Inverter module having multiple half-bridge modules for a power converter of an electric vehicle

An inverter module, comprising:

• first, second and third half-bridge inverter modules coupled with each other in a triplet configuration, wherein first, second, and third positive inputs of the first, second and third half-bridge inverter modules, respectively, are aligned with each other and first, second, and third negative inputs of the first, second and third half-bridge inverter modules, respectively, are aligned with respect to each other, and wherein first, second, and third output terminals of the first, second and third half-bridge inverter modules, respectively, are aligned with respect to each other;
• a positive bus-bar coupled with the first, second, and third positive inputs of the first, second and third half-bridge inverter modules;
• a negative bus-bar coupled with the first, second, and third negative inputs of the first, second and third half-bridge inverter modules, the positive bus-bar positioned adjacent to and parallel with the negative bus-bar;
• and
• first, second, and third phase bus-bars having first, second, and third phase outputs respectively, the first, second, and third phase outputs disposed at the same level with respect to a first surface of the first, second, and third half-bridge inverter modules.

A method, comprising:

• forming a first, second and third half-bridge inverter modules;
• coupling the first, second and third half-bridge inverter modules with each other in a triplet configuration;
• aligning first, second, and third positive inputs of the first, second and third half-bridge inverter modules, respectively, with each other;
• aligning first, second, and third negative inputs of the first, second and third half-bridge inverter modules, respectively, with each other;
• coupling a positive bus-bar with the first, second, and third positive inputs of the first, second and third half-bridge inverter modules;
• coupling a negative bus-bar with the first, second, and third negative inputs of the first, second and third half-bridge inverter modules such that the positive bus-bar is positioned adjacent to and parallel with the negative bus-bar;
• aligning first, second, and third output terminals of the first, second and third half-bridge inverter modules, respectively, with respect to each other;
• disposing a first cold plate, a first plurality of transistors, and a first ceramic layer within the first half-bridge module, the first ceramic layer disposed between the first cold plate and the first plurality of transistors;
• disposing a second cold plate, a second plurality of transistors, and a second ceramic layer within the second half-bridge module, the second ceramic layer disposed between the second cold plate and the second plurality of transistors;
• and
• disposing a third cold plate, a third plurality of transistors, and a third ceramic layer within the third half-bridge module, the third ceramic layer disposed between the third cold plate and the third plurality of transistors.

A method, comprising:

• providing an inverter module, the inverter module comprising:
• first, second and third half-bridge inverter modules coupled with each other in a triplet configuration, wherein first, second, and third positive inputs of the first, second and third half-bridge inverter modules, respectively, are aligned with each other and first, second, and third negative inputs of the first, second and third half-bridge inverter modules, respectively, are aligned with respect to each other, and wherein first, second, and third output terminals of the first, second and third half-bridge inverter modules, respectively, are aligned with respect to each other;
• a positive bus-bar coupled with the first, second, and third positive inputs of the first, second and third half-bridge inverter modules;
• a negative bus-bar coupled with the first, second, and third negative inputs of the first, second and third half-bridge inverter modules, wherein the positive bus-bar is positioned adjacent to and parallel with the negative bus-bar;
• and
• first, second, and third phase bus-bars extending from the first, second, and third half-bridge inverter modules respectively, the first, second, and third phase bus-bars disposed parallel with respect to each other.

An electric vehicle, comprising:

• an inverter module disposed in a drive train unit of the electric vehicle, the inverter module comprising:
• first, second and third half-bridge inverter modules coupled with each other in a triplet configuration, wherein first, second, and third positive inputs of the first, second and third half-bridge inverter modules, respectively, are aligned with each other and first, second, and third negative inputs of the first, second and third half-bridge inverter modules, respectively, are aligned with respect to each other, and wherein first, second, and third output terminals of the first, second and third half-bridge inverter modules, respectively, are aligned with respect to each other;
• a positive bus-bar coupled with the first, second, and third positive inputs of the first, second and third half-bridge inverter modules;
• a negative bus-bar coupled with the first, second, and third negative inputs of the first, second and third half-bridge inverter modules, the positive bus-bar positioned adjacent to and parallel with the negative bus-bar;
• a first phase bus-bar coupled with the first output terminal of the first half-bridge inverter module;
• a second phase bus-bar coupled with the second output terminal of the second half-bridge inverter module;
• and
• a third phase bus-bar coupled with the third output terminal of the third half-bridge inverter module.