Packaging of wide bandgap power electronic power stages
Design and packaging of wide bandgap (WBG) power electronic power stages are disclosed herein. An example apparatus includes a first printed circuit board (PCB) including: a first voltage phase circuit cluster; a second voltage phase circuit cluster; and a cluster of traces, the cluster of traces routed substantially perpendicular to the second voltage phase circuit cluster; a second PCB positioned below the first PCB; and a connector to connect the first PCB to the second PCB, the connector electrically coupled to the first voltage phase circuit cluster by the cluster of traces.
1. An apparatus comprising:
a power switching assembly having a rear face;
a capacitor bank having a top side and a front face; and
a bus bar having first and second subregions and including positive and negative voltage bus sheets, the first subregion positioned above the capacitor bank with an approximately congruent surface area to that of the top side of the capacitor bank, the second subregion curving along the front face of the capacitor bank and extending into a cavity between the capacitor bank and the rear face of the power switching assembly, the positive and negative voltage bus sheets coated with a dielectric thermal interface material (TIM) to improve at least one of thermal conductivity of the bus bar or electrical insulation of the bus bar, the dielectric TIM including a high thermal conductivity.
2. The apparatus of claim 1 , wherein the approximately congruent surface area is a first approximately congruent surface area, and the second subregion includes a second approximately congruent surface area to that of the front face of the capacitor bank and the rear face of the power switching assembly.
3. The apparatus of claim 1 , wherein:
the bus bar includes one or more press fit holes structured to receive one or more press fit pins; and
the capacitor bank includes one or more capacitors including the one or more press fit pins structured to be inserted into the one or more press fit holes, the one or more press fit holes and the one or more press fit pins to reduce capital expended in production of the apparatus.
4. The apparatus of claim 1 , wherein at least the dielectric TIM and the positive and negative voltage bus sheets of the bus bar are to reduce an inductance between the power switching assembly and a traction drive of a vehicle including the apparatus.
5. The apparatus of claim 1 , wherein the apparatus further includes a top cover to encase the power switching assembly, the capacitor bank, and the bus bar, the top cover coated with the dielectric TIM.
6. The apparatus of claim 5 , wherein the dielectric TIM thermally bonds the top cover and the bus bar.
7. The apparatus of claim 1 , wherein the first subregion having the approximately congruent surface area to that of the top side of the capacitor bank is to cool the capacitor bank, the cooling to avoid peaks in a temperature of one or more capacitors of the capacitor bank when heat is generated by the power switching assembly.
8. The apparatus of claim 1 , wherein the dielectric TIM includes a silicone-based material.
9. The apparatus of claim 1 , wherein the dielectric TIM includes a non-silicone-based material.
10. The apparatus of claim 9 , wherein the non-silicone-based material includes one or more of zinc oxide, aluminum, aluminum oxide, or aluminum nitride.
11. The apparatus of claim 1 , wherein the dielectric TIM includes one or more embedded objects within the dielectric TIM.
12. The apparatus of claim 11 , wherein the one or more embedded objects include one or more silver beads.
13. The apparatus of claim 11 , wherein the apparatus further includes a top cover to encase the power switching assembly, and the one or more embedded objects are to increase thermal conductivity between the bus bar and top cover while maintaining the electrical insulation provided by the dielectric TIM.
14. The apparatus of claim 11 , wherein the one or more embedded objects are at least one of micrometer-scale or nanometer-scale.
15. The apparatus of claim 1 , wherein the high thermal conductivity of the dielectric TIM is between 3 Watts per meter-Kelvin (W/m-K) and 8.5 W/m-K.
16. The apparatus of claim 15 , wherein the high thermal conductivity of the dielectric TIM is 3 W/m-K for a thickness of 0.25 millimeters.