Power inverter

• US 9,007,767 B2
• Filed: 03/30/2011
• Issued: 04/14/2015
• Est. Priority Date: 04/01/2010
• Status: Active Grant

• Current Assignee: Hitachi Astemo Ltd. (Hitachi, Ltd.)
• Original Assignee: Hitachi Automotive Systems Limited (Hitachi, Ltd.)
• Inventors: Nakajima, Kenichiro
• Primary Examiner(s): THOMPSON, GREGORY D
• Application Number:
  US13/638,400
• Publication Number:
  US 20130021749A1
• Time in Patent Office: 1,476 Days
• US Class Current: 361/699
• CPC Class Codes: H01L 2224/40137 the bodies being arranged next to each other, e.g. on a common substrate
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/48247 connecting the wire to a bond pad of the item
• CPC Class Codes: H01L 2224/73265 Layer and wire connectors
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/00012 Relevant to the scope of the group, the symbol of which is combined with the symbol of this group
• 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: H01L 2924/13055 Insulated gate bipolar transistor [IGBT]
• CPC Class Codes: H01L 2924/13091 Metal-Oxide-Semiconductor Field-Effect Transistor [MOSFET]
• CPC Class Codes: H01L 2924/181 Encapsulation
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H05K 7/20927 Liquid coolant without phase change

Abstract

A power inverter includes a metallic chassis having a containing space at an inner portion thereof, having a lid on one side in a vertical direction, the other side thereof being enclosed by a bottom, a cooling block of forming a coolant path along a bottom side in the vertical direction of the chassis, and a side portion of the inner portion of the chassis, plural semiconductor modules each incorporating a semiconductor chip for configuring an inverter circuit of converting a direct current power into an alternate current power, and provided with a direct current terminal for making a current flow to the semiconductor chip and a control terminal for controlling an operation of the semiconductor chip to be protruded to an outer portion.

Claims

1. A power inverter comprising:

a metallic chassis having a containing space at an inner portion thereof, having a lid on one side in a vertical direction, other side thereof being enclosed by a bottom;

a cooling block forming a coolant path on a side of the bottom in the vertical direction of the chassis along a side portion of the inner portion of the chassis;

a plurality of power semiconductor modules each incorporating a semiconductor chip for configuring an inverter circuit of converting a direct current (DC) power into an alternate current (AC) power, a direct current terminal for making a current flow to the semiconductor chip and a control terminal for controlling an operation of the semiconductor chip being provided to be protruded to an outer portion;

a capacitor module arranged on a center side relative to a coolant path formed along the side portion of the chassis and including a direct current terminal;

an alternate current busbar assembly arranged on a side of the lid in the vertical direction of the chassis relative to the capacitor module and the coolant path; and

a driver circuit arranged on the lid side in the vertical direction relative to the alternate current busbar assembly;

wherein the respective power semiconductor modules are fixed to the cooling block in a state of being inserted into the coolant path; and

wherein the alternate current busbar assembly includes a plurality of alternate current bus bars for making alternate currents generated by the respective power semiconductor modules flow and a plurality of fixing portions for fixing the alternate current busbar assembly, the plurality of alternate current bus bars configure a shape of extending along the coolant path, and the alternate current busbar assembly is fixed by the plurality of fixing portions.

2. The power inverter according to claim 1, wherein the capacitor module configures a shape of substantially a rectangular shape, the coolant path is formed along a long side of a rectangular shape, and the plurality of fixing portions of the alternate current busbar assembly are arranged along the coolant path.

3. The power inverter according to claim 1, wherein the coolant path is formed along an outer periphery of the capacitor module;

and

wherein the driver circuit is formed at a driver board, the driver board includes a plurality of driver fixing portions for fixing, and the driver fixing portion is arranged along the coolant path.

4. A power inverter comprising:

a metallic chassis having a containing space at an inner portion thereof, having a lid on one side in a vertical direction, and having a bottom on other side thereof;

a cooling block of forming a coolant path on a side of the bottom in the vertical direction of the chassis;

a plurality of power semiconductor modules each incorporating a semiconductor chip for configuring an inverter circuit of converting a direct current power into an alternate current power, a direct current terminal for making a current flow to the semiconductor chip, an alternate current terminal for making an alternate current flow and a control terminal for controlling an operation of the semiconductor chip being provided to be protruded to an outer portion;

a capacitor module arranged along with the coolant path and including a direct current terminal;

an alternate current busbar assembly arranged on a side of the lid in the vertical direction of the chassis relative to the capacitor module and the coolant path; and

a driver circuit of supplying a control signal of the semiconductor chip to the control terminal of the power semiconductor module;

wherein the direct current terminal of the capacitor module and the direct current terminal of each of the power semiconductor modules are electrically connected;

wherein the alternate current busbar assembly includes a plurality of alternate current bus bars comprising wide width conductors extended along the coolant path and a plurality of fixing portions for fixing the alternate current busbar assembly;

wherein a narrow face of each of the wide width conductors of each of the alternate current bus bars comprising the wide width conductor is directed in the vertical direction;

wherein the wide width face is directed in a direction of traversing the vertical direction and the wide width faces of the respective alternate current bus bars are arranged to be opposed to each other via a space; and

wherein the respective alternate current bus bars of the alternate current busbar assembly are connected to the corresponding alternate current terminals of the power semiconductor module.

5. The power inverter according to claim 4, wherein a board having the driver circuit is arranged on the lid side of the alternate current busbar assembly;

and

wherein the alternate current terminal of the power semiconductor module and the corresponding alternate current busbar assembly are connected by welding, and the board having the driver circuit and the control terminal of the power semiconductor module are connected by soldering.

6. A power inverter comprising:

a metallic chassis having a containing space at an inner portion thereof, and having a lid on one side in a vertical direction and a bottom on other side thereof;

a cooling block forming a first and a second coolant path on a side of the bottom in the chassis respectively along both side portions of the inner portion of the chassis;

a power semiconductor module incorporating a semiconductor chip for configuring an inverter circuit of converting a direct current power into an alternate current power, a direct current terminal for making a current flow in the semiconductor chip, an alternate current terminal for making an alternate current flow, and a control terminal for controlling an operation of the semiconductor chip being provided to be protruded to an outer portion;

a capacitor module arranged by being interposed by the first and the second coolant path and including a direct current terminal;

an alternate current busbar assembly arranged on the lid side in the chassis relative to the capacitor module and the coolant path; and

a driver circuit of supplying a control signal to the control terminal of the power semiconductor module;

wherein a plurality of the power semiconductor modules are arranged to be respectively inserted into the first and the second coolant paths;

wherein the direct current terminal of the capacitor module and the corresponding direct current terminal of the power semiconductor module are electrically connected;

wherein the alternate current busbar assembly includes sets of a first and a second alternate current bus bar respectively arranged along the first and the second coolant paths and having respective pluralities of alternate current bus bars of a wide width shape, and a plurality of fixing portions for fixing the alternate current busbar assembly;

wherein the sets of the respective alternate current bus bars are fixed by directing respective narrow faces of the alternate current bus bars of the wide width shape in the vertical direction and directing wide width faces thereof in a direction of traversing the vertical direction, the set of the first alternate current bus bars is arranged along the first coolant path, and the set of the second alternate current bus bars is arranged along the second coolant path; and

wherein an electrical circuit is arranged between the sets of the first and the second alternate current bus bars.

7. The power inverter according to claim 6, wherein the electrical circuit arranged between the sets of the first and the second alternate current bus bars is an inverter circuit for accessories for generating an alternate current power of driving a motor for accessories.

8. A power inverter comprising:

a metallic chassis having a containing space at an inner portion thereof;

a capacitor module for smoothing arranged at the inner portion of the chassis and including a direct current terminal;

a cooling block of forming a coolant path along the capacitor module;

a power semiconductor module incorporating a series circuit of upper and lower arms for configuring an inverter circuit of converting a direct current power into an alternate current power, a direct current terminal for making a current flow to the series circuit of the upper and lower arms, an alternate current terminal for outputting an alternate current power, and a control terminal for controlling an operation of the upper and lower arms being provided to be protruded to an outer portion;

an alternate current busbar assembly arranged on one side in a vertical direction of the chassis relative to the capacitor module and the coolant path; and

a driver circuit further arranged on the one side in the vertical direction relative to the alternate current busbar assembly;

wherein a plurality of the power semiconductor modules are arranged to be inserted into the coolant path;

wherein the direct current terminal of the capacitor module is electrically connected to the direct current terminal of the power semiconductor module so as to supply a direct current power;

wherein the alternate current busbar assembly includes a plurality of alternate current bus bars having a wide width extended along the coolant path and a fixing portion for fixing the alternate current busbar assembly;

wherein the power semiconductor module includes cooling surfaces on both faces thereof, includes a semiconductor module case configured by a shape slender in the vertical direction and slender along the flow path, and the direct current terminal and the alternate current terminal protruded from the semiconductor module case to the one side in the vertical direction, and is provided with the control terminal further protruded to be long to the one side in the vertical direction relative to the direct current terminal and the alternate current terminal;

wherein the alternate current busbar assembly is electrically connected to the corresponding alternate current terminal of the power semiconductor module; and

wherein the driver circuit supplies a control signal for controlling the upper arm or the lower arm to the corresponding control terminal of the power semiconductor module.

9. The power inverter according to claim 8, wherein the alternate current bus bars having the wide width of the alternate current busbar assembly are configured by a shape of directing respective narrow faces thereof in the vertical direction and respectively extending the alternate current bus bars along the coolant path, and wide width faces of the alternate current bus bars configuring the alternating busbar assembly being arranged to be opposed to each other via a space.

10. The power inverter according to claim 8, wherein the alternate current output terminals are provided respectively in an extending direction along the coolant path.

11. The power inverter according to claim 9, wherein the alternate current output terminals are provided respectively in an extending direction along the coolant path.

12. A power inverter comprising:

a metallic chassis having a containing space at an inner portion thereof;

a capacitor module for smoothing including a direct current terminal and provided at an inner portion of the chassis;

a cooling block forming a coolant path to be along the capacitor module at the inner portion of the chassis;

a power semiconductor module incorporating a semiconductor chip for configuring an inverter circuit of converting a direct current power into an alternate current power, the semiconductor chip being provided with a direct current terminal for making a current flow to the semiconductor chip, an alternate current terminal for making an alternate current flow, and a control terminal for controlling an operation of the semiconductor chip to be protruded to an outer portion;

an alternate current busbar assembly arranged on one side in a vertical direction of the chassis relative to the capacitor module and the coolant path; and

a driver circuit arranged on the one side in the vertical direction relative to the alternate current busbar assembly;

wherein the direct current terminal of the capacitor module and the direct current terminals of the respective power semiconductor modules are connected by welding; and

wherein the alternate current busbar assembly includes a plurality of alternate current bus bars extended along the coolant path and a fixing portion for fixing the alternate current busbar assembly, the alternate current busbar assembly being fixed to the cooling block by the fixing portion.

13. The power inverter according to claim 12, wherein the alternate current terminals of the respective power semiconductor modules are connected to the corresponding alternate current terminal of the power semiconductor module by welding.

14. A power inverter comprising:

a metallic chassis having a containing space at an inner portion thereof, having a lid on one side in a vertical direction, other side thereof being enclosed by a bottom;

a cooling block forming a coolant path along a side portion of the inner portion of the chassis;

a power semiconductor module incorporating a semiconductor chip for configuring an inverter circuit of converting a direct current power into an alternate current power, a direct current terminal for making a current flow to the semiconductor chip, an alternate current terminal for making an alternate current flow, and a control terminal for controlling an operation of the semiconductor chip being provided to be protruded to an outer portion;

a capacitor module arranged to a center side relative to the coolant path, fixed to the cooling block, and including a direct current terminal;

an alternate current busbar assembly arranged on the one side in the vertical direction of the chassis relative to the capacitor module and the coolant path; and

a driver circuit;

wherein a plurality of the power semiconductor modules are fixed by being inserted into the coolant path;

wherein the alternate current busbar assembly includes a plurality of alternate current bus bars having a wide width, and a fixing portion for fixing the alternate current busbar assembly;

wherein the alternate current bus bars are arranged such that respective narrow width faces thereof are directed in the vertical direction, and the respective wide width faces are opposed to each other via a space;

wherein the alternate current busbar assembly is fixed to the cooling block by the fixing portion; and

wherein the driver circuit is fixed to the cooling block.

15. A power inverter comprising:

a metallic chassis having a containing space at an inner portion thereof, having a lid on one side in a vertical direction, other side thereof being enclosed by a bottom;

a cooling block arranged at the inner portion of the chassis, and forming a coolant path along a side portion of the chassis;

a plurality of power semiconductor modules each incorporating a semiconductor chip for configuring an inverter circuit of converting a direct current power into an alternate current power, a direct current terminal for making a current flow to the semiconductor chip, an alternate current terminal for making an alternate current flow, and a control terminal for controlling an operation of the semiconductor chip being provided to be protruded to an outer portion and fixed by being inserted into the coolant path;

a capacitor module for smoothing arranged at a center side relative to the coolant path, fixed to the cooling block, and including a direct current terminal;

an alternate current busbar assembly arranged on the one side in the vertical direction of the chassis relative to the capacitor module and the coolant path; and

a driver circuit of supplying a control signal to the control terminal of the power semiconductor module;

wherein the direct current terminal of the capacitor module is protruded from the capacitor module to be extended to a side of the corresponding direct current terminal of the power semiconductor module, an end portion thereof configures a shape of being extended to the one side in the vertical direction along a main current terminal of the power semiconductor module, and an end portion of the direct current terminal of the capacitor module is connected to the direct current terminal of the power semiconductor module by welding;

wherein an alternate current bus bar configuring a wide width shape included in the alternate current busbar assembly is extended to a side of the alternate current terminal of the power semiconductor module, an end portion thereof configures a shape of being extended to the one side in the vertical direction along the alternate current terminal, and the end portion is connected to the alternate current terminal by welding; and

wherein the driver circuit is connected to the control terminal of the power semiconductor module by soldering.

16. The power inverter according to claim 15, wherein a direct current bus bar protruded from the capacitor module and connected to the corresponding direct current terminal of the power semiconductor module has a first portion of extending from the capacitor module to a side of the main current terminal of the power semiconductor module, and a second portion of extending an end portion thereof to the one side in the vertical direction along the direct current terminal, and connected to the direct current terminal of the power semiconductor module by welding at the second portion;

and

wherein an alternate current bus bar of a wide width conductor included in the alternate current busbar assembly has a first portion of extending to a side of the alternate current terminal of the power semiconductor module, and a second portion of extending an end portion thereof to be folded to bend to the one side in the vertical direction along the alternate current terminal, and is connected to the alternate current terminal of the power semiconductor module by welding at the second portion.

17. A power inverter comprising:

a metallic chassis having a containing space at an inner portion thereof, having a lid on one side in a vertical direction, other side thereof being enclosed by a bottom, and having a fixing portion for fixing to a transmission for a vehicle at an outer portion on the other side; and

a cooling block arranged at the inner portion of the metallic chassis, and forming a coolant path for making a coolant flow, a power semiconductor module incorporating a semiconductor chip of configuring an inverter circuit for converting a direct current power into an alternate current power, a capacitor module including a direct current terminal, an alternate current busbar assembly for making an alternate current generated by the power semiconductor module flow;

and a current sensor;

wherein the capacitor module and the coolant path are arranged to align so as to arrange the coolant path along the capacitor module;

wherein the alternate current busbar assembly is arranged on the one side in the vertical direction relative to the capacitor module;

wherein the alternate current busbar assembly includes a plurality of alternate current bus bars for making an alternate current flow, and a holder of holding the plurality of alternate current bus bars and a fixing portion for fixing, and the alternate current busbar assembly is fixed to the cooling block by the fixing portion of the holder; and

wherein the current sensor for measuring a current flowing in the alternate current bus bar is fixed to the alternate current busbar assembly.

18. A power inverter arranged with:

a metallic chassis having a containing space at an inner portion thereof, having a lid on one side in a vertical direction, other side thereof being enclosed by a bottom, and having a fixing portion for fixing to a transmission at other portion of the other side; and

a cooling block of forming coolant paths for respectively making a coolant flow to both side portions of the inner portion of the metallic chassis, a power semiconductor module of converting a direct current power into an alternate current power, and the capacitor module for smoothing, the power inverter being arranged with;

an alternate current busbar assembly for making an alternate current flow to the one side in the vertical direction relative to the capacitor module, the power inverter being arranged with;

a current sensor for measuring a current flowing in the alternate current bus bar on the one side in the vertical direction relative to the capacitor module, and within a range interposed by the coolant paths arranged on the both side relative to an axial direction of making the coolant flow.

19. The power inverter according to claim 18, wherein the alternate current busbar assembly is arranged on the one side in the vertical direction relative to the power semiconductor module and the capacitor module;

wherein the alternate current busbar assembly is further fixed to the cooling block; and

wherein the cooling block is contained in the chassis.