Patent Publication Number: US-6909607-B2

Title: Thermally matched fluid cooled power converter

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application claims the benefit of U.S. Provisional Application No. 60/349,259, filed Jan. 16, 2002. 

   GOVERNMENT LICENSE RIGHTS 
   This invention was made with Government support under Cooperative Agreement No. DE-FC02-99EE50571 awarded by the Department of Energy. The Government has certain rights in this invention. 

   BACKGROUND OF THE INVENTION 
   The present technique relates to power electronic devices and their incorporation into modules and systems. More particularly, the technique relates to the configuration, packaging and thermal matching within of power electronic devices and supports within modular power converters. 
   A wide array of applications are known for power electronic devices, such as power switches, transistors, and the like. For example, in industrial applications, silicon controlled rectifiers (SCRs), insulated gate bipolar transistors (IGBTs), field effect transistors (FETs), and so forth are used to provide power to loads. In certain applications, for example, arrays of power switches are employed to convert direct current power to alternating current waveforms for application to loads. Such applications include motor drives. However, many more applications exist for inverter circuitry and other circuitry incorporating such devices. Other settings include electric vehicle applications grid tie inverters, DC to DC converters, AC to AC power Converters, and many other solid state power conversion elements that require a packaged power device switch topology. In electric vehicles, a source of direct current is typically available from a battery or power supply system incorporating a battery or other direct or rotating energy converter. Power electronic devices are employed to convert this power to alternating current waveforms for driving one or more electric motors. The motors serve to drive power transmission elements to propel the vehicle. While numerous constraints exist in such settings which differ from those of industrial settings, numerous problems and difficulties are shared in all such applications. 
   Demands made on power electronic devices typically include their reliability, power output, size and weight limits, and requirements regarding the environmental conditions under which they must operate. Where size and weight constraints force reductions in the packaging dimensions, difficulties arise in appropriately placing the power electronic devices, and drive and control circuitry associated with the devices to sufficiently remove heat generated during their operation. Where size, cost and weight are less important, large heat sinks and heat dissipation devices may be employed utilizing any fluid that can be accommodated by choice of materials that are compatible. However, as packaging sizes are reduced, more efficient and effective techniques are needed. Electrical and electronic constraints also impose difficulties on package design. For example, reduction of inductance in the circuits and circuit layout is commonly a goal, while solutions for reducing inductance may be difficult to realize. Shielding from electromagnetic interference originating both within the package and outside the package may be important, depending upon the surrounding environment. Similarly, appropriate interfacing with external circuitry, and the facility to install, service and replace power electronics packages may be important in certain applications. It has typically been necessary in many instances to configure the power electronic element to match closely the specific needs of the application and by doing so meet cost, size, performance targets that can be achieved by no other means. Finally, certain environments, such as vehicle environments, impose a wide range of difficult operating conditions, including large temperature spans, vibration and shock loading, and so forth. 
   A particular problem arising in power electronics circuitry, and particularly in converting circuitry arises from differential thermal expansion and contraction between various circuit components. Because extremes in environmental and enclosure temperatures, significantly different rates of expansion and contraction may arise within the power electronics circuits and within supporting structures. In such circumstances, delamination, deterioration, and malfunction can arise due to repeated thermal cycles and the consequent expansion and contraction. A particular challenge arises in cooling such circuitry, while preventing the degradation of the packaging and circuitry due to the thermal expansion and contraction. 
   There is a need, therefore, for improved techniques in packaging of power electronic devices. There is a particular need for techniques which offer good thermal management while addressing the issue of differential thermal expansion and contraction. 
   SUMMARY OF THE INVENTION 
   The present technique provides power electronics modules designed to respond to such needs. The technique makes use of novel packaging, thermal management, interconnect, and grounding shielding approaches which both improve performance, and offer smaller, lighter and more efficient configurations of the power electronic devices and their drive circuitry. The technique offers multiple facets for such packaging and thermal management which can be adapted to a variety of settings, including industrial power electronics applications, vehicular applications, and so forth. Many of the embodiments of the present technique permit utilization of standardized cells designed to be reconfigured into a number of optimum configurations matching key application requirements. 
   The features of the technique offer modular packaging, such as around a thermal management system, generally including a thermal support and thermal matching between circuitry and the support, and within the circuitry (i.e. between component layers). Power electronic devices may be mounted directly to the support for removal of heat. The arrangement of the devices, and their interconnection with incoming and outgoing power conductors may vary, and may make use of the thermal support for extraction of heat and for mounting of various components. A number of improved power device assemblies, their attachment means to the thermal support are accommodated with the scope of the present technique. 
   In an exemplary embodiment, and modular power converter is featured, although other types of power electronic circuitry may be adapted in the package. Incoming power conductors interface with the converter circuitry, which converts the incoming power to desired output power, such as alternating current waveforms. The incoming and outgoing power conductor configurations and arrangements may facilitate installation of the module into enclosures or vehicular mounting spaces, with plug-in connections being offered for both power and control. Coolant may be routed through the thermal support via additional connections. Exemplary coolant configurations are envisaged that effectively extract heat by close and thermally matched mounting of power electronics and other electronic devices immediately adjacent to heat removal surfaces. Locations, positioning and interconnection of control, drive, and power electronic circuitry facilitate close packaging of these elements. Shielding from electromagnetic interference may be facilitated through the use of the thermal support and, where desired, additional external shielding and closures. Optimum power device temperature regulation means may be accommodated in the intrinsic features of the thermal support such that they work in close harmony with electrical power switching elements or other circuitry and their thermomechanical attachment to both the inputs, outputs and the thermal system. 
   The present technique offers a wide range of improvements in power electronics packaging and management. The improvements reside both in the particular configuration of the packages, the configuration of the package components and the interrelationship and layout of the components, their interfaces, and their operational interdependence. The technique also offers more effective shielding from EMI/RFI. Moreover, better high frequency grounds may be achieved by low inductance connection means integrated into the thermal support. Connections may be cooled by means of integrated bus structure in contact with electrically insulating but thermally conductive features in or integrated with the thermal support and coolant circulating system. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The foregoing and other advantages and features of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which: 
       FIG. 1  is a diagrammatical representation of a power electronics module in accordance with certain aspects of the present technique; 
       FIG. 2  is a diagrammatical representation of a variation of the module of  FIG. 1  including additional circuitry supported on a thermal base; 
       FIG. 3  is a further diagrammatical representation of a power electronics module having power electronic devices mounted to two sides of a thermal base; 
       FIG. 4  is a diagrammatical representation of a power electronics module having multiple thermal bases; 
       FIG. 5  is a block diagram of certain functional circuitry in an exemplary application of a power electronics module in accordance with aspects of the present technique for a vehicle drive; 
       FIG. 6  is a diagram of a power electronics module in accordance with aspects of the present technique employed in an enclosure, such as in a vehicle or industrial setting; 
       FIGS. 7A and 7B  are block diagrams of functional circuitry which may be supported in a package in accordance with the present techniques, including an inverter drive and a converter drive; 
       FIG. 8  is an exploded perspective view of an exemplary power electronics module and its associated packaging components; 
       FIG. 9  is a perspective view of the external interfaces of an exemplary package module of the type illustrated in  FIG. 8 , with slightly different interface connections; 
       FIG. 10  is a perspective view of the package module of  FIG. 9  illustrating additional interfaces on a rear side of the module package; 
       FIG. 11  is a perspective view of the package of  FIG. 10  with a housing cover removed to display internal arrangements of power electronics and associated circuitry and components; 
       FIG. 12  is a perspective view of the internal power module as shown in  FIG. 11  with the module removed from the base housing; 
       FIG. 13  is an exploded perspective view of the arrangement of  FIG. 12  with control and drive circuitry removed; 
       FIG. 14  is a perspective view of a thermal base and power electronics substrate and device subassembly of the type employed in the arrangement of  FIG. 13 ; 
       FIGS. 15A-15R  are diagrammatical detail views of exemplary arrangements for mounting and removal of heat from the power electronics substrate and thermal base; 
       FIG. 16  is an exploded perspective view of one arrangement for providing a switch frame on a thermal base where the switch frame is removable from the base; 
       FIG. 17  is a perspective view of a substrate for use with a thermal base and illustrating an exemplary layout of power electronics device subassemblies on the substrate; 
       FIG. 18  is an exploded perspective view of one of the exemplary device subassemblies shown in  FIG. 17 and a  preferred manner of forming the device subassembly on the substrate; 
       FIGS. 19A and 19B  are perspective view of an exemplary terminal strip employed with a thermal base for routing incoming and outgoing power to power electronic devices and their associated circuitry; 
       FIG. 20  is a diagrammatical representation of a preferred layout of terminals and conductors in a terminal strip of the type illustrated in  FIG. 19 ; 
       FIG. 21  is a circuit diagram illustrating the signal flow offered through the layout of  FIG. 20 ; 
       FIGS. 22A-22F  are diagrammatical perspective views of an exemplary power electronics module illustrating various possible routing orientations for incoming power, outgoing power, and coolant; 
       FIG. 23  is a perspective view of an exemplary connector interface for use in a power electronics module in accordance with aspects of the present technique; 
       FIG. 24  is a perspective view of an alternative connector interface arrangement designed to achieve various orientations of the type illustrated in  FIG. 22 ; 
       FIG. 25  is a perspective view of an alternative configuration for power electronics module wherein a canister is provided for mounting and shielding of the module components; 
       FIG. 26  is a perspective view of the elements of  FIG. 25  after mounting an assembly; 
       FIGS. 27A-27D  are diagrammatical representations of alternative terminal and terminal assembly connection arrangements for use in a module in accordance with the present technique; 
       FIGS. 28A-28D  are diagrammatical representations of alternative terminal and terminal assembly cooling arrangements for use in a module in accordance with the present technique; 
       FIGS. 29A and 29B  are diagrammatical representations of alternative terminal and plug configurations for EMI shielding and grounding for a module in accordance with the present technique; 
       FIGS. 30A-30C  are diagrammatical representations of alternative power electronics substrate mounting arrangements for interfacing with heat removal structures in the module; 
       FIG. 31A  is a diagrammatical prospective view of an alternative power and control low inductance shield and ground arrangement for use in the module, while  FIG. 31B  is an exploded perspective view of an exemplary implementation of such an arrangement; 
       FIG. 32A  is a diagrammatical elevational view of an alternative plug-in module arrangement based upon the modules such as those illustrated in the previous Figures, while  FIG. 32B  is a perspective view of an exemplary implementation of the plug-in module arrangement; 
       FIG. 33  is a further alternative plug-in arrangement incorporating such modules; 
       FIG. 34  is a diagrammatical representation of a module of the type illustrated in the previous Figures incorporating flow control circuitry for regulating the flow of coolant into and from the module; 
       FIGS. 35A-35C  are diagrammatical views of circuits and physical layouts of components for a converter arrangement employing aspects of the present technique; 
       FIGS. 36A-36C  are diagrammatical views of circuits and physical layouts of components for a matrix switch topology implementation of aspects of the present technique; 
       FIG. 37  is a further diagrammatical view of a circuit in accordance with the passing technique adapted for supply of power for a mid-frequency welding application; and 
       FIGS. 38A and 38B  are exemplary configurations of modules adapted for cooling of circuitry through indirect conduction to the thermal support. 
   

   DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS 
   Before detailing specific embodiments of the inventive technique as presently contemplated, certain definitional notes are in order. Firstly, reference is made in the present disclosure to power devices and subassemblies incorporating such devices. Such devices may include a range of components, such as power electronic switches (e.g. IGBTs, FETs) of various power ratings. The devices may also include gate driver circuitry for such components, sensing and monitoring circuitry, protection circuitry, filtering circuitry, and so forth. The devices may be provided in the subassemblies in various groupings, both integrally and separate from supporting substrates and/or thermal expansion coefficient members and heat transfer elements. Reference is also made herein to energy storage and conditioning circuitry. Such circuitry may vary in composition depending upon the particular configuration of the associated power electronic devices and circuits. For example, in inverter drive applications as discussed below, the energy storage and conditioning circuitry may include one or more capacitors, capacitor/inductor circuits or networks. Filtering circuitry may also be included for signal conditioning. In other applications, such as medium frequency welding, the energy storage and conditioning circuitry may include one or more transformers. Finally, while reference is made herein to a thermal support used in conjunction with power devices and other circuitry, various configurations and functions may be attributed to the support. For example, as described below, the support may provide both mechanical and electrical support for the various components, as well as offer integrated and highly efficient cooling of some or all of the components. Moreover, the support may provide electrical and shielding functions, such as for EMI and RFI shielding both of external fields that may affect the components as well as fields that may be generated by the components during operation. Thermal regulating components and circuits may also be incorporated into or associated with the support. 
   Turning now to the drawings, and referring first to  FIG. 1 , an exemplary power electronics module  10  is illustrated. Module  10  includes a thermal support  12  on which power electronic circuit  14  is disposed. As described in greater detail below, thermal support  12  may include a range of thermal management features, such as porting for routing of coolant for extracting heat from circuit  14 . Similarly, circuit  14  may include a wide range of functional circuitry, such as inverter circuitry, converter circuitry, and so forth which is mounted on support  12  for mechanical and electrical support, improved EMI/RFI shielding and high frequency grounding, as well as for extraction of heat generated during its operation. In the embodiment of  FIG. 1 , module  10  further includes control and driver circuitry, designated generally by reference numeral  16 . Incoming power, as indicated by arrow  18  is applied to circuitry  14  and outgoing power  20  is routed from the circuitry to external devices (not shown). Similarly, in the diagrammatical representation of  FIG. 1 , coolant  22  is applied to the thermal support  12  to extract heat from the power electronic circuit  14  and from the thermal support, as well as from the control and driver circuitry  16 . Outgoing coolant  24  is routed from the thermal support to carry heat away to a cooling system (not shown). In the embodiment of  FIG. 1 , both the power electronic circuit  14  and the control and driver circuitry  16  are mounted on a side  26  of the thermal support  12 . Both incoming and outgoing power are routed to the circuitry at an edge  28  of the thermal support. Finally, interconnections  32  are provided between the control and driver circuitry  16  and the power electronic circuit  14  for control of operation of the circuitry as described more fully below. 
     FIG. 2  illustrates an exemplary alternative configuration of a power module  10  in which components are mounted on both sides of the thermal support. In the embodiment of  FIG. 2 , power electronic circuit  14  is again mounted to side  26  of the thermal support  12 . In the embodiment of  FIG. 2 , however, driver circuitry  34  for controlling functioning of the power electronic circuit is mounted to the same side  26  of the thermal support, while control circuitry  36  is separated from the driver circuitry. Energy storage and conditioning circuitry, as indicated generally at reference numeral  38 , is also mounted on the thermal base. As before, interconnections  32  between driver circuitry  34  and power electronic circuit  14  are provided, as are similar connections  40  between the control circuitry and the driver circuitry, and interconnections  42  between the power electronic circuit  14  and the energy storage and conditioning circuitry  38 . As will be noted, in the embodiment of  FIG. 2 , the geometry, layout and space utilization of the thermal support are adapted such that the control circuitry  36  and the energy storage and conditioning circuitry  38  are mounted on a lower side  44  of the thermal support  12 . All such components may therefore be mechanically and electrically supported on the thermal support, while receiving cooling via coolant flow as indicated by arrows  22  and  24 . 
     FIG. 3  illustrates a further exemplary configuration of a module  10  wherein power electronic circuits are mounted on both sides of the thermal support. Thus, as shown in  FIG. 3 , a thermal support  12  serves for mechanical and electrical mounting of both power electronic circuit  14 , and control and a driver circuitry  16  with the necessary interconnections  32  being provided between these circuits. A second power electronic circuit  46 , and second control and driver circuitry  48  are provided on the opposite side of the thermal support  12  thus making the use of the cooling fluid nearly significantly more effective as it would be with only one side of the heat exchanger used for active cooling. Thus, heat may be extracted from both power electronic circuits bus work, input output terminals, energy storage elements and support electronics by virtue of coolant flow through or around the thermal support. 
     FIG. 4  illustrates a further exemplary configuration of a module  10 . In the exemplary configuration of  FIG. 4 , power electronic circuit  14  is again mounted to a side of the thermal support  16  along with control and driver circuitry  16 . Energy storage and conditioning circuitry  38  is mounted on an opposite side of the thermal support. In this alternative configuration, a second thermal support  50  is secured to the first thermal support  12 , and itself supports additional energy storage and conditioning circuitry  38 . As will be appreciated by those skilled in the art, the particular circuitry supported on the one or more additional thermal supports may vary depending upon the system needs. Accordingly, capacitor circuitry, power electronic circuitry, driver circuitry, control circuitry, energy storage components, inductors, filters, braking resistors, and so forth, or any other ancillary circuitry may be provided on the additional thermal support. Moreover, in the embodiment of  FIG. 4 , coolant is routed separately to the second thermal support  50 . A modular system of stacking interconnect, thermal connection, and support features may be provided such that thermal base, power terminal assemblies can interconnect in parallel and series combinations to form larger and differently rated power converters using the core thermal-electrical base described. Depending upon thermal management needs and available plumbing, however, coolant could be routed to one of the thermal supports alone, or coolant could be routed internally between the thermal supports. Similarly, interconnection  52  made between the energy storage and conditioning circuitry  38  of  FIG. 4  could include a range of interconnections between functional circuitry, including power electronic circuits, and their associated drive and control circuits. 
   The exemplary configurations of  FIGS. 1-4  can be adapted to support a wide range of functional power electronic circuits.  FIGS. 5 and 6  illustrate exemplary applications of the power electronics modules. In the illustration of  FIG. 5 , a vehicle drive  54  is provided, such as a drive for an automobile or other mobile application. The vehicle drive  54 , which may include the functional circuits of  FIG. 5  as well as a wide array of additional support, control, feedback and other interrelated components, will generally include a power supply  56  which provides the power needed for driving the vehicle. In a typical application the power supply  56  may include one or more batteries, generators or alternators, fuel cells, utility source, alternators, voltage regulators, and so forth. Power supply  56  applies power, typically in the form of direct current via direct current conductors  58  to the power electronics module  10 . Control circuitry  60  provides control signals for regulating operation of the power electronics module, such as for speed control, torque control, acceleration, braking, and so forth. Based upon such control signals, power electronics module  10  outputs alternating current waveforms along output conductors, as indicated generally at reference numeral  20  in FIG.  5 . The output power is then applied to a vehicle drive train as indicated generally at reference numeral  62 . As will appreciated by those skilled in the art, such drive trains will typically include one or more alternating current electric motors which are driven in rotation based upon the frequency and power levels of the signals applied by the power electronics module  10 . The vehicle drive train may also include power transmission elements, shafts, gear trains, and the like, ultimately designed to drive one or more output shafts  64  in rotation. Sensor circuitry  66  is provided for sensing operating characteristics of both the vehicle, the drive train, and the power electronics module. The sensor circuitry  66  typically collects such signals and applies them to the control circuitry, such as for regulation of speeds, torques, power levels, temperatures, flow rates of coolants, and the like. 
     FIG. 6  illustrates a further application of a power electronics module  10  in an industrial or mobile setting. In an industrial setting, the power electronics module  10  may be applied for application of power to various loads, such as electric motors, drives, valving, actuators, and so forth. In the system, designated generally by reference numeral  68 , an enclosure  70  is provided that may be divided into bays  72 . Within each bay various components are mounted and interconnected for regulating operation of processes, such as manufacturing, material handling, chemical processes, and the like. The components, designated generally by reference numeral  74 , are mounted within the bays and receive power via an alternating current bus  76 . A control network  78  applies control signals for regulating operation of the components  74  and of the power electronics module  10 . An enclosure, such as enclosure  70  may be included in various industrial settings, such as in motor control centers, assembly line or process controls, and so forth. However, such enclosures may also be provided in a vehicular setting, such as for driving one or more drive trains of an automobile, utility vehicle, transport or other vehicle. 
   As mentioned above, various circuit configurations may be designed into the power electronics module. The circuit configurations will vary widely depending upon the particular requirements of each individual application. However, certain exemplary circuit configurations are presently envisaged, both of which include power electronic devices which require robust and compact packaging along with thermal management. Two such exemplary circuits are illustrated in  FIGS. 7A and 7B . In  FIG. 7A , the circuitry includes a rectifier circuit  80  which converts alternating current power from a bus  76  to direct current power for output along a DC bus, corresponding to incoming power lines  18 . An inverter circuit  82  receives the direct current power and converts the direct current power to alternating current waveforms at desired frequencies and amplitudes. The alternating current power may then be applied to a load via the outgoing conductors  20 . Filter and storage circuitry  84  may be coupled across the direct current bus to smooth and condition the power applied to the bus. A control circuit  86  regulates operation of the rectifier and inverter circuits. In the example of  FIG. 7B , a direct and/or matrix converter  90  includes a set of AC switching power devices per phase of power controlled. Inverter  90  receives incoming alternating current power and supplies an outgoing waveform to power switches  88 . The set of AC switches effectively convert fixed frequency incoming power  18  to controlled frequency outgoing power  20  for application to a load. The arrangement of  FIG. 7B  is illustrated in greater detail in FIG.  36 C. It should be borne in mind, however, that the particular circuitry of  FIGS. 7A and 7B  are exemplary only, and any range of power electronic circuits may be adapted for incorporation into a module in accordance with the present techniques. 
     FIG. 8  illustrates an exemplary physical configuration for a power electronics module  10 . In the embodiment of  FIG. 8 , a circuit assembly  92  is positioned within a housing  94  and enclosed within the housing by a cover  96  fitted to the housing. Circuit assembly  92  includes the components described above, and in the particular embodiment illustrated corresponds generally to the configuration of FIG.  2 . As illustrated, thus, the circuit assembly  92  includes a thermal support  12  on which power electronic circuit  14  is disposed. Control and driver circuitry are also disposed on the thermal support for regulating operation of the power electronic circuit with cooling of such circuitry. In the embodiment of  FIG. 8 , the module is particularly configured for operating as an inverter drive for a vehicle application. Incoming direct current power is received via conductors  18 , and converted to three-phase waveforms output via conductors  20 . 
   In the embodiment of  FIG. 8 , housing  94  presents a control interface  98  which is designed to permit control signals to be received within and transmitted from the housing. As described in greater detail below, the control interface may be provided on a bottom side of the housing as illustrated in  FIG. 8 , or at other positions on the housing. A power interface, designated generally by reference numeral  100  in  FIG. 8 , is provided for transmitting power to and from the circuit assembly  92 . As described below, various configurations can be provided and are presently envisaged for interfacing the module  10  with external circuitry. In the embodiment of  FIG. 8 , for example, the power interface  100  permits five conductors two direct current conductors and three alternating conductors, to be directly interfaced from the circuit assembly, such as in a plug-in arrangement. In addition to the control and power interfaces, a coolant interface  102  is provided for receiving and circulating coolant as described more fully below. In present embodiments, the coolant interface may include tubes or specialized fittings adapted to receive conduits for channeling fluid to and from the module. It should be noted, however, that where appropriate, liquids, gases, compressed gases, and any other suitable cooling media may be employed in the present technique. Thus, while in vehicle applications the combination of water and conventional vehicle coolant may be used, other specialized or readily available cooling media may be employed. 
   In the embodiment of  FIG. 8 , housing  94  forms a metallic shell, such as of aluminum, which is cast to provide shielding of EMI, both generated by the module circuitry and which may be present in the environment of the module. Cover  96  is made of a similar material to provide shielding on all sides of the module. As described below, connector interfaces may also provide additional shielding, and are particularly useful in applications where high frequency waveforms are generated by the power electronic components, such as inverter drives. Where appropriate, other types of housings and supports may be employed. For example, where sufficient EMI shielding is provided, or where EMI transmissions are sufficiently reduced by proximity of the power electronic components to the thermal support, plastic housings, doped plastic housings, and the like may be employed. 
   In the illustrated embodiment, housing  94  includes a cavity  104  in which circuit assembly  92  is disposed. Conductors  106  transmit DC power to the circuit assembly  92 , while conductors  108  transmit the AC waveforms from the circuit assembly  92  for application to a load. An interface plate  110  is provided through which conductors  106  and  108  extend. Where desired, sensors may be incorporated into the assembly, such as current sensors  112  which are aligned about two of the outgoing power conductors  108  to provide feedback regarding currents output by the module. As will be appreciated by those skilled in the art, other types and numbers of sensors may be employed, and may be incorporated both within the housing, within a connector assembly, or within the circuit assembly itself. 
   As described more fully below, thermal support  12  may incorporate a variety of features designed to improve support, both mechanical and electrical, for the various components mounted thereon. Certain of these features may be incorporated directly into the thermal support, or may be added, as is the case of the embodiment of FIG.  8 . As shown in  FIG. 8 , a frame  114 , made of a non-metallic material in this embodiment, is fitted to the thermal support  12 , and components mounted to the thermal support are at least partially surrounded by the frame. The frame serves both as an interface for conductors  106  and  108 , and for surrounding circuitry supported on thermal support  12  to receive an insulating or potting medium. In the embodiment of  FIG. 8  terminals  116  are formed on frame  114 , and may be embedded within the frame during molding of the frame from an insulative material. A preferred configuration for the terminals is described more fully below. Separators  118  partially surround terminals  116  for isolating the conductors coupled to the terminals from one another. 
   An alternative configuration for the housing  94  and cover  96  of the module is illustrated in  FIGS. 9 and 10 . As shown in  FIG. 9 , the housing may provide for interfaces for power conductors at different locations, such as along topside as illustrated in  FIG. 9  for incoming power, and along an edge for outgoing power. Accordingly, an incoming power interface  120  may be specifically adapted to provide connections to conductors  106 , such as from a DC power source. An outgoing power interface  122  may provide similar connections for conductors  108  used to transmit controlled AC waveforms to a load. As will appreciated, the interfaces may be provided either in the housing itself or in the cover, or both. The coolant interface  102  may be similarly provided at various locations about the housing and cover, such as along an edge as shown in FIG.  9 . 
     FIG. 10  is a rear prospective or the arrangement of FIG.  9 . As shown in  FIG. 10 , the control interface  98  may be available from various locations on the housing and cover. In the embodiment of  FIG. 10  a multi-pin connector  124  is provided for receiving a control cable. Pin designations for the connection may follow any suitable protocol, and in a present embodiment may include pins designated for transmission to an RS232 or other serial or parallel data transmission port. Once closed, the housing and cover may define a water-tight, EMI-shielded package within which the circuit assembly is positioned. Moreover, the packaging may include any suitable handles, tool geometries, and the like for plugging the module into an application, or for otherwise supporting the module in an application. For example, where a handle (not shown) is provided on the package, the handle may be grasped by a user to simply plug the module into a mating interface, such as within a vehicle or enclosure. 
     FIG. 11  illustrates certain internal configurations of the embodiment of  FIGS. 9 and 10  with cover  96  removed. As shown in  FIG. 11 , the module  10  comprises the housing  94  in which the circuit assembly  92  is disposed. Conductors  108 , separated by an interface plate  110  from the surrounding environment, are available for connection within power interface  122 . A similar power interface may be provided, as illustrated in  FIG. 9 , for other power conductors. The control interface  98  is positioned on an opposite side of the housing in the embodiment of  FIG. 11 , and supports multi-pin connection  124 . 
   In the arrangement of  FIG. 11 , an integral flange  126  is formed on the thermal support  12  and extends generally upwardly from the plane of the thermal support, partially replacing the removable frame illustrated in FIG.  8 . The integral flange serves to support and interface the circuit assembly  92  within the housing (such as by mating with the cover where desired), and surrounds certain of the circuitry, such as to form a cavity  128  within which the circuitry is mounted and within which an insulating or potting medium may be disposed. Power electronic device subassemblies  130  are provided within the cavity, and form the power electronic circuits  14  as described more fully below. In the illustrated embodiment, six such device subassemblies or switching circuits are provided for defining a three-phase inverter circuit. As will be appreciated by those skilled in the art, in practice, two or more such switching circuits may be grouped on each device subassembly, or entire set of circuits may be provided in a single device subassembly. Connection pads  132  are provided adjacent to device subassemblies  130  for interfacing the device subassemblies with incoming and outgoing power conductors. In the illustrated embodiment, a terminal strip  134 , described in greater detail below, is provided at an edge of the thermal support  12 , and mates with the integral flange  126  to define the cavity within which the circuitry is disposed and within which a potting medium may be placed. The terminal strip may include molded-end features, including the connection pads  132 , as well as terminals and conductors as described below. 
   Within the housing, various other features may facilitate interconnections between the various circuits and components. For example, in the illustrated embodiment sensor cabling  136  is provided for receiving signals from current sensors  112 . Such signals may be routed, via the cabling  136  around the housing to drive circuitry  34  or control circuitry  36 , so as to monitor operating conditions of the power electronic circuitry. Other types of sensors and placements of such sensors, along with signal transmission cabling may, of course, be incorporated in the arrangement. 
     FIG. 12  illustrates the circuit assembly  92  of  FIG. 11  removed from housing  94 . Again, in the illustrated embodiment the thermal support  12  is provided with an integral flange  26  which partially surrounds the power electronic circuit  14 . In the illustrated embodiment, the driver circuitry  34  for the device subassemblies  130  is also provided within the cavity defined by flange  126 . The driver circuitry  34  and the control circuitry  36  may be provided on a single printed circuit board or on two or more boards, and may define a single-sided board component arrangement or double sided arrangement. Where a double-sided board is provided, spacers, standoffs, or similar arrangements may be provided for insuring that an insulating or potting material may be provided between the board and the thermal support. 
   Returning to  FIG. 11 , to provide the desired sealing, a peripheral edge  138  may be provided on the housing and cover, with a groove  140 , or other interface feature, provided for receiving a seal, a sealing compound or the like. As shown in both  FIGS. 11 and 12 , while one or more of the circuits may be provided on a top or bottom side of the thermal support as described above, in the present embodiment, a rear board support  142  is provided as an integral feature of the thermal support  12 . Thus, the control circuitry  36  may be supported on the rear board support  142  and interfaced directly with the driver circuitry via interconnections  40 . These features of the present arrangement are best illustrated in  FIG. 13 , where the drive circuitry  34  and control circuitry  36  have been exploded from the thermal support to illustrate the manner in which they may be disposed and interconnected along with cabling  136  from sensors  112 . As also shown in  FIG. 13 , housings  144  may be incorporated in the design, such as to support sensors  112 . 
   A variety of interface configurations may be envisaged for mounting the various components on the thermal support  12 . In the embodiment illustrated in  FIG. 13 , for example, an energy storage and conditioning circuitry package  38  is enclosed in a housing  146  which is mounted directly to a lower side of the thermal support  12 . Capacitors within the housing  146  are interconnected with the power electronic circuitry as described more fully below. As also shown in  FIG. 13 , an interface plate  148  is secured to the thermal support  12  and the power electronic device subassemblies  130  are disposed directly on the interface plate  148 . Thus, in accordance with aspects of the present technique, the device subassemblies may be formed directly on and processed on the interface plate  148  which is later secured to the thermal support  12 . Special processing, therefore, of the components making up device subassemblies  130  is facilitated by separately processing the device subassemblies and interface plate  148 , and later assembling the interface plate with the thermal support.  FIG. 13  also shows an exemplary connection sensor  113  coupled to cabling  136  for detecting whether appropriate connections have been made to the module (e.g., to prevent operation until such connections are completed), as described below. 
   As illustrated in  FIG. 14 , the interface plate  148  is assembled with the thermal support  12  in a present embodiment. Various securement features or pads may be provided on the thermal support  12 , such as indicated at reference numeral  150  in FIG.  14 . The pads provide locations at which the thermal support may be secured within a housing of the type described above, or another mechanical structure. The thermal support itself is preferably made of a conductive metal, such as aluminum. The support may be formed in any suitable manner, such as by assembly, machining, or, as in a present embodiment, by casting followed by certain machining operations. The support includes features which facilitate circulation of coolant for extracting heat from the power electronic circuit  14 . In the embodiment of  FIG. 14 , these features include a trough or channel  152  formed within the thermal support. The channel extends between the coolant inlet  22  and the coolant outlet  24  for the circulation of coolant. The channel preferably extends at least along an area of the interface plate  148  to remove sufficient heat from the circuitry during operation, and may route coolant through other portions of the thermal support, such as those supporting other circuitry and components. In the illustrated embodiment, channel  152  extends beneath the interface plate  148 , adjacent to a lower surface on which the energy storage and conditioning circuitry is mounted. 
   Features are formed within channel  152  for enhancing the heat transfer from the power electronic circuit. In the embodiment of  FIG. 14 , a diversion plate  154  is secured within the channel for diverting coolant within the channel. As described in greater detail below, additional heat transfer elements, such as fins or other cooling features may also be positioned within the channel, and may be integral with or separate from the interface plate  148 . As also illustrated in  FIG. 14 , thermal support  12  may include sealing features to ensure isolation of the coolant from the circuitry mounted thereon. A peripheral channel  156  is formed in a present embodiment to receive a seal (not shown) fitted between the thermal support  12  and the interface plate  148 . The seal both promotes isolation of the coolant from the circuitry, and allows for some degree of differential thermal expansion and contraction between the interface plate  148  and the support  12 . Finally, in the illustrated embodiment, a baffle  158  is formed within channel  152  to further direct coolant through the channel for heat extraction. As will be appreciated by those skilled in the art, various alternative configurations, impingement surfaces, and flow of path-defining elements may be inserted into the thermal support to define desired thermal gradients and produce optimum patterns of turbulence and optimum transitions between turbulent and laminar flow regimes within the support adjacent to the power electronic circuit  14 . 
     FIGS. 15A-15G  illustrate certain exemplary configurations of features envisaged for removal of heat via the interface plate  148  and the thermal support  12 . As shown first in  FIG. 15A , the interface plate  148  may include integral features, such as fins  160 , small heat pipes, impingement targets, turbulators. In the present embodiment, plate  148  is made of a material dissimilar to that of which the thermal support itself is comprised. The material may be adapted to the particular electronics and the methods for processing the electronic device subassembly. In a present embodiment, plate  148  is made of aluminum silicon carbide (AlSiC). A seal  162  is positioned adjacent to the interface plate  148  and would be received within a groove of the type illustrated in FIG.  14 . Along a lower surface  164  of plate  148 , a series of fins  160  are formed, such as during a casting operation. The fins could also be added to the plate in an assembly process. The plate also presents an upper surface  166  on which the power electronic device subassemblies  130  are formed as described in greater detail below. 
   Where fins  160  extend from plate  148 , various types of fins and patterns of arrangement may be provided. As illustrated in  FIG. 15B , the fins may be formed as pins  160  which extend from the lower surface of the plate. Again, any desired form of pin may be provided, such as pins having a generally trapezoidal cross section. In the embodiment of  FIG. 15B , a straight matrix pattern  168  is provided with the pins being aligned within parallel rows and columns. As illustrated in  FIG. 15C , staggered patterns  170  may be provided in which rows or columns of pins are offset with respect to one another. Moreover, as illustrated in  FIG. 15D , pins  160  may extend from plate  148 , while additional pins or other thermal transfer features  170  may intermesh with the pins of the plate, and extend from other plates, or from the base of the channel  152  formed within the thermal support. The fins, pins, or other thermal conduction extended area enhancements may be staggered in pitch such that when assembled one on top of the other or when inserted from opposite sides of the thermal base the patterns inter-mesh to form optimum arrangement and minimum geometry that cannot be achieved effectively by a single manufactured piece. 
     FIG. 15E  illustrates an alternative configuration in which the interface plate  148  does not include integral thermal transfer features, but wherein a heat dissipation element  174  is assembled between the interface plate  148  and the base of channel  152 . In a present embodiment, element  174  may include a corrugated or bent-fin structure having a plurality of generally parallel sheet-like sections defining a large surface area for heat removal; in addition, many other extended surface enhanced configurations can be accommodated by this mechanical arrangement such as metal foams, metal matrix foams, metal polymer matrix foams, and so forth. As a further alternative configuration, as illustrated in  FIG. 15F , thermal transfer features may be formed on additional elements interfaced with the thermal support. In the example of  FIG. 15F , power electronic device subassemblies  130  are mounted to a pair of plates on either side of the thermal support. In this case, each of the interface plates includes thermal features which extend into channel  152  for heat removal. It should be noted that where 2-sided arrangements are utilized, channel  152  may define an aperture extending completely through the thermal support, or may form two separate channels with flow paths interconnecting with one another. Alternatively, two completely separate channels may be formed within the support. Finally, as noted above, various alternative flow paths may be provided within the thermal support, as illustrated generally in FIG.  15 G. Thus, owing to the form of the channel, any diversion plates and baffles, and the like within the thermal support, a flow path  178  may be defined which routes coolant in a desired path so as to establish the desired temperature gradient within the thermal support. 
     FIGS. 15H-15R  represent additional alternative flow and cooling configurations designed to extract heat from the power electronic devices during operation. As illustrated in  FIG. 15H , the thermal support  12  may include a diversion plate  154  provided with apertures  155  for directing flow. Flow may thus be directed through the diversion plate between a coolant inlet  22  and a coolant outlet  24 . As flow is directed by the diversion plate and through the apertures, it is permitted to flow adjacent to the interface plate  148 , and through or around a heat dissipation element  174  as shown in FIG.  15 I. In the alternative arrangement of  FIGS. 15J and 15K , a diversion plate  154  is again provided with a series of apertures  155 . Flow is directed through a coolant inlet  22 , around and through the diversion plate, and exits through a return channel  153 . As shown in  FIG. 15K , the arrangement may make use of a baffle  158  for defining a passageway between channel  152  and channel  153 , and for partially partitioning these channels from one another. As shown in  FIGS. 15L and 15M , in a further alternative arrangement, coolant inlet and outlets may be provided on the same side of the thermal support  12 . Apertures  155  in diversion plate  154  may provide for routing coolant upwardly into close contact with interface plate  154  for flow through or around a heat dissipation element disposed between the pair of channels  152 . In  FIGS. 15N and 15O  a diversion plate  154  is again positioned between the interface plate  148  and an internal baffle  158  to cause flow to rise up above the diversion plate and through or around a heat dissipation element. Again, flow is thus directed adjacent to the interface plate for heat removal. In the alternative of  FIGS. 15P and 15Q , apertures  155  are provided in a diversion plate  154  and direct flow from a central channel  152  upwardly and around heat dissipating fins extending from the interface plate  148  as described above. Flow is then directed downwardly and into return channels  153  on either side of the central channel  152 . Finally, as shown in  15 R, a diversion plate may be provided in a construction similar to that described above with reference to  FIGS. 15A-15E . In this embodiment, however, a baffle  158  is provided to define channels  152 . Flow is then directed from a coolant inlet  22  upwardly, around the diversion plate, and through heat dissipating elements, such as pins  160  and  172  extending from the interface plate  148  and from the diversion plate  154 , respectively. Following flow through the circuitous path defined by the pins, flow is directed downwardly into the opposite channel  152  and outwardly through the coolant outlet  24 . 
   It should be noted that the various alternative configurations described herein for routing coolant can be subject to wide variation and adaptation depending upon the heat dissipating requirements, the configuration of the thermal support, the location and disposition of the power electronic circuits, and so forth. The examples provided are intended to be exemplary only. 
   As described above, the interface plate  148  may be separately fabricated from the body of the thermal support  12 . Moreover, the thermal support  12  may incorporate a substantial number of features useful for extracting heat, mechanically mounting the various circuitry and components, establishing an electrical reference plane for the circuitry, and shielding the surrounding circuitry, at least somewhat, from stray electromagnetic interference generated by operation of the power electronic devices. The thermal support structure may be formed out of a number of materials and manners (e.g., polymers, polymer matrix composites, thermosetting materials and processes, utilizing a number of net shape, forming, discrete machining, fixture bonding, and similar Processes). The number of integrated features that the thermal base may provide may be broken into cellular elements that can be included or excluded by means of settings in the tooling of manufacture so that many power electronic designs, topologies, and configurations can be built to order from the core elements embodied in the tooling and design. Moreover, features may be formed on or added to the thermal support for receiving the interface plate  148  and for defining a volume in which an insulation or potting material may be deposited. In present embodiments, the thermal support may include a partial integral flange  126  (see, e.g., FIG.  14 ). In alternative arrangements, a frame  114  may be added to the thermal support to accomplish certain of the mounting and insulation and potting functions, as illustrated in FIG.  16 . In this embodiment also, however, the thermal support  12  is fabricated separately from the interface plate  148  to permit any special processing of the circuitry disposed on the interface plate. 
     FIG. 17  illustrates an exemplary interface plate  148  with power electronic device subassemblies  130  disposed thereon. As noted above, the interface plate forms a substrate on which the power electronic device subassemblies are disposed, and may be made of any suitable material. In a present embodiment, however, the plate is made of AlSiC. The material of which the plate is fabricated is preferably at least partially thermally matched to the materials utilized for the power electronic device subassemblies disposed thereon. Thus, while different coefficients of thermal expansion will be anticipated between the materials, these are preferably kept to a level sufficiently low to reduce stresses between the materials and to prevent or significantly limit delamination of the materials from one another during their useful life. 
   An exemplary electronic device subassembly is illustrated in FIG.  18 . As noted above, the electronic device subassembly  130  is placed directly on the interface plate  148  to promote good thermal transfer from the electronics devices to the interface plate. In the embodiment of  FIG. 18 , a bonding layer  180  is disposed on the plate  148  at a pad location corresponding to the location of the respective device subassembly  130 . A substrate  182  is then placed on the bonding layer  180 . The substrate includes pad locations for mounting the power electronic circuits and for interconnecting circuits with external circuitry. In the illustrated embodiment, the substrate  182  is a direct bond copper or direct bond aluminum substrate including pads for the electronic devices and pads for wire bonding the interconnections between the devices and the interfacing circuitry. A ceramic electrical insulating layer and a metal layer beneath the ceramic layer may be provided, but are not visible in FIG.  18 . Thus, regions of direct bond material  148  are formed directly on the substrate prior to assembly. At locations where the electronic devices are to be placed, additional bonding layers  186  are provided. Bonding layers  186  may be similar to bonding layer  180  interposed between the substrate  182  and the interface plate  148 . Where desired, sensors may be incorporated into the device subassembly, such as a temperature sensor  188  in the embodiment illustrated in FIG.  18 . The power electronic devices are then placed on the bonding layers  186 . In the illustrated example, each device subassembly  130  forms a portion of an inverter circuit, and thus includes a solid state switch assembly  190  (such as an IGBT assembly) and a fly-back diode assembly  192 . Again, interconnections between the switch assembly  190  and the diode assembly  192  are made subsequently by wire bonding. 
   The device subassembly design illustrated in  FIG. 18  provides several significant advantages. For example, a grease layer which might otherwise be employed in such arrangements is eliminated by direct bonding of the device subassembly to the interface plate  148 . The use of direct bond copper or direct bond aluminum for substrate  182  provides high voltage insulation, good thermal characteristics, and good expansion control during operation of the device. Again, the selection of the particular materials employed in the device subassembly preferably provide for reduced differential thermal expansion and contraction, at least for adjacent components of the device subassembly. Where desired, the material selections may provide for a gradient in thermal expansion and contraction coefficients to further reduce stresses. 
     FIGS. 19A and 19B  illustrate a present embodiment for a terminal strip used to channel power to and from the power electronic devices described above. The terminal strip is particularly well-suited for use with a thermal support of the type illustrated in  FIGS. 11-13 . The features of the terminal strip may, however, be incorporated into other types of structures within the device, such as the frame  114  illustrated in FIG.  16 . The terminal strip  134  includes features designed to serve as terminal or contact points for the conductors described above. The strip also provides conductive elements or straps which communicate between the power electronics circuitry and energy storage and conditioning circuitry, thereby eliminating the need for a DC bus as in conventional devices. Thus, as illustrated in  FIG. 19A , terminals  116  are provided for the outgoing power conductors (not shown in FIG.  19 A). Terminals  116  are separated from one another and from conductors for the incoming DC power by insulative separator  118 . On a back side of the terminal strip  134  a series of connection pads  132  are provided and are integral with the terminal conductors as described below. 
   As shown in  FIG. 19B , on a connection side of the terminal strip, terminals include elements designed to interface with conductors for the incoming DC power in the embodiment shown. It should be borne in mind, however, that where other power types and ratings are provided, such as for incoming and outgoing AC power as in converter circuits, the configuration of the terminal strip can be adapted accordingly. 
   The terminal strip illustrated in  FIGS. 19A and 19B  is particularly well-suited for fabrication via molding operations, being itself made of an insulative material. The various conductors and conductive elements of the terminal strip may be molded in place within the insulative material so as to be easily retained within the material for later installation and connection. As shown, in  FIG. 19B , power terminal conductors  194  are embedded within the insulative material of the terminal strip for connection to leads or conductors interfacing the terminal strip with outgoing power lines. Additional terminals  196  are provided for similar leads for coupling the terminal strip to incoming power conductors. In the embodiment illustrated in  FIG. 19B , the terminals  196  are formed as conductive straps which permit connection of the incoming power, typically direct current power in an inverter application, with elements on both sides of the thermal support as described below. In particular, because in applications requiring energy storage and conditioning circuitry conductive paths may be required between the power electronic devices and a capacitor bank, the arrangement of  FIG. 19B  permits such connections to be easily made without the need for a DC bus. Accordingly, it has been found that the arrangement reduces the incidence of parasitic inductance within the assembly. In the embodiment of  FIG. 19B , similar conductive straps  198  are provided at ends of the terminal strip to further facilitate connection to the power electronic devices as described more fully below. The molded (or net shaped) interconnects can be made of various combinations of thermally conductive but electrically insulating materials or elements. These may include but are not limited to: thermally conductive polymers, polymer combinations with direct bond copper, direct bond aluminum, ceramic metal sprayed systems, sheet electrical insulators, fluid coolant ports and passages, and so forth. By using thermally conductive polymers (which may, however be electrically insulating) for the support structure of the conductors in terminal strip  134 , a direct thermal path between the conductors  116  and  198  and the thermal support  12  allows for cooling of those conductors and interconnections with them. This provides a major cooling path for the conductors and reduces heat flow into any components connected to them. This also allows for reduced heating of the energy storage and conditioning circuitry package attached to the terminal strip, as well as any connector circuitry also attached to the terminal strip. The reduced heating, in turn, promotes greater reliability of the circuit components as well as a higher electrical rating. A further benefit of the arrangement is to reduce stress on external, interconnecting components and circuitry. 
   As shown in  FIG. 20 , the arrangement of the terminal strip of  FIGS. 19A and 19B  facilitate interconnection of the power electronic device subassemblies  130 , the energy storage and conditioning circuitry  38 , and the terminals of the device. In particular, the arrangement of  FIG. 20  provides power electronic device subassemblies  130  arranged in a row of six device subassemblies. In a typical inverter application, two such device subassemblies will be associated with each output phase so as to provide positive and negative lobes of a simulated AC waveform. In the arrangement shown, first end pads, which may be referred to as DC end pads  200 A and  200 B, are provided adjacent to each end of the terminal strip. End pads  200 A and  200 B correspond to the end pads  132  adjacent to ends of the terminal strip illustrated in FIG.  19 A. Additional pads  202 A and  202 B are provided spaced from pads  200 A and  200 B at locations corresponding to the incoming power terminals  196  (see, e.g., FIG.  19 B). Finally, pads  204 A,  204 B and  204 C are provided at locations corresponding to the outgoing power terminals  194 . Pads  200 A and  202 B, and pads  200 B and  202 A are interconnected as illustrated in  FIG. 20  so as to electrically couple the pads adjacent to ends of the terminal strip to the pads adjacent to terminals  196  as shown in FIG.  20 . These same interconnected pads are then electrically coupled to high and low sides of the energy storage and conditioning circuitry  38  as illustrated diagrammatically in FIG.  20 . The device subassemblies  130  are then electrically coupled to pads  200 A,  200 B,  202 A,  202 B,  204 A,  204 B and  204 C as illustrated in  FIG. 20  such as by wire bonding connections  206 . This wire bonding, it will be noted, effectively couples each device subassembly both with a pad electrically coupled to the energy storage and conditioning circuitry  38 , and to a pad associated with an outgoing power terminal  194 . Many alternative methods of bonding the device subassemblies to the power terminations may be envisioned in the present technique; for example: tape bonding, metal braid resistance welding, brazing, mechanical attachment, laminated thin metal tapes, soldered or brazed metal straps with intrinsic strain relief, flexible metal straps with gas tight pressure connections, and so forth. Each pair of device subassemblies then, defines a portion of the inverter circuit for each phase of outgoing power. 
     FIG. 21  illustrates diagrammatically the electrical circuit established through the terminal and interconnection arrangement of FIG.  20 . As shown in  FIG. 21 , control circuitry  36  is interconnected with driver circuitry  34  in a typical inverter drive application, such as via interconnections  40 . The driver circuitry  34 , which may be mounted on the same side of the thermal support described above as the power electronics devices forming the inverter circuit itself, is interconnected with the device subassemblies  130  via additional wire bonding  208 . Each device subassembly  130 , then, is electrically coupled to an output terminal  194  positioned at alternate locations along the terminal strip illustrated in  FIGS. 19A and 19B . The device subassemblies  130  are also electrically coupled to the incoming power terminals  196 , and circuitry  38  is similarly coupled to the terminals via the straps  98  illustrated in FIG.  19 B. Also in the example illustrated in  FIG. 21 , sensor circuitry  112  is associated with at least two of the outgoing power lines. 
   As noted above, the packaging and configuration of the module  10  may be arranged so as to permit incoming power and outgoing power to be routed in a variety of manners depending upon the arrangement of interface circuitry and components. The packaging may also permit various routing arrangements for coolant.  FIGS. 22A-22F  illustrate exemplary arrangements for such routing options. As shown in  FIG. 22A , a first configuration  210  corresponds generally to that illustrated in FIG.  8 . That is, incoming power conductors  18  are provided along an edge  28  of the module, along with outgoing power conductors  20 . Incoming coolant line  22  is provided along an adjacent edge offset from edge  28 , along with outgoing coolant line  24 . In an alternative configuration  212  shown in  FIG. 22B , the incoming power conductors  18  and outgoing power conductors  20  are again provided along edge  28 . However, coolant is supplied and returned via a manifold  222  provided along a bottom side  224  of the module. In an other alternative configuration  214  shown in  FIG. 22C , incoming power conductors  18  enter through a top side  226  of the module. Outgoing power conductors  20  are still provided along edge  28 , and coolant lines  22  and  24  are provided along edge  30 . In another configuration  228  of  FIG. 22D , incoming power lines  18  enter through edge  28 , as do outgoing power lines  20 . In this embodiment, however, coolant enters through an edge  30  of the module as indicated at line  22 , and is extracted from the module along an opposite edge at line  24 . As will be appreciated by those skilled in the art, such arrangements may be useful for establishing desired temperature gradients through the module as defined by coolant flow and the positioning of heat-generating elements within the assembly. In a further alternative configuration  218  shown in  22 E, all lines, incoming power  18 , outgoing power  20 , and coolant lines  22  and  24 , are accessed along edge  28 . Thus, arrangement  218  of  FIG. 22E  may facilitate one-sided or plug-in mounting of the module. As a further example of alternative interconnections, the configuration  220  of  FIG. 22F  provides incoming power lines  18  along a top side of the module. Outgoing power lines  20  are provided along an opposite bottom side. Coolant may be routed through another surface, such as edge  230  as indicated for lines  22  and  24  in FIG.  22 F. 
   As noted above, various connector configurations can be provided in the present technique for routing power and coolant to and from the module.  FIGS. 23 and 24  illustrate exemplary configurations for plug-in connections to the module. As illustrated in  FIG. 23  where multiple connections are provided on one surface of the module, a ganged-type connector may be employed. A connection interface, designated in  FIG. 23  by reference numeral  232  may thus include a plurality of conductors extending from the module  10 . In  FIG. 23  connectors  106  and  108  have a generally circular or cylindrical shape. Other forms may, of course, be employed, such as flat conductors, plate-like conductors, angled conductors, and so forth. The connector interface  232  in  FIG. 23  is surrounded by a peripheral flange  234  which serves both to align a mating connector  236  and to extend shielding of the conductors beyond the housing of the module. Accordingly, flange  234  may, where desired, be a metallic extension of the housing. The mating connector  236  preferably includes an insulation plate  238  which forms a rear wall of the connector and which at least partially surrounds interface sockets  240 . The housing  242  of the mating connector  236  supports the insulation plate and interface sockets, and interconnections between the sockets and leads  246  are made within the connector. A peripheral wall  244  may extend around the sockets to provide protection for the sockets, alignment with flange  234  of interface  232 , and extension of shielding to the sockets and connections once made. 
   The connections are made to the module, then, by simply plugging the mating connector  236  into the interface  232  as indicated by arrow  248 . As will be appreciated by those skilled in the art, various locking features, securement features, straps, fasteners, or the like may be provided to ensure that the connector is fully and securely installed. Moreover, a sensor or switch assembly (not shown) may be provided in either the connector interface  232  or the mating connector  236  to sense whether the connection is appropriately completed. Feedback signals from such devices may be used by the controller to prevent or limit application of power to the module until appropriate interconnections are made. 
   In configurations employing more than one entry location for conductors, multiple connectors may be provided as indicated in FIG.  24 . The arrangement of  FIG. 24  provides two incoming power conductors  106  along a top surface of the module, with three outgoing power conductors  108  along a bottom surface as in the arrangement of FIG.  22 F. As shown in  FIG. 24 , a first connection with the incoming power conductors from leads  246  is made at an incoming power connection interface  250 . The incoming power connector  254 , in the illustrated embodiment, may include a peripheral flange  244  as in the previous example, with an insulation plate  238  protecting connections between the leads and interface sockets. The connector  254  is then simply plugged into the incoming power connector interface  250 . Outgoing power connections are made in a similar manner via an outgoing power connector interface  252 . This interface, similarly, is surrounded by a peripheral flange  234 . A connector  256 , similarly surrounded by a peripheral flange  244  and having an insulation plate  238 , is connected into the outgoing power connector interface  252 . Again, shielding may be provided at one or both locations by the cooperation of the peripheral flanges. Also, securement devices may be provided at each location to ensure that the connectors are appropriately made. As in the previous example, sensors or switches may be provided in both connectors to ensure that the appropriate connections are made prior to application of power to the module. 
   As mentioned above, various alternative configurations may be envisaged for the particular external packaging of the module, as well as for its shielding from stray EMI.  FIGS. 25 and 26  illustrate exemplary alternative configurations based upon a drop-in design. As shown in  FIG. 25 , an interface plate  258  may be provided, as an example, with interconnections made directly to a rear surface of the interface plate. The configuration of the module  10  may generally follow the lines described above including fabrication about a thermal support  12 . Coolant conduits  260  may be provided for routing coolant to and from the thermal support. In such cases, the coolant conduits may be routed directly through the interface plate  258 . A canister-type housing  262  (see particularly  FIG. 26 , is provided which connects to interface plate  258  to surround, support and shield the module. Interconnections with the interface plate may then be made via a ganged-type connector  236  as illustrated in FIG.  26 . 
     FIGS. 27A-27D  represent exemplary techniques for joining the contacts with terminal strip  134  to circuits formed in the power electronic device subassembly  130 . In the exemplary embodiment of  FIG. 27A , stamped or similar contact members  266  are soldered or otherwise bonded to the device subassemblies  130  and extend to the terminal strip  148 . The connective elements  166  may be soldered, welded, brazed, laser or Ebeam welded, conductively adhesively bonded, or electrically coupled in any other way to the device subassemblies  130  and to the terminal strip  134 . Strain reliefs may be formed within stamped, coined, cut, or molded conductive elements of this type to provide an optimal section for the transmission of current. In the alternative illustrated in  FIG. 27B , metal laminates, plastic metal tapes, multiple such tapes, electrical braids, ribbons, and the like, denoted generally by reference numeral  268  similarly extend between the circuits formed on the device subassembly  130  and the terminal strip  134 . Electrical contact may also be provided via power assembly gas-tight pressure contact structures. Where desired, the separate elements of such tapes, ribbons or braids may be joined through a portion or their entire length, such as by resistance welding. In the further alternative illustrated in  FIG. 27C , separate contact members  270  and  272  are provided on the device subassembly  130  and the terminal strip  134 , and are joined to one another during assembly of the module. Each of the contact members may be formed by any appropriate method, such as by stamping or coining, and bonding or otherwise securing the contact members electrically and mechanically to the device subassembly and terminal strip. Finally, as illustrated in  FIG. 27D , an extension  274  of a thermally conductive layer of the device subassemblies themselves may be provided for connection to the terminal strip  134 . For example, in modules employing direct bond copper or direct bond aluminum, a conductor may be extended from an output terminal to the terminal strip. Stress relief may be provided as in the aforementioned arrangements, as well as selective patterning of the conductive layer of the device subassembly, where desired. 
     FIGS. 28A-28D  illustrate alternative terminal and terminal assembly cooling arrangements. As mentioned above, both incoming and outgoing current may be passed through terminal strip  134 . In use, heating within the terminal strip may occur and may be extracted through any appropriate arrangement, such as the arrangements illustrated in  FIGS. 28A-28D . In a first exemplary arrangement shown in  FIG. 28A , the terminal strip comprises one or more sections  276  and  278  which may be made of a thermally conductive, electrically insulating material that surrounds and supports the various conductive elements described above of the terminal strip. Examples of such materials might include ceramic-filled thermoplastics or liquid crystal polymers. 
   In the arrangement illustrated in  FIG. 28B , a manifold  280  is formed for receiving a coolant, such as by interconnection with the coolant passages formed within the thermal support  12  as described above. The manifold serves to feed channels  282  which route coolant into and out of the terminal strip for cooling purposes. In the arrangement of  FIG. 28C , a thermal extension  284  is provided which adds surface area to contact between the thermal support  12  and the terminal. The thermal extension  184  is designed to interface with a corresponding and similarly formed recess or groove  286  formed within the terminal strip  134 . As will be appreciated by those skilled in the art, any suitable configuration or cross-sectional shape for the extension and recess may be provided. Similarly, as shown in  FIG. 28D , an extension  288  may be formed in the terminal strip  134  and designed to interface with a corresponding groove or recess  290  formed within a portion of the thermal support  12 . 
     FIGS. 29A and 29B  represent alternative configurations for terminal plugs and connections useful in the various connection configurations described above. As shown in  FIG. 29A , housing  94  is designed to surround conductor  108 , while conductor  108  receives lead conductor  246  when the connector is made up. Housing  242  is provided on the mating connector  236  and at least partially surrounds the lead conductor  246 . An electrically insulating body  292  is provided within the housing  94  around the conductor  108 . A wire shield and ground connection  294  is provided within the housing  242 , while an insulating member  295  is provided between the connection  294  and the lead conductor  246 . The resulting assembly provides for both a good electrical connection of the conductor of the module and the mating connector, as well as the offering EMI shielding and continuity of shielding between the connector and the module.  FIG. 29B  represents a similar arrangement, but wherein a conductive receptacle shell  298  is formed to interface with the flange  244  of the connector housing  242 . 
     FIGS. 30A-30C  illustrate alternative power device substrate mounting and heat exchanging configuration for use in a module of the type described above. In the embodiment of  FIG. 30A , an interface  300  is provided as described above for transmitting thermal energy from the power electronic device subassembly  130  through the interface plate  148 . As shown in  FIG. 30B , various arrangements may be provided for installing two or more power electronic device subassemblies  130  on a common thermal support  12 . For example, two such arrangements are illustrated in  FIG. 30B , including channels  152  for conveying cooling fluid through the support. In one exemplary configuration, pins  160  extend from an interface plate  148  and are cooled by fluid flowing through one of the channels  152 . In another exemplary configuration shown in  FIG. 30B , a heat dissipation element  174  is disposed in a channel for similarly removing heat. The plate  148  may be attached by any suitable method, such as soldering, brazing, welding, or via adhesive and gaskets to provide adequate sealing. The heat exchanger base module defined by the support may be made of any conductive metal or polymer or can be made of a variety of non-conductive materials such as thermoplastics, thermoset plastics, epoxy cast structures, and so forth. Also shown in  FIG. 30B , an insert molded seal flange  302  may be provided for enhancing the seal between the interface plate and the thermal support  12 . Such seal flanges may be made by any suitable process, such as injection, compression, casting, vacuum casting, adhesive attachment, and so forth. The flange may be bonded during molding or as a secondary step into the thermal base, such as at an edge, flange or lip so as to seal against the opening provided in the thermal support for this purpose. As shown in  FIG. 30C , a specially adapted interface surface  304  may be provided for receiving a device subassembly and interface plate assembly. Where provided, pins  160  or similar heat dissipation elements may extend through especially provided apertures  306  within the thermal support. Again, a sealing element  162  may be provided around the interface plate for sealing against the thermal support. 
     FIGS. 31A and 31B  represent exemplary configurations for a low inductance shield and ground arrangement for use in a module of the type described above. In the arrangement shown in  FIG. 31A , a thermal support  12  includes a partial peripheral flange  126  as described above. Low inductance paths for metal shielding may be formed as indicated at reference numerals  310 ,  312  and  314 , with the paths  310  being provided on a cover  308  designed to be fitted to the thermal support. The ground paths may be made of any suitable material, such as metallized polymers or may comprise metal or other conductive elements molded into polymeric materials at specific locations as desired. The paths may be defined from intrinsic thinning of metal sections of castings and by shaping contact areas for low inductance. Moreover, the paths may be specifically shaped to provide high frequency power ground contacts, and the paths may be brought into areas adjacent to the switch substrates. Laminated bus sections  311  may be provided that defines connections between the high frequency capable conduction paths. Bonding tabs  313  may provide for connection between the bus and the device substrates. Through the use of such shielding approaches, the shell or housing for the overall module may be made of metals, plastics (including thermoplastics), or any other suitable material or combination of materials. 
     FIG. 31B  illustrates the power electronic device subassemblies  130  disposed within an exemplary arrangement of the type shown in FIG.  31 A. The cover  308 , which acts as an EMI shield plate is placed over the subassemblies, which constitutes combined gate driver circuitry and control board circuitry in the illustrated embodiment. Mechanical connection and electrical paths are defined by fasteners used to secure the cover to the support  12 . 
     FIGS. 32A and 32B , and  FIG. 33  illustrate alternative exemplary configurations for plug-in modules in arrangements accommodated by backplane configurations. As shown in  FIG. 32A , modules comprised of thermal supports  12  and power electronic device subassemblies  130  are coupled to terminal strips  134 , with conductors  108  being electrically coupled to parallel backplane conductors represented generally at reference numeral  322 . The backplane conductors may route power to and from the modules once these are plugged into or otherwise coupled to the backplane. The backplane represented generally by reference numeral  318  in  FIG. 32A , may also provide for connections to coolant streams. In the embodiment illustrated in  FIG. 32A , for example, a coolant backplane connection adapter  326  serves to interface the inlet and outlet ports of the thermal supports with coolant supply lines  324  provided in the backplane. The individual modules, then, may be plugged into the backplane and connected for independent or joint operation in a larger system. An exemplary physical implementation of a modular unit for such backplane configurations is shown in  FIG. 32B , based generally upon the arrangement shown in FIG.  25 . Handles may be provided on the package for facilitating insertion and removal, while connections may be provided on a single side for completing all necessary interconnects to external circuitry. Moreover, sealed coolant conduits may be provided for interconnecting to the coolant supply lines of the backplane. The connections may be extended at different lengths or designed in alternative manners, such as to ensure making or breaking of certain connections before or after others during installation or removal. These might include, but are not limited to, ultra-fast turnoff and ultra-fast “crowbar” function. 
   In the embodiment illustrated in  FIG. 33 , three such modules are provided in a similar arrangement and are similarly coupled to the backplane conductors  322  and coolant supply lines  324 . However, as shown in  FIG. 33 , fluid connections may also be provided between the modules as represented at reference numeral  330  to facilitate parallel or series flow of coolant among the various modules mounted on the backplane. 
   To enhance thermal control in modules of the type described above, various fluid flow controls may be incorporated into the structures as illustrated generally in FIG.  34 . The flow control system, indicated generally by reference numeral  332 , may include various sensors  334  which detect local temperatures at various locations around the power electronic device subassembly  130  and at other locations in the system. Input lines  336  feed signals representative of the temperatures to a flow control circuit  338 . The flow control circuit  338  regulates the flow of coolant to and from the module via a flow control valve  340  coupled to the flow control circuit via an output line  342 . Thus, closed-loop temperature control may be provided in the module so as to optimize coolant flow and to minimize variations in thermal cycling, thereby enhancing the life of the power electronic components within the device subassembly  130 . 
   As noted above, a wide range of circuits may be accommodated that may benefit from the various configurations described above. In particular, as mentioned above, various types of converter circuits may be supported on the thermal support and connected, cooled, shielded and so forth as described.  FIGS. 35A-35C  illustrate exemplary configurations for circuitry which may define AC—AC converters, voltage source converters, synchronous rectifiers and similar topologies. In  FIG. 35A , a device subassembly  130  comprises a series of solid state switches and diodes coupled to a DC source in half bridges. The individual subassemblies  130  are mounted on a thermal support  12  as described above, and as shown in FIG.  35 B. Electrically, the subassemblies  130  may be connected to circuitry for producing controlled AC output signals, as illustrated in FIG.  35 C. 
   Also as noted above, another type of circuitry which may be accommodated in the arrangements described are AC—AC converters, matrix switch topologies of the type illustrated in  FIGS. 36-36C . As shown, in such topologies each device subassembly includes a pair of switch and diode sets coupled to an AC power source.  FIG. 36B  illustrates a three phase implementation of such subassemblies mounted to a thermal support  12  as described above. An input bus and an output bus are coupled to the subassemblies for routing of input and output power signals. As shown in  FIG. 36C , in the three phase implementation, phase inputs and outputs are electrically coupled to the subassemblies to produce the desired power output. 
   It should be noted that, while certain three-phase topologies are discussed herein, the present technique may extend to single phase and other arrangements. Such arrangements may accommodate applications such as mid-frequency welding applications. Such applications may incorporate a high frequency transformer rather than certain of the capacitors disposed on the thermal support. The circuitry supported on and thermally serviced by the support then becomes somewhat modular between application-specific designs. 
     FIG. 37  illustrates an exemplary circuit for one such application, in this case a mid-frequency welding implementation. As will be appreciated by those skilled in the art, in such applications, circuits  130  include pairs of solid state switches and diodes. The circuits are coupled through sources of power by the intermediary of transformers. Additional transformers are provided for output, such to a welding head. As in the previous examples, both the circuits and the energy storage and transforming circuitry may be supported and cooled by the thermal support and related techniques described above. 
     FIGS. 38A and 38B  represent further alternative configurations in which cooling may be provided at locations removed from the thermal support itself. As shown in  FIG. 38A  thermal support  12  supports circuitry within a peripheral flange  126  as described above. Circuitry may be mounted to both sides of the thermal support  12  as previously described. Moreover, a cover  308  is provided, such as for providing the EMI shielding as described above. In the embodiment illustrated in  FIG. 38A , a circuit board is mounted outside the primary cavity in which other circuitry is mounted. In the illustrated embodiment, the circuit board comprises a control circuit board  36 . Because the cooling requirements of certain of the circuitry, such as the control circuit board  36 , may be less stringent than those of the other circuitry, such components may be mounted remote from the thermal support  12 . However, additional cooling for such circuitry can nevertheless be provided, such as the heat pipes of the type illustrated in FIG.  38 A and designated generally by the reference numeral  344 . As will be appreciated by those skilled in the art, such heat pipes will typically comprise thermally conductive materials which are extended into contact with the inlet and/or outlet of the coolant stream. Conduction of heat along the heat pipe  344  then permits removal of heat from the circuitry mounted on board  36 .  FIG. 38B  illustrates the same arrangement following assembly. An appropriate jumper cable  346  may be provided for channeling signals and power to and from the circuit board  36 . 
   While the invention may be susceptible to various modifications and alternative forms, specific embodiments have been shown in the drawings and have been described in detail herein by way of example only. However, it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the following appended claims.