Low stray interconnection inductance power converting molecule for converting a DC voltage into an AC voltage, and a method therefor

• US 6,954,368 B1
• Filed: 06/25/1997
• Issued: 10/11/2005
• Est. Priority Date: 07/22/1996
• Status: Expired due to Fees

• Current Assignee: Tm4 Inc. (Dana, Inc.)
• Original Assignee: Hydro-Quebec (Province of Québec)
• Inventors: Francoeur, Bruno, Couture, Pierre
• Primary Examiner(s): Laxton, Gary L.
• Application Number:
  US09/147,574
• Time in Patent Office: 3,030 Days
• Field of Search: 361/709, 361/715, 361717-720, 361/746, 361760-763, 361/781, 361/783, 361/807, 363/131, 363/132, 363/141, 363/144
• US Class Current: 363/144
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/48111 the wire connector extending above another semiconductor or solid-state body
• CPC Class Codes: H01L 2224/48472 the other connecting portion not on the bonding area also being a wedge bond, i.e. wedge-to-wedge
• 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 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections

Abstract

The low stray interconnecton power converting module is for converting a DC voltage into an AC voltage. It comprises two DC voltage terminals for receiving the DC voltage, an AC voltage terminal for delivering the AC voltage, and a half-bridge including a pair of power switching elements connected as a series totem pole between the DC voltage terminals via the AC voltage terminal. It also comprises a decoupling device for decoupling the half-bridge. The decoupling device comprises a series of at least two adjacent superimposed electrode plates separated by a dielectric material and extending proximately in overlapping relation with the half-bridge. Each of the adjacent electrode plates is connected to a different one of the DC terminals. The electrode plates form with the two power switching elements, the DC terminals and the AC terminal, a reduced cross section belt-like current closed loop by which a low stray interconnection inductance power converting module is obtained.

Claims

1. A low stray interconnection inductance power converting module for converting a DC voltage into an AC voltage, comprising two DC voltage terminals for receiving the DC voltage;

an AC voltage terminal for delivering the AC voltage;

a half-bridge including a pair of power switching elements connected as a series totem pole between the DC voltage terminals via the AC voltage terminal; and

a decoupling means for decoupling the half-bridge, the decoupling means comprising a series of at least two adjacent superimposed electrode plates separated by a dielectric material, each of the adjacent electrode plates being connected to a different one of the DC terminals;

wherein;

the at least two adjacent superimposed electrode plates extend proximately in overlapping relation with the half bridge; and

the electrode plates form with the two power switching elements, the DC terminals and the AC terminal, a reduced cross section belt-like closed loop conductive path.

2. A power converting module according to claim 1, comprising a base made of ceramic material, onto which the power switching elements are mounted, and wherein:

each of the power switching elements includes a row of power semiconductor devices mounted in parallel;

the AC terminal includes a central metal plate mounted on the base; and

each of the two DC voltage terminals includes a lateral metal plate mounted onto the base, and a lateral upright metal wall connected between the lateral metal plate and the decoupling means, the power switching elements being connected as a series totem pole between the lateral metal plates of the DC voltage terminals via the central metal plate of the AC voltage terminal.

3. A power converting module according to claim 2, wherein the reduced cross section belt-like closed loop conductive path is formed by the central plate, the lateral metal plates, the lateral upright metal walls, the superimposed electrode plates and the power switching elements, and has a rectangular cross section.

4. A power converting module according to claim 3, further comprising drivers mounted on the base nearby the power semiconductor devices, for driving the power semiconductor devices.

5. A power converting module according to claim 4, wherein said semiconductor devices are gate capacitance controlled semiconductor devices, and wherein each of the drivers includes:

a terminal to receive a gate signal for the corresponding semiconductor device;

a first resistor connected between the terminal and a gate of the corresponding semiconductor device;

a circuit segment including a voltage gate controlled switch and a second resistor connected in series, the circuit being connected in parallel to the first resistor;

a capacitor connected between a gate of the voltage gate controlled switch and the collector of the corresponding semiconductor device for monitoring a collector voltage signal of the corresponding semiconductor device;

a voltage clamping means connected between the gate of the voltage gate controlled switch and the terminal, whereby, in operation, the first resistor limits gate current of the corresponding semiconductor device prior to a drop of the collector voltage signal thereby limiting rise time of the collector current, and whereby, in operation, the first and second resistors limit the gate current of the corresponding semiconductor device during said drop of the collector voltage thereby limiting dropping time of collector voltage.

6. A power converting module according to claim 2, further comprising drivers mounted on the base nearby the power semiconductor devices, for driving the power semiconductor devices.

7. A power converting module according to claim 6, wherein said semiconductor devices are gate capacitance controlled semiconductor devices, and wherein each of the drivers includes:

a terminal to receive a gate signal for the corresponding semiconductor device;

a first resistor connected between the terminal and a gate of the corresponding semiconductor device;

a circuit segment including a voltage gate controlled switch and a second resistor connected in series, the circuit being connected in parallel to the first resistor;

a capacitor connected between a gate of the voltage gate controlled switch and the collector of the corresponding semiconductor device for monitoring a collector voltage signal of the corresponding semiconductor device;

a voltage clamping means connected between the gate of the voltage gate controlled switch and the terminal, whereby, in operation, the first resistor limits gate current of the corresponding semiconductor device prior to a drop of the collector voltage signal thereby limiting rise time of the collector current, and whereby, in operation, the first and second resistors limit the gate current of the corresponding semiconductor device during said drop of the collector voltage thereby limiting dropping time of collector voltage.

8. A power converting module according to claim 2, 3, 6, 4, 7 or 5 comprising a control board for controlling the power semiconductor devices, the control board being located between the base onto which the power switching elements are mounted and the decoupling means.

9. A power converting module according to claim 1, 2, 3, 6, 4, 7 or 5, further comprising walls made of conductive material for closing open ends of the belt-like current closed loop, each of the open ends being delimited by edges of the central plate, of the lateral metal plates and of the lateral metal walls and by a lower edge of the superimposed metal plates whereby, in operation, an electric current is magnetically induced into the conductive walls to further reduce voltage spikes associated to stray interconnection inductance.

10. The combination of three power converting modules according to claim 1, 2, 3, 6, 4, 7 or 5, in a motor wheel provided with a stator frame supported by a cross member made of conductive material, wherein the three modules are mounted respectively on three legs of the cross member within the motor wheel, the modules forming a three-phase power converter which further comprises:

a first conductive bus connecting one of the DC terminals of each module on one side of the cross member, and

a second conductive bus connecting the other of the DC terminals of each module on the other side of the cross member, the two conductive bus delimiting spaces between adjacent modules that are filled with the conductive material of the cross member, the two conductive bus and the cross member being separated by insulating material, whereby, in operation, an electric current is magnetically induced in the cross member to suppress the voltage oscillations on the capacitor of each module due to the stray interconnection inductance present between the modules.

11. A power converting module according to claim 1, 2, 3, 6, 4, 7 or 5, further comprising a housing including conductive walls surrounding the reduced cross section belt-like current closed loop, whereby, in operation, an electric current is magnetically induced into the conductive walls to further reduce voltage spikes associated to stray interconnection inductance.

12. The combination of three power converting modules according to claim 11, in a motor wheel provided with a stator frame supported by a cross member made of conductive material, wherein the three modules are mounted respectively on three legs of the cross member within the motor wheel, the modules forming a three-phase power converter which further comprises:

a first conductive bus connecting one of the DC terminals of each module on one side of the cross member; and

a second conductive bus connecting the other of the DC terminals of each module on the other side of the cross member, the two conductive bus delimiting spaces between adjacent modules that are filled with the conductive material of the cross member, the two conductive bus and the cross member being separated by insulating material, whereby, in operation, an electric current is magnetically induced in the cross member to suppress the voltage oscillations on the capacitor of each module due to the stray interconnection inductance present between the modules.

13. A power converting module according to claim 11, wherein at least one of the conductive walls of the housing are formed by a metal deposition over insulating walls.

14. The combination of three power converting modules according to claim 13, in a motor wheel provided with a stator frame supported by a cross member made of conductive material, wherein the three modules are mounted respectively on three legs of the cross member within the motor wheel, the modules forming a three-phase power converter which further comprises:

a first conductive bus connecting one of the DC terminals of each module on one side of the cross member; and

a second conductive bus connecting the other of the DC terminals of each module on the other side of the cross member, the two conductive bus delimiting spaces between adjacent modules that are filled with the conductive material of the cross member, the two conductive bus and the cross member being separated by insulating material, whereby, in operation, an electric current is magnetically induced in the cross member to suppress the voltage oscillations on the capacitor of each module due to the stray interconnection inductance present between the modules.

15. A power converting module according to claim 13, wherein the conductive walls of the housing are made of at least two parts connected together.

16. The combination of three power converting modules according to claim 15, in a motor wheel provided with a stator frame supported by a cross member made of conductive material, wherein the three modules are mounted respectively on three legs of the cross member within the motor wheel, the modules forming a three-phase power converter which further comprises:

a first conductive bus connecting one of the DC terminals of each module on one side of the cross member; and

a second conductive bus connecting the other of the DC terminals of each module on the other side of the cross member, the two conductive bus delimiting spaces between adjacent modules that are filled with the conductive material of the cross member, the two conductive bus and the cross member being separated by insulating material, whereby, in operation, an electric current is magnetically induced in the cross member to suppress the voltage oscillations on the capacitor of each module due to the stray interconnection inductance present between the modules.

17. A power converting module according to claim 13, further comprising a capacitor connected between the conductive walls of the housing and one DC terminal, the conductive walls providing one connecting point for electrical connection purpose.

18. The combination of three power converting modules according to claim 17, in a motor wheel provided with a stator frame supported by a cross member made of conductive material, wherein the three modules are mounted respectively on three legs of the cross member within the motor wheel, the modules forming a three-phase power converter which further comprises:

a first conductive bus connecting one of the DC terminals of each module on one side of the cross member; and

a second conductive bus connecting the other of the DC terminals of each module on the other side of the cross member, the two conductive bus delimiting spaces between adjacent modules that are filled with the conductive material of the cross member, the two conductive bus and the cross member being separated by insulating material, whereby, in operation, an electric current is magnetically induced in the cross member to suppress the voltage oscillations on the capacitor of each module due to the stray interconnection inductance present between the modules.

19. A power converting module according to claim 17, wherein the capacitor is formed by a wall of the conductive walls that is adjacent to a top electrode plate of the decoupling means, and that is separated from the top electrode plate by means of dielectric material.

20. The combination of three power converting modules according to claim 19, in a motor wheel provided with a stator frame supported by a cross member made of conductive material, wherein the three modules are mounted respectively on three legs of the cross member within the motor wheel, the modules forming a three-phase power converter which further comprises:

a first conductive bus connecting one of the DC terminals of each module on one side of the cross member; and

a second conductive bus connecting the other of the DC terminals of each module on the other side of the cross member, the two conductive bus delimiting spaces between adjacent modules that are filled with the conductive material of the cross member, the two conductive bus and the cross member being separated by insulating material, whereby, in operation, an electric current is magnetically induced in the cross member to suppress the voltage oscillations on the capacitor of each module due to the stray interconnection inductance present between the modules.

21. A power converting module according to claim 11, wherein the conductive walls of the housing are made of at least two parts connected together.

22. A power converting module according to claim 21, further comprising a capacitor connected between the conductive walls of the housing and one DC terminal, the conductive walls providing one connecting point for electrical connection purpose.

23. The combination of three power converting modules according to claim 22, in a motor wheel provided with a stator frame supported by a cross member made of conductive material, wherein the three modules are mounted respectively on three legs of the cross member within the motor wheel, the modules forming a three-phase power converter which further comprises:

a first conductive bus connecting one of the DC terminals of each module on one side of the cross member; and

a second conductive bus connecting the other of the DC terminals of each module on the other side of the cross member, the two conductive bus delimiting spaces between adjacent modules that are filled with the conductive material of the cross member, the two conductive bus and the cross member being separated by insulating material, whereby, in operation, an electric current is magnetically induced in the cross member to suppress the voltage oscillations on the capacitor of each module due to the stray interconnection inductance present between the modules.

24. A power converting module according to claim 22, wherein the capacitor is formed by a wall of the conductive walls that is adjacent to a top electrode plate of the decoupling means, and that is separated from the top electrode plate by means of dielectric material.

25. The combination of three power converting modules according to claim 24, in a motor wheel provided with a stator frame supported by a cross member made of conductive material, wherein the three modules are mounted respectively on three legs of the cross member within the motor wheel, the modules forming a three-phase power converter which further comprises:

a first conductive bus connecting one of the DC terminals of each module on one side of the cross member; and

a second conductive bus connecting the other of the DC terminals of each module on the other side of the cross member, the two conductive bus delimiting spaces between adjacent modules that are filled with the conductive material of the cross member, the two conductive bus and the cross member being separated by insulating material, whereby, in operation, an electric current is magnetically induced in the cross member to suppress the voltage oscillations on the capacitor of each module due to the stray interconnection inductance present between the modules.

26. The combination of three power converting modules according to claim 21, in a motor wheel provided with a stator frame supported by a cross member made of conductive material, wherein the three modules are mounted respectively on three legs of the cross member within the motor wheel, the modules forming a three-phase power converter which further comprises:

a first conductive bus connecting one of the DC terminals of each module on one side of the cross member; and

a second conductive bus connecting the other of the DC terminals of each module on the other side of the cross member, the two conductive bus delimiting spaces between adjacent modules that are filled with the conductive material of the cross member, the two conductive bus and the cross member being separated by insulating material, whereby, in operation, an electric current is magnetically induced in the cross member to suppress the voltage oscillations on the capacitor of each module due to the stray interconnection inductance present between the modules.

27. A power converting module according to claim 11, further comprising a capacitor connected between the conductive walls of the housing and one DC terminal, the conductive walls providing one connecting point for electrical connection purpose.

28. The combination of three power converting modules according to claim 27, in a motor wheel provided with a stator frame supported by a cross member made of conductive material, wherein the three modules are mounted respectively on three legs of the cross member within the motor wheel, the modules forming a three-phase power converter which further comprises:

a first conductive bus connecting one of the DC terminals of each module on one side of the cross member; and

a second conductive bus connecting the other of the DC terminals of each module on the other side of the cross member, the two conductive bus delimiting spaces between adjacent modules that are filled with the conductive material of the cross member, the two conductive bus and the cross member being separated by insulating material, whereby, in operation, an electric current is magnetically induced in the cross member to suppress the voltage oscillations on the capacitor of each module due to the stray interconnection inductance present between the modules.

29. A power converting module according to claim 27, wherein the capacitor is formed by a wall of the conductive walls that is adjacent to a top electrode plate of the decoupling means, and that is separated from the top electrode plate by means of dielectric material.

30. The combination of three power converting modules according to claim 29, in a motor wheel provided with a stator frame supported by a cross member made of conductive material, wherein the three modules are mounted respectively on three legs of the cross member within the motor wheel, the modules forming a three-phase power converter which further comprises:

a first conductive bus connecting one of the DC terminals of each module on one side of the cross member; and

a second conductive bus connecting the other of the DC terminals of each module on the other side of the cross member, the two conductive bus delimiting spaces between adjacent modules that are filled with the conductive material of the cross member, the two conductive bus and the cross member being separated by insulating material, whereby, in operation, an electric current is magnetically induced in the cross member to suppress the voltage oscillations on the capacitor of each module due to the stray interconnection inductance present between the modules.

31. A method for converting a DC voltage into an AC voltage, comprising:

applying the DC voltage on two DC voltage terminals between which a half bridge is connected, the half bridge including a pair of power switching elements connected as a series totem pole between the DC voltage terminals via an AC voltage terminal;

alternately switching the power switching elements;

decoupling the half bridge by means of a decoupling means comprising a series of at least two adjacent superimposed electrode plates separated by a dielectric material and extending proximately in overlapping relation with the half bridge, each of the adjacent electrode plates being connected to a different one of the DC terminals, the electrode plates forming with the two power switching elements, the DC terminals and the AC terminal. reduced cross section belt like current closed loop; and

delivering the AC voltage by means of the AC voltage terminal.

32. A method according to claim 31, comprising the additional step of surrounding the reduced cross section belt like current closed loop by means of a housing including conductive walls, whereby, in operation, an electric current is magnetically induced into the conductive walls to further reduce voltage spikes associated to stray interconnection inductance.