the pockets. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A power module comprising:
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one or more body units, each including a semiconductor element, a control terminal connected to the semiconductor element, a power terminal through which a current corresponding to an electrical signal to the control terminal flows, and a heat dissipation layer; one or more cooling units which are arranged alternately with the main body units and which cool the main body units; and a metal member which is integrally formed and which includes one or more pockets separating each of the main body units and the cooling units from each other; wherein the main body units are exposed to one side from the metal member, and the cooling units are exposed to another side opposite to the one side from the metal member, the pockets are each recessed towards the other side and accommodate the main body units therein, the cooling units and the main body units, accommodated in the pockets, are arranged alternately and separated by the metal member, and the cooling units exchange heat with the main body units via the pockets.
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14. A method for manufacturing a power module, comprising:
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positioning one or more main body units, each having a semiconductor element, a control terminal connected to the semiconductor element, a power terminal through which a current corresponding to an electrical signal to the control terminal flows, and a heat dissipation layer, from one side into one or more pockets of a metal member, and positioning one or more cooling units to be arranged alternately with the main body units accommodated in the pockets and separated from the main body units by the pockets; connecting together a busbar and the power terminal of each of the main body units; forming a box having a casing in contact with and supported by the metal member, where the box has one side thereof which is open, at least a contact part of the casing with the busbar is insulating, and at least the main body units and the busbar are disposed inside the box; filling an inside of the box with an insulating sealant; wherein the control terminal and the power terminal extend to the one side from the semiconductor element in each of the main body units, and the pockets are recessed towards another side opposite to the one side, the cooling units and the main body units, accommodated in the pockets, are arranged alternately and separated by the metal member, and the cooling units exchange heat with the main body units via the pockets.
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Specification