Inverter DC bus bar assembly

• US 10,135,355 B2
• Filed: 08/31/2015
• Issued: 11/20/2018
• Est. Priority Date: 08/31/2015
• Status: Active Grant

• Current Assignee: Faraday & Future Inc.
• Original Assignee: Faraday & Future Inc.
• Inventors: Doo, Young Mok, Schulz, Steven E., Hiti, Silva
• Primary Examiner(s): Nguyen, Hoa C
• Assistant Examiner(s): Patel, Amol
• Application Number:
  US14/841,526
• Publication Number:
  US 20170063065A1
• Time in Patent Office: 1,177 Days
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections

Abstract

Power inverter assemblies are provided herein for use with motor vehicles. An inverter assembly may have a symmetrical structure configured to convert DC input power to AC output power. The inverter assembly may include a housing enclosing a symmetrical DC input portion, a symmetrical AC output portion, a DC link capacitor, and a gate drive portion having a pair of power modules. The symmetrical DC input portion can include a DC input bus bar sub-assembly to which the DC link capacitor is coupled, and a second DC bus bar sub-assembly that may electrically couple the DC link capacitor with the power modules. The symmetrical AC output portion may include a three phase output AC bus bar sub-assembly to which the power modules can be electrically coupled. A cooling sub-assembly may be provided for cooling the power modules with fluid transfer using a coolant.

Claims

1. A DC bus bar sub-assembly, comprising:

a negative DC bus bar having a negative input tab and a negative output tab;

a positive DC bus bar, which is nested within the negative DC bus bar, the positive and negative bus bars being spaced apart from one another to form a space therebetween, the positive bus bar comprising a positive input tab and a positive output tab;

wherein the positive and negative input tabs are disposed in a spaced apart and side-by-side relationship to one another, and further wherein the positive and negative output tabs are disposed in a spaced apart and side-by-side relationship to one another;

wherein the negative DC bus bar comprises a negative bar body having a first section and a second section that are disposed orthogonally to one another;

wherein the positive DC bus bar comprises a positive bar body having a first section and a second section that are disposed orthogonally to one another;

wherein the positive output tab and the negative output tab are offset from the second sections of their respective bar bodies; and

wherein the positive and negative output tabs are substantially L-shaped and comprise an aperture for receiving a connection for a power cable.

2. The DC bus bar sub-assembly according to claim 1, wherein the positive input tab extends from a first section of the positive bar body and the negative input tab extends from a first section of the negative bar body.

3. The DC bus bar sub-assembly according to claim 1, further comprising an insulating housing that encloses the first section of both of the pair of bus bars to prevent the pair of bus bars from contacting a terminal block onto which the pair of bus bars are installed.

4. The DC bus bar sub-assembly according to claim 1, wherein an insulating spacer is disposed within a space formed between the pair of bus bars.

5. A DC bus bar sub-assembly, comprising:

a pair of bus bars that each comprise;

an input tab;

an output tab; and

a bar body, the input tab extending in alignment with a first section of the bar body, the output tab extending normally to a second section of the bar body; and

an insulating housing that encloses the first section of both of the pair of bus bars;

wherein the input tabs of the pair of bus bars are disposed above the output tabs of the pair of bus bars.

6. The DC bus bar sub-assembly according to claim 5, wherein the insulating housing is configured to contact a terminal block that couples the DC bus bar sub-assembly with a lower enclosure of a housing.

7. The DC bus bar sub-assembly according to claim 5, wherein the input tabs of the pair of bus bars are orthogonal to the output tabs of the pair of bus bars.

8. A DC bus bar sub-assembly for an inverter assembly, the DC bus bar sub-assembly comprising:

a pair of bus bars that each comprise;

an input tab;

an output tab; and

a bar body, the input tab extending in alignment with a first section of the bar body, the output tab extending normally to a second section of the bar body;

wherein the first section and the second section of the bar body are disposed at substantially a right angle relative to one another.

9. The DC bus bar sub-assembly according to claim 8, wherein the bar body of a first of the pair of bus bars is spaced apart from a second of the pair of bus bars so as to minimize inductance therebetween.

10. The DC bus bar sub-assembly according to claim 8, further comprising an insulating housing that encloses the first section of both of the pair of bus bars to prevent the pair of bus bars from contacting a terminal block onto which the pair of bus bars are installed.

11. The DC bus bar sub-assembly according to claim 10, further comprising an insulating spacer disposed within a space formed between the pair of bus bars, wherein a plate is disposed above the insulating spacer, the plate being configured to secure to the terminal block to secure the insulating housing against the terminal block.

12. The DC bus bar sub-assembly according to claim 8, wherein the output tabs of the pair of bus bars are configured to couple with a DC link capacitor of the inverter assembly.

13. The DC bus bar sub-assembly according to claim 8, wherein the output tabs of the pair of bus bars extend in a direction that disposes the output tabs above and in parallel with the bar bodies.