# US 12,214,677 B2 · Systems and methods for integrated gate driver for inverter for electric vehicle

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- Number: US 12,214,677 B2
- Document ID: US12214677B2
- Status: Granted
- Kind: B2
- Application number: 18/161,992
- Filed: 2023-01-31
- Published: 2024-03-28
- Granted: 2025-02-04
- Earliest claimed: 2022-09-28
- Assignees: BorgWarner US Technologies LLC
- Applicants: BorgWarner US Technologies LLC
- Inventors: Mark Wendell Gose; Seyed R. Zarabadi; David Paul Buehler; Kevin M. Gertiser
- Web page: https://patentgrep.com/patent/US12214677B2

## CPC

- H05K 7/20436: {Inner thermal coupling elements in heat dissipating housings, e.g. protrusions or depressions integrally formed in the housing}
- B60L 3/0084: {relating to control modules}
- G01R 31/006: {on road vehicles, e.g. automobiles or trucks (testing of ignition installations peculiar to internal combustion engines F02P17/00)}
- G01R 31/2621: {for testing field effect transistors, i.e. FET's}
- G01R 31/27: Testing of devices without physical removal from the circuit of which they form part, e.g. compensating for effects surrounding elements {(testing printed circuit boards G01R31/2801)}
- G01R 31/42: AC power supplies
- G01R 31/52: Testing for short-circuits, leakage current or ground faults
- H02M 1/0048: {Circuits or arrangements for reducing losses (using snubbers H02M1/34)}
- H02M 1/0054: {Transistor switching losses (periodically suspending operation of switching converter in low power mode H02M1/0035)}
- H02M 1/327: {against abnormal temperatures}
- H02M 1/36: Means for starting or stopping converters
- H02M 1/38: Means for preventing simultaneous conduction of switches
- H02M 7/48: using discharge tubes with control electrode or semiconductor devices with control electrode
- H02M 7/539: with automatic control of output wave form or frequency (H02M7/5375 - H02M7/5387 take precedence)
- H02P 27/08: with pulse width modulation
- H02P 29/0241: {the fault being an overvoltage}
- H02P 29/0243: {the fault being a broken phase}
- H02P 29/025: {the fault being a power interruption}
- H02P 29/026: {the fault being a power fluctuation}
- H03F 1/26: Modifications of amplifiers to reduce influence of noise generated by amplifying elements
- H03K 5/1252: Suppression or limitation of noise or interference (specially adapted for transmission systems H04B15/00, H04L25/08)
- H03K 17/08104: {in field-effect transistor switches (H03K17/0812, H03K17/0814 take precedence)}
- H03K 17/08116: {in composite switches (H03K17/0812, H03K17/0814 take precedence)}
- H03K 17/08122: {in field-effect transistor switches}
- H03K 17/0822: {in field-effect transistor switches}
- H03K 17/12: Modifications for increasing the maximum permissible switched current
- H03K 17/122: {in field-effect transistor switches}
- H03K 17/162: {without feedback from the output circuit to the control circuit}
- H03K 17/164: {using parallel switching arrangements}
- H03K 17/165: {by feedback from the output circuit to the control circuit}
- H03K 17/167: {using parallel switching arrangements}
- H03K 17/18: Modifications for indicating state of switch
- H03K 17/284: in field effect transistor switches
- H03K 17/689: with galvanic isolation between the control circuit and the output circuit (H03K17/78 takes precedence)
- H03K 17/722: with galvanic isolation between the control circuit and the output circuit (H03K17/78 takes precedence)
- H03K 17/723: using transformer coupling
- H04L 25/0266: {Arrangements for providing Galvanic isolation, e.g. by means of magnetic or capacitive coupling}
- H04L 25/03834: {using pulse shaping}
- H04L 25/4902: {Pulse width modulation; Pulse position modulation}
- H05K 7/14329: {specially adapted for the configuration of power bus bars}
- H05K 7/20154: {Heat dissipaters coupled to components}
- H05K 7/20254: {Cold plates transferring heat from heat source to coolant}
- H05K 7/2049: {Pressing means used to urge contact, e.g. springs}
- H05K 7/20854: {Heat transfer by conduction from internal heat source to heat radiating structure (H05K7/20863 takes precedence)}
- H05K 7/209: {Heat transfer by conduction from internal heat source to heat radiating structure (H05K7/20909 takes precedence)}
- H05K 7/20927: {Liquid coolant without phase change}
- H10W 40/037: {Assembling together parts thereof}
- H10W 40/22: characterised by their shape, e.g. having conical or cylindrical projections
- H10W 40/255: {having a laminate or multilayered structure, e.g. direct bond copper [DBC] ceramic substrates}
- H10W 40/43: by flowing gases, e.g. forced air cooling
- H10W 40/611: {Bolts or screws}
- H10W 40/641: {Snap-on arrangements, e.g. clips}
- H10W 40/778: {in encapsulations}
- H10W 44/501: {Inductive arrangements (H10W44/20 takes precedence)}
- H10W 70/481: {for devices being provided for in groups H10D8/00 - H10D48/00}
- H10W 70/611: {for connecting multiple chips together}
- H10W 70/65: Shapes or dispositions of interconnections
- H10W 90/00: Package configurations
- H10W 90/401: {characterised by multiple insulating or insulated package substrates, interposers or RDLs}
- H10W 90/701: {characterised by the relative positions of pads or connectors relative to package parts}
- B60L 3/003: {relating to inverters}
- B60L 15/007: {Physical arrangements or structures of drive train converters specially adapted for the propulsion motors of electric vehicles}
- B60L 15/08: using pulses
- B60L 15/20: for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed
- B60L 50/40: using propulsion power supplied by capacitors
- B60L 50/51: characterised by AC-motors
- B60L 50/60: using power supplied by batteries (in combination with fuel cells B60L50/75)
- B60L 50/64: Constructional details of batteries specially adapted for electric vehicles
- B60L 53/20: characterised by converters located in the vehicle
- B60L 53/22: Constructional details or arrangements of charging converters specially adapted for charging electric vehicles
- B60L 53/62: in response to charging parameters, e.g. current, voltage or electrical charge
- B60L 2210/30: AC to DC converters
- B60L 2210/40: DC to AC converters
- B60L 2210/42: Voltage source inverters
- B60L 2210/44: Current source inverters
- B60L 2240/36: Temperature of vehicle components or parts
- B60L 2240/525: Temperature of converter or components thereof
- B60L 2240/526: Operating parameters
- B60L 2240/527: Voltage
- B60L 2240/529: Current
- B60R 16/02: electric {constitutive elements}
- G01R 15/20: using galvano-magnetic devices, e.g. Hall-effect devices {, i.e. measuring a magnetic field via the interaction between a current and a magnetic field, e.g. magneto resistive or Hall effect devices}
- G06F 1/08: Clock generators with changeable or programmable clock frequency
- G06F 13/4004: {Coupling between buses}
- G06F 2213/40: Bus coupling
- H02J 7/855: {with circuits adapted for supplying loads from the battery}
- H02J 2207/20: Charging or discharging characterised by the power electronics converter
- H02M 1/0009: {Devices or circuits for detecting current in a converter}
- H02M 1/08: Circuits specially adapted for the generation of control voltages for semiconductor devices incorporated in static converters
- H02M 1/084: using a control circuit common to several phases of a multi-phase system
- H02M 1/088: for the simultaneous control of series or parallel connected semiconductor devices
- H02M 1/123: {Suppression of common mode voltage or current}
- H02M 1/32: Means for protecting converters other than automatic disconnection
- H02M 1/322: {Means for rapidly discharging a capacitor of the converter for protecting electrical components or for preventing electrical shock}
- H02M 1/4258: {using a single converter stage both for correction of AC input power factor and generation of a regulated and galvanically isolated DC output voltage (H02M1/4241 takes precedence)}
- H02M 1/44: Circuits or arrangements for compensating for electromagnetic interference in converters or inverters
- H02M 3/003: {Constructional details, e.g. physical layout, assembly, wiring or busbar connections}
- H02M 3/33523: {with galvanic isolation between input and output of both the power stage and the feedback loop}
- H02M 7/003: {Constructional details, e.g. physical layout, assembly, wiring or busbar connections}
- H02M 7/537: using semiconductor devices only, e.g. single switched pulse inverters
- H02M 7/5387: in a bridge configuration
- H02M 7/53871: {with automatic control of output voltage or current}
- H02M 7/53875: {with analogue control of three-phase output}
- H02M 7/5395: by pulse-width modulation
- H02P 27/06: using DC to AC converters or inverters (H02P27/05 takes precedence)
- H02P 27/085: {wherein the PWM mode is adapted on the running conditions of the motor, e.g. the switching frequency}
- H02P 29/024: Detecting a fault condition, e.g. short circuit, locked rotor, open circuit or loss of load
- H02P 29/027: {the fault being an over-current}
- H02P 29/68: based on the temperature of a drive component or a semiconductor component
- H02P 2207/05: Synchronous machines, e.g. with permanent magnets or DC excitation
- H03F 2200/168: Two amplifying stages are coupled by means of a filter circuit
- H03K 19/20: characterised by logic function, e.g. AND, OR, NOR, NOT circuits (H03K19/003 - H03K19/01 take precedence)
- H03K 2017/0806: {against excessive temperature}
- H03K 2217/0063: High side switches, i.e. the higher potential [DC] or life wire [AC] being directly connected to the switch and not via the load
- H03K 2217/0072: Low side switches, i.e. the lower potential [DC] or neutral wire [AC] being directly connected to the switch and not via the load
- H05K 1/145: {Arrangements wherein electric components are disposed between and simultaneously connected to two planar printed circuit boards, e.g. Cordwood modules}
- H05K 1/181: associated with surface mounted components
- H05K 1/182: associated with components mounted in printed circuit boards [PCB], e.g. insert-mounted components [IMC]
- H05K 5/0247: {Electrical details of casings, e.g. terminals, passages for cables or wiring}
- H05K 7/2039: {characterised by the heat transfer by conduction from the heat generating element to a dissipating body (arrangements for increasing/decreasing heat-transfer, e.g. fins details, F28F13/00)}
- H05K 2201/042: Stacked spaced PCBs; Planar parts of folded flexible circuits having mounted components in between or spaced from each other
- H05K 2201/10166: Transistor
- H10D 64/018: {Spacers formed inside holes at the prospective gate locations, e.g. holes left by removing dummy gates}
- H10W 40/226: {characterised by projecting parts, e.g. fins to increase surface area (leadframes for cooling H10W70/461)}
- H10W 40/228: {the projecting parts being wire-shaped or pin-shaped}
- H10W 40/235: {attached to package parts}
- H10W 40/47: by flowing liquids, e.g. forced water cooling
- H10W 40/60: Securing means for detachable heating or cooling arrangements, e.g. clamps
- H10W 70/685: comprising multiple insulating layers
- H10W 70/692: Ceramics or glasses
- H10W 72/00: Interconnections or connectors in packages
- H10W 72/07231: {Techniques}
- H10W 72/07331: {Connecting techniques}
- H10W 72/07354: {changes in dispositions}
- H10W 72/30: Die-attach connectors
- H10W 72/347: {Dispositions of multiple die-attach connectors}
- H10W 76/138: having another interconnection being formed by a cover plate parallel to the conductive base, e.g. sandwich type
- H10W 90/734: {between a chip and a stacked insulating package substrate, interposer or RDL}
- H10W 90/736: {between a chip and a stacked lead frame, conducting package substrate or heat sink}
- H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- 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
- G01R: MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES (indicating correct tuning of resonant circuits H03J3/12)
- 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
- H03F: AMPLIFIERS
- H03K: PULSE TECHNIQUE (measuring pulse characteristics G01R; modulating sinusoidal oscillations with pulses H03C; transmission of digital information H04L; discriminator circuits detecting phase difference between two signals by counting or integrating cycles of oscillation H03D3/04; automatic control, starting, synchronisation or stabilisation of generators of electronic oscillations or pulses where the type of generator is irrelevant or unspecified H03L; coding, decoding or code conversion, in general H03M)
- H04L: TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION (arrangements common to telegraphic and telephonic communication H04M)
- H10W: GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
- B60R: VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- G06F: ELECTRIC DIGITAL DATA PROCESSING (computer systems based on specific computational models G06N)
- H02J: ELECTRIC POWER NETWORKS; CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
- H10D: INORGANIC ELECTRIC SEMICONDUCTOR DEVICES

## Abstract

A system includes an inverter including: a point-of-use controller for a power module, the point-of-use controller including: a positive voltage connection configured to receive a positive control voltage from a high-voltage controller; a command connection configured to receive a command from the high-voltage controller; a message connection configured to send and receive a message to and from the high-voltage controller; a negative voltage connection configured to receive a positive control voltage from the high-voltage controller; a north gate connection configured to output a north gate control signal to a north group of one or more switches; a south gate connection configured to output a south gate control signal to a south group of one or more switches; a north sense connection configured to connect to a first portion of a sensing trace; and a south sense connection configured to receive a second portion of the sensing trace.

## Claims

### Claim 1

A system comprising:
an inverter configured to convert DC power from a battery to AC power to drive a motor, wherein the inverter includes:
a point-of-use controller for a power module for the inverter, the point-of-use controller including:
a positive voltage connection configured to receive a positive control voltage from a high-voltage controller;
a command connection configured to receive a command from the high-voltage controller;
a message connection configured to send and receive a message to and from the high-voltage controller;
a negative voltage connection configured to receive a positive control voltage from the high-voltage controller;
a north gate connection configured to output a north gate control signal to a north group of one or more switches;
a south gate connection configured to output a south gate control signal to a south group of one or more switches;
a north sense connection configured to connect to a first portion of a sensing trace; and
a south sense connection configured to receive a second portion of the sensing trace.

### Claim 2 (depends on 1)

The system of claim 1, wherein the north gate connection is configured to output the north gate control signal based on the command from the high-voltage controller, and the south gate connection is configured to output the south gate control signal based on the command from the high-voltage controller.

### Claim 3 (depends on 2)

The system of claim 2, wherein the north gate connection is configured to output the north gate control signal with an adjusted waveform timing and adjusted waveform shape relative to the command from the high-voltage controller, and the south gate connection is configured to output the south gate control signal with an adjusted waveform timing and adjusted waveform shape relative to the command from the high-voltage controller.

### Claim 4 (depends on 1)

The system of claim 1, wherein the message connection is configured to send the message to the high-voltage controller based on a signal from one or more of the north sense connection or the south sense connection.

### Claim 5 (depends on 1)

The system of claim 1, wherein the message connection is configured to send the message to the high-voltage controller based on a temperature of the point-of-use controller.

### Claim 6 (depends on 1)

The system of claim 1, wherein the north gate connection is configured to output the north gate control signal based on the command from the high-voltage controller, and by using sense and control methods to output the north gate control signal to minimize switching losses based on one or more of variation in intrinsic parameters of a group of one or more switches, parameter drift over a life of the group of one or more switches, or an operating temperature of the group of one or more switches.

### Claim 7 (depends on 1)

The system of claim 1, wherein the point-of-use controller is an application-specific integrated circuit.

### Claim 8 (depends on 1)

The system of claim 1, further comprising:
the battery configured to supply the DC power to the inverter; and
the motor configured to receive the AC power from the inverter to drive the motor.

### Claim 9

A system including:
a point-of-use controller for a power module for an inverter, the point-of-use controller including:
a positive voltage connection configured to receive a positive control voltage from a high-voltage controller;
a command connection configured to receive a command from the high-voltage controller;
a message connection configured to send and receive a message to and from the high-voltage controller;
a negative voltage connection configured to receive a positive control voltage from the high-voltage controller;
a north gate connection configured to output a north gate control signal to a north group of one or more switches;
a south gate connection configured to output a south gate control signal to a south group of one or more switches;
a north sense connection configured to connect to a first portion of a sensing trace; and
a south sense connection configured to receive a second portion of the sensing trace.

### Claim 10 (depends on 9)

The system of claim 9, wherein the north gate connection is configured to output the north gate control signal based on the command from the high-voltage controller, and the south gate connection is configured to output the south gate control signal based on the command from the high-voltage controller.

### Claim 11 (depends on 10)

The system of claim 10, wherein the north gate connection is configured to output the north gate control signal with an adjusted waveform timing and adjusted waveform shape relative to the command from the high-voltage controller, and the south gate connection is configured to output the south gate control signal with an adjusted waveform timing and adjusted waveform shape relative to the command from the high-voltage controller.

### Claim 12 (depends on 9)

The system of claim 9, wherein the message connection is configured to send the message to the high-voltage controller based on a signal from one or more of the north sense connection or the south sense connection.

### Claim 13 (depends on 9)

The system of claim 9, wherein the message connection is configured to send the message to the high-voltage controller based on a temperature of the point-of-use controller.

### Claim 14 (depends on 9)

The system of claim 9, wherein the point-of-use controller is an application-specific integrated circuit.

### Claim 15

A system comprising:
a point-of-use controller for a power module for an inverter, the point-of-use controller including:
a communication manager configured to control one or more of inter-controller communications to and from the point-of-use controller or intra-controller communications;
a north switches control and diagnostics controller configured to send one or more signals to a north group of switches of the power module to control an operation of the north group of switches, and configured to receive one or more signals from the north group of switches that provide information about the north group of switches; and
a south switches control and diagnostics controller configured to send one or more signals to a south group of switches of the power module to control an operation of the south group of switches, and configured to receive one or more signals from the south group of switches that provide information about the south group of switches.

### Claim 16 (depends on 15)

The system of claim 15, wherein the point-of-use controller further comprises:
a north thermal sensor configured to sense a first temperature at a first location in the point-of-use controller; and
a south thermal sensor configured to sense a second temperature at a second location in the point-of-use controller.

### Claim 17 (depends on 16)

The system of claim 16, wherein the point-of-use controller further comprises:
a command manager configured to control commands received from communication manager and issued to the north switches control and diagnostics controller and south switches control and diagnostics controller; and
a waveform adjuster configured to control a waveform timing and shape of commands received from communication manager and issued to the north switches control and diagnostics controller and south switches control and diagnostics controller.

### Claim 18 (depends on 17)

The system of claim 17, wherein the point-of-use controller further comprises:
a functional safety controller configured to control safety functions of the point-of-use controller;
a testing interface controller configured to control testing functions of the point-of-use controller;
a self-test controller configured to control a self-test function of the point-of-use controller; and
a memory including one or more volatile or non-volatile storage media for operation of the point-of-use controller.

### Claim 19 (depends on 18)

The system of claim 18, wherein the point-of-use controller further comprises:
an upper auto-calibrator configured to calibrate the north switches control and diagnostics controller; and
a lower auto-calibrator configured to calibrate the south switches control and diagnostics controller.

### Claim 20 (depends on 19)

The system of claim 19, wherein the point-of-use controller further comprises:
an upper regulator configured to regulate a north control voltage of the point-of-use controller; and
a lower regulator configured to regulate a south control voltage of the point-of-use controller.