Patent ID: 12261543

DETAILED DESCRIPTION

Referring now in detail to the drawings for the purpose of illustrating preferred embodiments of the present invention, a power module2of the present invention is illustrated inFIG.1.

FIG.1illustrates a power module2according to an embodiment of the invention. The power module2is a three-level power module and comprises a molded package4comprising a first side40and a second opposite side42. Three power terminals6,8,10protrude from the first side40of the molded package4. The power terminals6,8,10include a positive DC terminal6, a neutral terminal8and a negative terminal10.

The phase output power terminal12protrudes from the second side42of the molded package4. The power module2comprises a plurality of control pins14,16,18,20,22,24,26,28protruding from the second side42of the molded package4. These control pins14,16,18,20,22,24,26,28extend parallel to each other.

A centrally arranged hole38is provided in each of the power terminals6,8,10,12. The holes38may be used to mechanically and electrically attach the terminals6,8,10,12to other parts (e.g. a DC link) by means of screws (not shown) being inserted through holes38. Each screw will typically be screwed into a corresponding nut. Accordingly, the screws can mechanically keep the terminals6,8,10,12of the power module2in contact with the structures, to which the terminals6,8,10,12are electrically connected. Other means of attachment may also be used where necessary, such as welding, gluing, soldering, brazing, or other means known in the field. Some attachment means may not require the presence of a hole38.

In one embodiment, the molded package4is encapsulating the electronic components of the power module2. In one embodiment, the molded package4encapsulates a base plate of the power module2.

FIG.2Aillustrates a top view of the power module2in Neutral Point Clamped (NPC)-1 topology shown inFIG.1. Besides from the structures shown inFIG.1, it can be seen that the power module2comprises several electrically separated metallisation areas44,46,48,50,52,54. A first metallisation area44is electrically connected to the negative DC terminal10. A semiconductor switch T4and a diode D3are arranged on the first metallisation area44.

A second metallisation area46is arranged between the first metallisation area44and a third metallisation areas48that is electrically connected to the phase output power terminal12. A semiconductor switch T3and two diodes D1and D4are arranged on the second metallisation area46. A semiconductor switch T2and a diode D5are arranged on the third metallisation area48.

A fourth metallisation area50is electrically connected to the neutral terminal8. A diode D2is arranged on the fourth metallisation area50.

A fifth metallisation area52is arranged between the fourth metallisation areas50and a sixth metallisation area54that is electrically connected to the positive DC terminal6. A semiconductor switch T1and a diode D6are arranged on the fifth metallisation area52.

The metallisation areas44,46,48,50,52,54are shaped as elongated structures having a longitudinal axis extending along the axis X. It can be seen that the metallisation areas44,46,48,50,52,54are substantially mirror symmetrically arranged with respect to the axis X. Moreover, the metallisation areas44and54are substantially mirror symmetrically arranged with respect to the axis X. Likewise, the metallisation areas46and52are basically mirror symmetrically arranged with respect to the axis X, whereas the metallisation areas48and50are essentially mirror symmetrically arranged with respect to the axis X.

Hereby, it is possible to provide a design having a lower number of electrical interconnections.

The control pins14,16are electrically connected to electronic components arranged on the fifth metallisation area52. The control pins18,20are electrically connected to electronic components arranged on the third metallisation area48. The control pins22,24are electrically connected to electronic components arranged on the second metallisation area46. The control pins26,28are electrically connected to electronic components arranged on the first metallisation area44.

The power module2comprises a first row I, a second row II, a third row III, a fourth row IV and a fifth row V. The first metallisation area44is arranged in the first row I. The second metallisation area46is arranged in the second row II. Both the third metallisation area48and the fourth metallisation area50are arranged in the third row III. The fifth metallisation area52is arranged in the fourth row IV and the sixth metallisation area54is arranged in the fifth row V. It can be seen that central (midmost) row III of metallisation area comprises two separated metallisation areas48,50. Accordingly, the separated metallisation areas48,50are arranged in the central area62of the power module2. The central area62is indicated with a dotted rounded rectangle.

Moreover, it can be seen that the semiconductor switches T1, T2, T3, T4are bonded to the outermost four rows I, II, III, IV.

It can also be seen that no semiconductor switches T1, T2, T3, T4are arranged at the rows others than the outermost four rows I, II, III, IV.

FIG.2Billustrates an equivalent circuit of the power module shown inFIG.2A.

Two diodes D3, D4(arranged in series) and two semiconductor switches T3, T4(arranged in series) constituting a first half bridge58are provided between the positive DC terminal DC+ and the phase terminal U (shown as12inFIG.2A).

Likewise, two diodes D5, D6(arranged in series) and two semiconductor switches T2, T1(arranged in series) constituting a second half bridge58′ are provided between the negative DC terminal DC− and the phase terminal U.

Two diodes D1, D2are arranged in series and constitute a diode bridge60.

FIG.3Aillustrates a power module2according to one embodiment of the invention, whereasFIG.3Billustrates an equivalent circuit of the power module (NPC2 T-type topology) shown inFIG.3A.FIG.3Aillustrates a top view of the power module2comprising a plurality of metallisation areas44,48,50,52,54,56spaced apart from each other.

The power module2is a three-level power module2and comprises a first side40and a second opposite side42. Three power terminals6,8,10protrudes from the first side40of the power module2. The power terminals6,8,10include a positive DC terminal6, a neutral terminal8and a negative terminal10. The phase output power terminal12protrudes from the second side42of the power module2. The power module2comprises a plurality of control pins14,16,18,20,22,24,26,28protruding from the second side42of the power module2. These control pins14,16,18,20,22,24,26,28are extending parallel to an axis X indicated with a dotted line.

A first metallisation area44is electrically connected to the negative DC terminal10. Two control pins22,24are electrically connected to electronic components arranged on this first metallisation area44.

Another metallisation area48is electrically connected to the phase output power terminal12. A further metallisation area50is electrically connected to the neutral terminal8. Two control pins18,20are electrically connected to electronic components arranged on this metallisation area48.

A metallisation area54is electrically connected to the positive DC terminal6.

A metallisation area56is arranged between the metallisation area48and the metallisation area50. Two control pins26,28are electrically connected to electronic components arranged on this metallisation area56.

The metallisation areas44,48,50,52,54are substantially mirror symmetrically arranged with respect to the axis X. The axis X basically corresponds to the longitudinal axis of the power module2

It can be seen that the metallisation areas44and54are essentially mirror symmetrically arranged with respect to the axis X. Likewise, the metallisation areas48,50and56are basically mirror symmetrically arranged with respect to the axis X.

The separated metallisation areas48,50,56are arranged in the central area62of the power module2. The central area62is indicated with a dotted rounded rectangle.

FIG.3Billustrates an equivalent circuit of the power module shown inFIG.3A.

Two diodes D3, D4(arranged in series) and two semiconductor switches T3, T4(arranged in series) are provided between the neutral terminal N and the phase terminal U (shown as12inFIG.3A).

A diode D1and a semiconductor switch T2are arranged between the negative DC terminal DC− and the phase terminal U. Similarly, a diode D2and a semiconductor switch T1are arranged between the positive DC terminal DC+ and the phase terminal U.

FIG.4Aillustrates a power module2according to one embodiment of the invention, whereasFIG.4Billustrates an equivalent circuit of the power module (Advanced Neutral Point Clamping (ANPC) topology) shown inFIG.4A.

FIG.4Aillustrates a top view of the power module2comprising a plurality of metallisation areas44,46,48,50,52,54spaced apart from each other.

The power module2comprises a first side40and a second opposite side42. Three power terminals6,8,10(a positive DC terminal6, a neutral terminal8and a negative terminal10) protrudes from the first side40of the power module2. The phase output power terminal12, however, protrudes from the second side42of the power module2.

The power module2comprises a plurality of control pins14,16,18,20,22,24,26,28,30,32,34,36protruding from the second side42of the power module2. These control pins14,16,18,20,22,24,26,28,30,32,34,36are extending parallel to an axis X indicated with a dotted line.

The power module2comprises a first metallisation area44being electrically connected to the negative DC terminal10. Two control pins34,36are electrically connected to electronic components arranged on this first metallisation area44.

Another metallisation area48is electrically connected to the phase output power terminal12. Two control pins22,24are electrically connected to electronic components arranged on this metallisation area48.

A further metallisation area50is electrically connected to the neutral terminal8. A control pin20is electrically connected to an electronic component arranged on this metallisation area50

A metallisation area54is electrically connected to the positive DC terminal6. A control pin14are electrically connected to this metallisation area54.

A metallisation area52is arranged between the metallisation area54and the metallisation area50. Two control pins16,18are electrically connected to electronic components arranged on this metallisation area52.

A metallisation area46is arranged between the metallisation area44and the metallisation area50. Four control pins26,28,30,32are electrically connected to electronic components arranged on this metallisation area46.

The metallisation areas44,46,48,50,52,54are substantially mirror symmetrically arranged with respect to the axis X. The axis X basically corresponds to the longitudinal axis of the power module2.

The metallisation areas44and54are elongated and are essentially mirror symmetrically arranged with respect to the axis X. Likewise, the metallisation areas48,50are basically mirror symmetrically arranged with respect to the axis X, whereas the metallisation areas46,52are basically mirror symmetrically arranged with respect to the axis X.

The power module2comprises a first row I, a second row II, a third row III, a fourth row IV and a fifth row V. The first metallisation area44is arranged in the first row I. The second metallisation area46is arranged in the second row II. Both the third metallisation area48and the fourth metallisation area50are arranged in the third row III. The fifth metallisation area52is arranged in the fourth row IV and the sixth metallisation area54is arranged in the fifth row V. The central (midmost and third) row III of metallisation area comprises two separated metallisation areas48,50. Accordingly, the separated metallisation areas48,50are arranged in the central area62of the power module2. The central area62is indicated with a dotted rounded rectangle.

Moreover, it can be seen that the semiconductor switches are bonded to the outermost four rows I, II, III, IV.

It can also be seen that no semiconductor switches are arranged at the rows others than the outermost four rows I, II, III, IV.

FIG.4Billustrates an equivalent circuit of the power module shown inFIG.4A. The power module comprises two diodes D1, D2(arranged in series) and two semiconductor switches Sa1, Sa2(arranged in series) constituting a first half bridge. The power module further comprises two diodes D3, D4(arranged in series) and two semiconductor switches Sa3, Sa4(arranged in series) constituting a second half bridge as well as a third half bridge comprising two diodes and two semiconductor switches Sa5, Sa6.

While the present disclosure has been illustrated and described with respect to a particular embodiment thereof, it should be appreciated by those of ordinary skill in the art that various modifications to this disclosure may be made without departing from the spirit and scope of the present disclosure.