# US 12,225,696 B2 · Systems and methods for low inductance phase switch for inverter for electric vehicle

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- Number: US 12,225,696 B2
- Document ID: US12225696B2
- Status: Granted
- Kind: B2
- Application number: 18/166,043
- Filed: 2023-02-08
- Published: 2024-03-28
- Granted: 2025-02-11
- Earliest claimed: 2022-09-28
- Assignees: BorgWarner US Technologies LLC
- Applicants: BorgWarner US Technologies LLC
- Inventors: Mark Wendell Gose; Seyed R. Zarabadi
- Web page: https://patentgrep.com/patent/US12225696B2

## 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 configured to convert DC power from a battery to AC power to drive a motor, wherein the inverter includes: a power module including: a first phase switch including one or more first phase power switches on a first side of a substrate; and a second phase switch including one or more second phase power switches on a second side of the substrate opposite to the first side.

## 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 power module including:
a first phase switch including one or more first phase power switches on a first side of a substrate and one or more first thermal spacers on the first side of the substrate; and
a second phase switch including one or more second phase power switches on a second side of the substrate opposite to the first side and one or more second thermal spacers on the second side of the substrate;
wherein the one or more first thermal spacers are approximately aligned with the one or more second phase power switches, and the one or more second thermal spacers are approximately aligned with the one or more first phase power switches.

### Claim 2 (depends on 1)

The system of claim 1,
wherein the first phase switch includes a first point-of-use controller on the first side of the substrate, the first point-of-use controller configured to control the one or more first phase power switches; and
wherein the second phase switch includes a second point-of-use controller on the second side of the substrate, the second point-of-use controller configured to control the one or more second phase power switches.

### Claim 3 (depends on 1)

The system of claim 1,
wherein the first phase switch is configured to be connected between a negative terminal of the battery and a phase terminal of the motor, and
wherein the second phase switch is configured to be connected between a positive terminal of the battery and the phase terminal of the motor.

### Claim 4 (depends on 1)

The system of claim 1, wherein the one or more of the first phase power switches or the second phase power switches includes one or more silicon carbide dies.

### Claim 5 (depends on 1)

The system of claim 1, wherein the first phase switch and the second phase switch are arranged in a 180-degree orientation relative to each other.

### Claim 6 (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 7

A system comprising:
a power module for an inverter, the power module including:
a first phase switch including one or more first phase power switches on a first side of a substrate, wherein the first phase switch is configured to be connected between a negative terminal of a battery and a phase terminal of a motor; and
a second phase switch including one or more second phase power switches on a second side of the substrate opposite to the first side, wherein the second phase switch is configured to be connected between a positive terminal of the battery and the phase terminal of the motor.

### Claim 8 (depends on 7)

The system of claim 7,
wherein the first phase switch includes a first point-of-use controller on the first side of the substrate, the first point-of-use controller configured to control the one or more first phase power switches; and
wherein the second phase switch includes a second point-of-use controller on the second side of the substrate, the second point-of-use controller configured to control the one or more second phase power switches.

### Claim 9 (depends on 7)

The system of claim 7,
wherein the first phase switch includes one or more first thermal spacers on the first side of the substrate; and
wherein the second phase switch includes one or more second thermal spacers on the second side of the substrate.

### Claim 10 (depends on 9)

The system of claim 9, wherein the one or more first thermal spacers are approximately aligned with the one or more second phase power switches, and the one or more second thermal spacers are approximately aligned with the one or more first phase power switches.

### Claim 11 (depends on 7)

The system of claim 7, wherein the first phase switch and the second phase switch are arranged in a 180-degree orientation relative to each other.

### Claim 12

A system comprising:
a power module for an inverter, the power module including:
a battery side negative tab;
a battery side positive tab;
a motor side tab;
a first phase switch extending along a first plane, the first phase switch configured to control a flow of current between the battery side negative tab and the motor side tab; and
a second phase switch extending along a second plane, the second phase switch configured to control a flow of current between the battery side positive tab and the motor side tab,
wherein the first phase switch is stacked on the second phase switch so that a normal vector from the first plane intersects the second plane.

### Claim 13 (depends on 12)

The system of claim 12, wherein one or more of the battery side negative tab or battery side positive tab extends in a first direction approximately perpendicular to the first plane and the second plane.

### Claim 14 (depends on 13)

The system of claim 13,
wherein the first phase switch includes one or more communication pins, and
wherein the one or more communication pins extends in a second direction opposite to the first direction.

### Claim 15 (depends on 12)

The system of claim 12,
wherein the battery side negative tab is arranged on a first end of the first phase switch,
wherein the battery side positive tab is arranged on a first end of the second phase switch, and
wherein the motor side tab is arranged on a second end of the first phase switch and a second end of the second phase switch.

### Claim 16 (depends on 12)

The system of claim 12,
wherein the first phase switch includes one or more communication pins, and
wherein the one or more communication pins extend from the first phase switch and pass through an opening in the battery side positive tab.

### Claim 17 (depends on 12)

The system of claim 12, further comprising:
a first heat sink provided on a first side of the power module; and
a second heat sink provided on a second side of the power module.