Vehicle drive module having improved cooling configuration
First Claim
1. An electric drive for a vehicle at least partially propelled by an electric motor, the drive comprising:
- a vehicle drive train;
a power converter operatively coupled to the drive train and comprising;
a thermal support configured to receive and to circulate a coolant stream;
a control circuit;
a driver circuit supported by the thermal support and coupled to the control circuit to receive control signals from the control circuit;
a power converter circuit coupled to the driver circuit to receive drive signals for outputting a controlled frequency output power, the inverter circuit including a plurality of power electronic device subassemblies bonded to a substrate for converting input power to AC power signals based upon the drive signals; and
a capacitor circuit coupled to the power converter circuit;
wherein at least the substrate of the inverter circuit is supported on the thermal support and extracting heat from the power electronic device subassemblies during operation of the power converter circuit.
2 Assignments
0 Petitions
Accused Products
Abstract
An electric vehicle drive includes a thermal support may receive one or more power electronic circuits. The support may aid in removing heat from the circuits through fluid circulating through the support. Power electronic circuits are thermally matched, such as between component layers and between the circuits and the support. The support may form a shield from both external EMI/RFI and from interference generated by operation of the power electronic circuits. Features may be provided to permit and enhance connection of the circuitry to external circuitry, such as improved terminal configurations. Modular units may be assembled that may be coupled to electronic circuitry via plug-in arrangements or through interface with a backplane or similar mounting and interconnecting structures.
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Citations
49 Claims
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1. An electric drive for a vehicle at least partially propelled by an electric motor, the drive comprising:
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a vehicle drive train;
a power converter operatively coupled to the drive train and comprising;
a thermal support configured to receive and to circulate a coolant stream;
a control circuit;
a driver circuit supported by the thermal support and coupled to the control circuit to receive control signals from the control circuit;
a power converter circuit coupled to the driver circuit to receive drive signals for outputting a controlled frequency output power, the inverter circuit including a plurality of power electronic device subassemblies bonded to a substrate for converting input power to AC power signals based upon the drive signals; and
a capacitor circuit coupled to the power converter circuit;
wherein at least the substrate of the inverter circuit is supported on the thermal support and extracting heat from the power electronic device subassemblies during operation of the power converter circuit. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. An electric drive for a vehicle at least partially propelled by an electric motor, the drive comprising:
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a vehicle drive train;
a power converter operatively coupled to the drive train and comprising;
a thermal support having first and second sides and configured to receive and to circulate a coolant stream;
a power converter circuit for outputting a controlled frequency output power, the converter circuit including a plurality of power electronic device subassemblies bonded to at least one substrate; and
an energy storage circuit coupled to the converter circuit;
wherein the substrate of the converter circuit is supported on the first side of the thermal support and the energy storage circuit is supported on the second side of the thermal support, whereby the coolant stream extracts heat from the substrate and the energy storage circuit during operation of the power converter circuit. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18)
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19. An electric drive for a vehicle at least partially propelled by an electric motor, the drive comprising:
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a vehicle drive train;
a power converter operatively coupled to the drive train and comprising;
a thermal support having first and second sides and configured to receive and to circulate a coolant stream;
a first power converter circuit for outputting a controlled frequency output power, the converter circuit including a plurality of power electronic device subassemblies secured to at least one first substrate; and
a second power converter circuit for outputting a controlled frequency output power, the converter circuit including a plurality of power electronic device subassemblies secured to a second substrate;
wherein the at least one first substrate is supported on the first side of the thermal support and the at least one second substrate is supported on the second side of the thermal support, whereby the coolant stream extracts heat from the first and second substrates during operation of the converter. - View Dependent Claims (20, 21, 22, 23, 24, 25)
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26. An electric drive for a vehicle at least partially propelled by an electric motor, the drive comprising:
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a vehicle drive train;
a power converter operatively coupled to the drive train and comprising;
a thermal support at least partially defining an electric reference plane and configured to receive and circulate a coolant stream for extraction of heat;
an interface plate secured to the thermal support and contacting the coolant stream during operation;
at least one power electronic device subassembly disposed on the interface plate and comprising a power electronic device and contact pads for transmitting signals to and from the power electronics device, the interface plate and the electronics device subassembly being at least partially thermally matched to create a desired thermal gradient to remove heat from the power electronics device during operation via the substrate and the thermal support;
wherein the interface plate and the thermal support are made of different materials. - View Dependent Claims (27, 28, 29)
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30. An electric drive for a vehicle at least partially propelled by an electric motor, the drive comprising:
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a vehicle drive train;
a power converter operatively coupled to the drive train and comprising;
a controlled power electronics circuit including solid state switches configured to convert incoming power to controlled outgoing power; and
a fluid cooled support on which the power electronics circuit is directly secured, the fluid cooled support including inlet and outlet ports for a cooling fluid and an internal fluid conduit for directing flow of cooling fluid adjacent to the power electronics circuit for removal of heat therefrom, the support further including an interface plate on which the power electronics circuit is secured and which contacts the cooling fluid during operation, interfaces between the power electronics circuit and and the interface plate being thermally matched to limit differential thermal expansion during operation of the solid state switches. - View Dependent Claims (31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 42, 43, 44, 45, 46, 47, 48, 49)
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41. An electric drive for a vehicle at least partially propelled by an electric motor, the drive comprising:
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a vehicle drive train;
a power converter operatively coupled to the drive train and comprising;
a plurality of controlled power electronics circuits including solid state switches configured to convert incoming power to controlled outgoing power, each circuit including a first bonding layer thermally matched to an underlying interface plate, a substrate disposed on the first bonding layer and thermally matched to the first bonding layer, a second bonding layer disposed on the substrate and thermally matched to the substrate, and a device layer disposed on the second bonding layer and thermally matched to the second bonding layer; and
a fluid cooled support on which the power electronics circuits are directly secured, the fluid cooled support including inlet and outlet ports for a cooling fluid and an internal fluid conduit for directing flow of cooling toward the interface plate for removal of heat therefrom during operation of the solid state switches.
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Specification