POWER MODULE WITH CURRENT SENSING

• US 20110292617A1
• Filed: 05/25/2010
• Published: 12/01/2011
• Est. Priority Date: 05/25/2010
• Status: Active Grant

• Current Assignee: Lear Corporation
• Original Assignee: Lear Corporation
• Inventors: Fabregas, Antoni Ferre, Fernandez, Jose Gabriel, Darroman, Yann
• Granted Patent: US 8,482,904 B2
• Time in Patent Office: Days
• US Class Current: 361/728
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/49111 the connectors connecting two common bonding areas, e.g. Litz or braid wires
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H02M 1/0009 Devices or circuits for detecting current in a converter
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections

Abstract

A power module operable to sense current, such as but not limited to a power module operable within a vehicle to sense current while rectifying an AC input to a DC output. The power module may include a shunt disposed relative an output of the power module to facilitate the current measurement.

Claims

1. A power module operable for use within a vehicle to rectify a three-phase, AC input to a DC output, the power module comprising:

a housing;

conducting first, second, and third input terminals disposed within the housing, the first, second, and third input terminals each operable to establish an electrical connection to one of three busbars carrying the AC input;

conducting first and second output terminals disposed within the housing, the first and second output terminals each operable to establish an electrical connection to one of two busbars carrying the DC output;

a rectifier disposed within the housing between the input terminals and the output terminals, the rectifier having a plurality of switches operably connected between the input terminals and the output terminals to rectify the three-phase AC input to the DC output;

a shunt electrically disposed between the connection to one of the output terminals and at least one of the switches such that current flow through the one of the output terminals must pass through the shunt;

first and second shunt pins adhered to the shunt at spaced apart locations; and

a printed circuit board (PCB) having control electronics operable to control opening and closing of each of the switches and measurement electronics operable to measure a voltage drop between the first and second shunt pins.

2. The power module of claim 1 further comprising the PCB including first and second electrically conducting apertures above the first and second shunt pins for establishing an electrical connection between each of the shunt pins and the measurement electronics.

3. The power module of claim 2 wherein the PCB is mechanically connected to the housing and a majority of a footprint of the PCB is disposed above the rectifier.

4. The power module of claim 3 wherein the shunt is disposed below the PCB and above the rectifier.

5. The power module of claim 4 wherein a cross-section of the shunt matches a cross-section of each of the busbars.

6. The power module of claim 4 wherein the shunt includes a first material and a second material, the first material being disposed on first and second sides of the second material, the first shunt pin being adhered to the first material proximate the first side of the second material and the second shunt pin being adhered to the first material proximate to the second side of the second material.

7. The power module of claim 6 wherein a cross-section of the first material matches a cross-section of the second material.

8. The power module of claim 1 further comprising threaded fasteners establishing the electrical connections between the terminals and the busbars and between the shunt and the at least one of the switches.

9. The power module of claim 1 wherein each shunt pin has an L-shaped configuration characterized by a horizontally extending pad and an upwardly extending leg, the pad being adhered to the shunt and the leg extending through the PCB.

10. The power module of claim 1 wherein each shunt pin is adhered to the shunt with a weld.

11. The power module of claim 1 wherein at least one of the shunt pins is rigid throughout.

12. A power module operable for use within a vehicle to rectify an AC input to a DC output, the power module comprising:

a housing;

conducting first and second input terminals disposed within the housing, the first and second input terminals each operable to establish an electrical connection to the AC input;

conducting first and second output terminals disposed within the housing, the first and second output terminals each operable to establish an electrical connection to one of two busbars carrying the DC output;

a circuit disposed within the housing between the input terminals and the output terminals, the circuit having a plurality of switches operably connected between the input terminals and the output terminals to rectify the AC input to the DC output;

a shunt electrically disposed between the connection to one of the output terminals and one of the switches such that current flow through the one or the output terminals must pass through the shunt; and

a printed circuit board (PCB) having control electronics operable to control opening and closing of each of the switches and measurement electronics operable to measure a voltage drop across a portion of the shunt.

13. The power module of claim 12 wherein the shunt is embedded within silicon of the circuit.

14. The power module of claim 12 wherein the shunt is embedded within the PCB.

15. The power module of claim 12 wherein the shunt is comprised solely of a measurement material.

16. The power module of claim 12 wherein the shut is comprised of a measurement material surround on opposed sides with a copper material.

17. The power module of claim 16 further comprising a first shunt pin adhered to the copper material proximate one side of the measurement material and a second shunt pin adhered to the copper material proximate an opposite side of the measurement material, wherein a leg of each shunt pin extends upwardly through the PCB to establish an electrical connection with the measurement electronics.

18. A power module having an input and an output, the power module comprising:

a non-conducting housing;

at least one conducting input terminal disposed within the housing, the each input terminal operable to establish an electrical connection to one busbar;

at least one conducting output terminal disposed within the housing, each output terminal operable to establish an electrical connection to one busbar;

a circuit disposed within the housing between the input terminals and the output terminals, the circuit operably connected between the input and the output to manipulate received current prior to output to the at lest one output terminal;

a shunt electrically disposed between the connection to one of the output terminals such that current flow through the one or the output terminals must pass through the shunt;

first and second shunt pins adhered at spaced apart portions of the shunt; and

a printed circuit board (PCB) having control electronics operable to control opening and closing of each of the switches and measurement electronics operable to measure a voltage drop between the first and second shunt pins.

19. The power module of claim 18 further comprising threaded fasteners establishing the electrical and mechanical connections between the shunt and the one of the output terminals.

20. The power module of claim 18 wherein each shunt pin has an L-shaped configuration with a horizontally extending pad and an upwardly extending leg, the pad being adhered to the shunt and the leg extending through the PCB.