# US 10,874,037 B1 · Power-module assembly with cooling arrangement

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- Number: US 10,874,037 B1
- Document ID: US10874037B1
- Status: Granted
- Kind: B1
- Application number: 16/579,490
- Filed: 2019-09-23
- Granted: 2020-12-22
- Earliest claimed: 2019-09-23
- Assignees: Ford Global Technologies, LLC
- Applicants: Ford Global Technologies, LLC
- Inventors: Man Prakash Gupta; Michael W. Degner; Edward Chan-Jiun Jih; Alfredo R. Munoz
- Web page: https://patentgrep.com/patent/US10874037B1

## CPC

- H05K 7/20927: {Liquid coolant without phase change}
- B60K 6/387: Actuated clutches, i.e. clutches engaged or disengaged by electric, hydraulic or mechanical actuating means
- B60K 6/445: Differential gearing distribution type
- B60L 15/007: {Physical arrangements or structures of drive train converters specially adapted for the propulsion motors of electric vehicles}
- H02M 3/158: including plural semiconductor devices as final control devices for a single load
- H02M 7/003: {Constructional details, e.g. physical layout, assembly, wiring or busbar connections}
- H02M 7/5387: in a bridge configuration
- H02M 7/53875: {with analogue control of three-phase output}
- H02P 29/60: Controlling or determining the temperature of the motor or of the drive (H02P29/02 takes precedence)
- H05K 7/20272: {Accessories for moving fluid, for expanding fluid, for connecting fluid conduits, for distributing fluid, for removing gas or for preventing leakage, e.g. pumps, tanks or manifolds}
- H05K 7/20872: {Liquid coolant without phase change}
- H10W 40/47: by flowing liquids, e.g. forced water cooling
- H10W 90/00: Package configurations
- B60K 6/28: characterised by the electric energy storing means, e.g. batteries or capacitors
- B60L 50/60: using power supplied by batteries (in combination with fuel cells B60L50/75)
- B60L 58/26: by cooling
- B60L 2210/40: DC to AC converters
- B60L 2240/525: Temperature of converter or components thereof
- B60Y 2200/91: Electric vehicles
- B60Y 2200/92: Hybrid vehicles
- B60Y 2306/05: Cooling
- B60Y 2400/112: Batteries
- H02M 1/007: {Plural converter units in cascade (push-pull DC/DC converters with pre-regulator H02M3/3374; DC-AC converters following a DC-DC stage including a high frequency transformer H02M7/4807; DC-AC converters following a DC-DC conversion stage generating periodically varying voltages H02M7/4826)}
- H02M 1/008: {Plural converter units for generating at two or more independent and non-parallel outputs, e.g. systems with plural point of load switching regulators}
- H02P 27/06: using DC to AC converters or inverters (H02P27/05 takes precedence)
- H10W 40/255: {having a laminate or multilayered structure, e.g. direct bond copper [DBC] ceramic substrates}
- H10W 40/613: {for stacked arrangements of a plurality of semiconductor devices}
- H10W 90/701: {characterised by the relative positions of pads or connectors relative to package parts}
- Y02T 10/62: Hybrid vehicles
- Y02T 10/64: Electric machine technologies in electromobility
- Y02T 10/70: Energy storage systems for electromobility, e.g. batteries
- Y02T 10/72: Electric energy management in electromobility
- Y02T 90/16: Information or communication technologies improving the operation of electric vehicles
- H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- B60K: ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60L: PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES (arrangements or mounting of electrical propulsion units or of plural diverse prime-movers for mutual or common propulsion in vehicles B60K1/00, B60K6/20; arrangements or mounting of electrical gearing in vehicles B60K17/12, B60K17/14; preventing wheel slip by reducing power in rail vehicles B61C15/08; dynamo-electric machines H02K; control or regulation of electric motors H02P); SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES (electric coupling devices combined with mechanical couplings of vehicles B60D1/64; electric heating for vehicles B60H1/00); ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL (control or regulation of electric motors H02P); MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- H02M: APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF (transformers H01F; dynamo-electric converters H02K47/00; controlling transformers, reactors or choke coils, control or regulation of electric motors, generators or dynamo-electric converters H02P)
- H02P: CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
- H10W: GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
- B60Y: INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

A power-module assembly includes a plurality of power modules each including a power stage having a substrate and a transistor-based switching arrangement supported on the substrate. The power modules are arranged in a stack that defines coolant chambers interleaved with the power stages and defines a pair of coolant-supply manifolds disposed on opposing sides of the stack and extending along a length of the stack. For each power module, the substrate defines a network of cooling channels connecting the supply manifolds to a corresponding one of the chambers. The network includes first channels each configured to receive coolant from the pair of coolant-supply manifolds, second channels substantially parallel to the first channels and each opening into the corresponding one of the chambers, and third channels crisscrossing the first and second channels to connect the first and second channels in fluid communication.

## Claims

### Claim 1

A power-module assembly comprising:
a plurality of power modules each including a power stage having a substrate and a transistor-based switching arrangement supported on the substrate, the power modules being arranged in a stack that defines coolant chambers interleaved with the power stages and defines a pair of coolant-supply manifolds disposed on opposing sides of the stack and extending along a length of the stack, wherein, for each power module, the substrate defines a network of cooling channels connecting the supply manifolds to a corresponding one of the chambers, the network including first channels each configured to receive coolant from the pair of coolant-supply manifolds, second channels substantially parallel to the first channels and each opening into the corresponding one of the chambers, and third channels crisscrossing the first and second channels to connect the first and second channels in fluid communication.

### Claim 2 (depends on 1)

The power-module assembly of claim 1, wherein the third channels are orthogonal to the first and second channels.

### Claim 3 (depends on 1)

The power-module assembly of claim 1, wherein, for each of power modules, the substrate includes an outer plate forming a boundary of the corresponding one of the chambers and defining the first and second channels and includes an interior plate disposed against the outer plate and defining the third channels.

### Claim 4 (depends on 3)

The power-module assembly of claim 3, wherein the outer plate includes a front that forms the boundary and a back that is disposed against a front of the interior plate, wherein the first channels are recessed into the back, the second channels extend from the front to the back to be completely through a thickness of the outer plate, and the third channels are recessed into the front of the interior plate.

### Claim 5 (depends on 4)

The power-module assembly of claim 4, wherein the outer plate and the interior plate are formed of copper alloy.

### Claim 6 (depends on 1)

The power-module assembly of claim 1, wherein, for each power-module assembly, the substrate includes opposing edges, and the first channels extend fully between the opposing edges and the second channels extend partially between the opposing edges.

### Claim 7 (depends on 1)

The power-module assembly of claim 1, wherein the stack defines a coolant-return manifold connecting the chambers in fluid communication.

### Claim 8 (depends on 1)

The power-module assembly of claim 1, wherein each of the power modules further includes a frame having opposing sides that each define at least one coolant-supply header extending from an associated one of the coolant-supply manifolds, and wherein, for each power module, each of the first channels defines a first entrance hole opening into one of the headers and a second first entrance hole opening into another of the headers.

### Claim 9 (depends on 1)

The power-module assembly of claim 1, wherein each of the power stages further includes a second substrate attached to the switching arrangement such that the substrate and the second substrate sandwich the switching arrangement.

### Claim 10 (depends on 9)

The power-module assembly of claim 9, wherein the second substrate defines a second network of channels connecting the supply manifolds to a corresponding one of the chambers, the second network including fourth channels each configured to receive coolant from the pair of coolant-supply manifolds, fifth channels substantially parallel to the fourth channels and opening into the corresponding one of the chambers, and sixth channels crisscrossing the fourth and fifth channels to connect the fourth and fifth channels in fluid communication.

### Claim 11

A power-module assembly comprising:
a plurality of power modules each including a power stage and a frame defining a pocket adjacent to the power stage and slots disposed on opposing sides of the power stage, wherein the power modules are stacked in an array such that pockets adjacent to each other form coolant chambers interleaved with the power stages and such that slots adjacent to each other form coolant headers, wherein each of the power stages has at least one substrate including:
first channels each configured to receive coolant from an associated pair of coolant headers,
second channels substantially parallel to the first channels and each opening into a corresponding one of the coolant chambers to provide coolant thereto, and
third channels crisscrossing the first and second channels to connect the first and second channels in fluid communication.

### Claim 12 (depends on 11)

The power-module assembly of claim 11, wherein the array defines a coolant inlet port in fluid communication with each of the headers.

### Claim 13 (depends on 12)

The power-module assembly of claim 12, wherein the array defines a pair of coolant-supply manifolds, wherein each of the headers includes a first end that opens into one of the coolant-supply manifolds.

### Claim 14 (depends on 12)

The power-module assembly of claim 12, wherein the third channels are orthogonal to the first and second channels.

### Claim 15 (depends on 11)

The power-module assembly of claim 11, wherein, for each of the power modules, the substrate includes an outer plate defining the first and second channels and an interior plate disposed against the outer plate and defining the third channels.

### Claim 16

A power-module assembly having a plurality of power modules arranged in a stack, each power module comprising:
a frame; and
a power stage supported in the frame, the power stage including a plurality of switches supported on a substrate and configured to transform direct current into alternating current, the substrate including:
an outer plate having opposing first and second edges, the outer plate defining first microchannels recessed into a back of the outer plate and oriented to extend between the opposing edges and defining second microchannels completely through a thickness of the outer plate, oriented to extend between the opposing edges, and positioned between the first microchannels such that the first and second microchannels alternate along the outer plate, and
an interior plate having a front disposed against the back of the outer plate and defining third microchannels recessed into the front and oriented to crisscross the first and second microchannels such that the third microchannels connect the first and second microchannels in fluid communication.

### Claim 17 (depends on 16)

The power module of claim 16, wherein the third microchannels are orthogonal to the first and second microchannels.

### Claim 18 (depends on 16)

The power module of claim 16, wherein the first microchannels extend fully between the opposing edges and the second microchannels extend partially between the opposing edges.

### Claim 19 (depends on 16)

The power module of claim 16, wherein the substrate is a direct-bonded copper substrate in which the outer plate and the interior plate are formed of copper.

### Claim 20 (depends on 16)

The power module of claim 16, wherein the substrate further includes:
an inner plate disposed against the switches, and
an insulator sandwiched between the inner plate and the interior plate.