Power converter module with cooled busbar arrangement. RU patent 2510604.

FIELD: electricity.

SUBSTANCE: invention relates to a power converter module with a at least one thermally active power semiconductor module (2, 4), mechanically connected to a liquid-cooled heat sink (6) and are electrically actively connected to leads of the power converter module by a busbar arrangement (8), having at least two power buses insulated from each other. The busbar arrangement (8) is connected via power and/or geometric closing with a second liquid-cooled heat sink (10). Between the top power bus of the busbar arrangement (8) and the second liquid-cooled heat sink there is a thermally active and electrically insulating layer (36). Additional power loss arising in the busbar arrangement (8) is removed through said second liquid-cooled heat sink (10), which is clamped to the surface of the busbar arrangement (8) of the power converter module using clamping elements.

EFFECT: designing a power converter module, the laminated set of buses of which allows efficient removal of heat using simple means.

10 cl, 3 dwg

The invention relates to the power of Converter module, according to the restrictive part of paragraph 1 of the claims.

Power conversion modules, in particular, high voltage, in question, are commercially available. In power conversion modules of this type are appropriate power semiconductor modules, in particular, disable power semiconductor modules, disconducive connected tires with the conclusions of the power Converter unit. This is due to the fact that used the power bus is planar and imposed one on another batch of tyres. Accordingly between two flat power tires is made of flat insulation layer. These insulating layers are for flat power bus, so you may be provided with limit values for air gap and track moving discharge (Luft-und Kriechstrecken). Thus such misconducting busbars contains at least two power bus and at least one of insulation layer. To provide the most compact tires used for power semiconductor modules of Converter module this package tire laminate. Thanks used laminating material laminated this leads has temperature border, for example, 105°C.

As in commercially available power semiconductor modules, in particular, turn off the power semiconductor modules, for example, a bipolar transistor with insulated gate (Insulated-Gate Bipolar-Transistor IGBT), constantly increasing allowable load current, it increases the current density in force tire laminated bus-power Converter unit. This leads to the square losses increase in laminated busbars, so also increases the temperature of the laminated bus. The temperature limit of this laminated bus determine the materials used for insulation layers and laminating material. Preferably currently in power conversion modules are used tires, laminated insulating foil. Here the temperature limit sets laminating material laminated bus. For target use of converters that means the capacity limit, which is not determined already used power semiconductor modules, and the maximum temperature of the corresponding laminating material busbars.

The next solution to this problem consists, on the one hand, to increase cross-section of each power bus laminated package and, on the other hand, to cool the laminated leads, for example, own convection. By improving cross-sectional power bus laminated package such busbars get not only more expensive, but also more wordy. In order laminated busbars cooling at the expense of own convection, it should be placed in power conversion device so that the flow of cooling air can flow around the laminated bus.

From the international publication WO 2005/109505 A1-known power semiconductor scheme, which leads cooled. In this power semiconductor scheme, at least one module soldered from the outside on which serves as a positive or a negative plate plate power bus. Positive or negative rail usually positioned as a top or bottom plate plate package of tyres. This top bus which is connected to the module, directly cooled cooling unit, and this cooling device is made as of air or liquid cooling. This cooling device is located in structure of type "sandwich" between top bus and lower insulation gasket another, located in parallel to the plane of the plate power bus. Further, under padding another insulating layer, there is power bus from the bottom side. These power bus form together with the cooling device is very compact layout. The elements of this package tire lamination is interconnected. As this power semiconductor scheme talking about inverter, this package tires are two capacitor DC link that bolts attached to the upper or lower power bus.

Of the patent document DE 10 2007 003 875 A1 known energy Converter module at least two power semiconductor modules, which are thermally active (thermally conductive way) mechanically connected with the cooler and through laminated package tyres are electrically connected with each other. At least one power bus laminated this package tire thermally actively connected to the cooler through at least one electrically insulating and thermally active support element. Through these supporting elements, at least one power bus laminated package tire thermally connected with the cooler. The amount of exhaust heat determines the number of thermally active support elements. Through these supporting elements laminated tyre also rely in the marginal zones. Through these thermally active support elements is limited to the amount withdrawn from the laminated tyre heat.

The objective of the invention is to offer energy Converter module, laminated package tyres which allows extraction of heat using simple tools, and this energy Converter module does not need to parse (entflechten) or re-designing.

This task is solved by the distinguishing signs of paragraph 1 of the claims. Because the second liquid cooler, thermally active, but electrically solonoise connected with power and/or flush with busbar power Converter unit, the heat can be dissipated with a large surface of these tyres. If the main surface of the second liquid cooler to be insufficient, optionally can be increased fluid flow. How good thermal connection of buses and second liquid cooler, depends on the efforts to which this second liquid cooler pressed to connecting buses. To this end, the energy Converter module according to the invention, contains at least one clamping element.

In the preferred form of carrying out power Converter unit, the second liquid coolers and liquid chiller energy Converter unit hydraulically connected. This means that the second liquid cooler fueled by liquid circuit of power Converter unit, which is also called the primary circuit. This has the advantage that the power Converter module remains its connections.

Other preferred form of exercising power Converter unit, according to the invention presented in the dependent paragraphs 4-10 claims.

For a more detailed explanation of the invention refers to a drawing that shows schematically the form of the invention.

Fig. 1 offers a preferred form of carrying out power Converter unit,

Fig. 2 represents the first form of exercise is mounted power Converter unit, according to Fig. 1, and

Fig. 3 shows partially the second form of implementation of hook item power Converter unit, according to Fig. 1.

In Fig. 1, which is the front view power Converter unit, according to the invention, items 2 and 4 are marked accordingly power semiconductor modules, in particular, disable power semiconductor modules, for example, bipolar transistor with insulated gate (IGBT), position 6 - liquid cooler, a position 8 - busbars, item 10 - second liquid cooling, item 12 - bracket, items 14 and 16, respectively protracted and bolt position 18 - supporting elements. In addition, in this image items 20 and 22 designated device inlet and outlet coolant.

Both power semiconductor module 2 and 4 mechanical rezhimno connected with liquid cooler 6. Busbars 8, which, in particular, laminated, may contain two power bus for example, one positive power bus and one load power bus, or one-load power bus and one negative power bus, or three power bus, for example, positive, stress and negative power bus. The number of power bus bus-8 depends on the electrical connection of both power semiconductor modules 2 and 4. When these two power semiconductor modules 2 and 4 are electrically connected in parallel, this leads 8 contains only two power bus. If, on the contrary, these two power semiconductor modules 2 and 4 electrically connected in series and form a phase Converter module, this leads 8 contains three power bus. If the Converter module is used as a phase module, then three power bus provided busbars 8 are positive, stress and negative power bus. These power bus are located one above another, and respectively between the two power tyres is the insulating layer, and in particular they are sealed.

This leads 8 are joined with the electrical conclusions of each of the power semiconductor modules 2 and 4, with both the power semiconductor modules 2 and 4 depict accordingly, only one electric outlet 24 1 1 and 26 . These electric conclusions 24 1 and 26 may 1 be a contact pins for soldering or screw-bolts. Starting from a certain power power semiconductor module 2, 4, power semiconductor modules of 2, 4 are as electrical terminals 24 and 26 only the threaded bolts. In accordance with the connection of both power semiconductor modules of 2, 4, their conclusions 24, 26 electrically actively connected respectively with one specific power bus bus-8. This leads 8 relies not only on the conclusions of 24, 26 power semiconductor modules of 2, 4, but also on a set of reference items 18. They are located along one of the longitudinal sides of the power Converter unit.

Because as the cooler this energy Converter module provides a liquid cooler 6, it enables the device supply 20 coolant and removal device 22 coolant. Through these devices supply and removal 20 and 22 of coolant in energy Converter module is hydraulically connected with the fluid circuit. As the coolant can be used any liquid, preferably water mixed with glycol.

Because it is constantly increasing allowable load current used in power conversion module power semiconductor modules of 2, 4, it increases the current in the power of the tyres of the bus-8. This leads to the square losses increase in busbars 8. As a consequence, increases the temperature in the busbars 8. How high could be the limiting temperature on the busbars 8, depends on the insulation material. This means that in laminated busbars 8 temperature limit sets laminating material of this bus-8. For target use of converters that means the capacity limit, which is not defined already used power semiconductor modules and specific limit temperature of the insulation material.

To take arising in busbars 8 power loss, this leads 8 comes with a second liquid chiller 10. Device inlet and outlet 28 and 30 of this second liquid cooler through the connecting sleeves 32 and 34, respectively connected with hydraulic cooling environment with fluid circuit liquid cooler 6. Liquid loop liquid cooler 6 designated as the primary circuit, and liquid loop second liquid cooler 10 - as the secondary circuit. Primary and secondary circuits can be hydraulically connected in parallel or in series. This second liquid chiller 10 in contrast image can cover approximately entire surface of the bus-8. To this second liquid chiller 10 electrically isolate from the bus-8, provides an insulating layer 36, which should be, however, good thermal conductivity. The insulation layer 36 in the simplest variant can be made by heat-conducting paste. To heat transfer has been effective, the second liquid chiller 10 connected to the bus with 8 power and/or flush.

For making connections to bus 8 with power and/or flush, you must have at least one clamping element. If there are multiple clamping elements, they come with the distribution in the longitudinal direction of the second liquid cooler 10. In depicts the form of realization as the clamping element is provided bracket 12 (Fig. 2) with two long screws 14 and 16. This bracket Fig. 2 has done according to the size of the second liquid cooler deepening 38. To adjust the pressures of the second liquid cooler 10 on the bus-bar 8, bracket 12 has at least two clamping element 40. Due to turn these clamping elements 40 increases the pressure on the second liquid chiller 10 and at the same time, on the corresponding surface of the bus-8.

Alternative forms of implementation of the clamping elements is a spring leaf or a bracket 42 with elastic intermediate part (Fig. 3). Bracket with 12 Fig. 2, besides the deepening of 38 for the second liquid cooler 10, has another deepening 46, so as to fit it in the form of a laminated surface of the bus-8. If bracket 12 are not used for more pressing items 40, deepening 38 should be made so that when it is mounted bracket 12 were paid a certain pressures along the second liquid cooler 10. According to the form of realization bracket with 42 Fig. 3, this bracket is in the middle of elastic intermediate element 44, which in assembled condition bracket 42 exerts pressures on the second liquid chiller 10.

1. Energy Converter module at least one power semiconductor modules (2, 4), thermally actively connected mechanically with liquid cooler (6) and by bus (8)that contain at least two separate one from another power bus is electrically active connection with the conclusions of the power Converter unit, wherein the busbars (8) connected with power and/or flush with the second liquid cooler (10), while between the upper power bus bus (8) and the second liquid cooler is thermally active and electrically insulating layer (36).

2. Energy Converter module according to claim 1, wherein the connection for the power and/or flush between the wheels (8) and second liquid cooler (10) has at least one clamping element.

3. Energy Converter module according to claim 1 or 2, wherein the second liquid cooler (10) hydraulically connected with liquid cooler (6).

4. Energy Converter module according to claim 1, wherein the second liquid cooler (10) the surface covers at least approximately the greater part of the surface of the bus (8).

5. Energy Converter module according to claim 2, characterized in that, as the clamping element is provided spring sheet with two long screws (14, 16).

6. Energy Converter module according to claim 2, characterized in that, as the clamping element is provided executed flush bracket (12) with two long screws (14, 16).

7. Energy Converter module of claim 6, wherein is made with a positive locking bracket (12) in the zone of the second liquid cooler (10) equipped with a flexible item (44).

8. Energy Converter module according to claim 1, characterized in that the insulation layer (36) made with thermally active front-end materials.

9. Energy Converter module according to claim 1, characterized in that the insulation layer (36) made with thermally active and interface electrically insulating materials.

10. Energy Converter module according to claim 1, characterized in that isolated power bus a bus (8) and insulation (36) laminated to each other.