Systems and methods for power module for inverter for electric vehicle
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 first power module, the first power module including: a first substrate including a first conductive layer; a second substrate including a second conductive layer; a power switch between the first conductive layer and the second conductive layer, the power switch including a gate connection, wherein the power switch is configured to selectively electrically connect the first conductive layer to the second conductive layer based on a signal to the gate connection; and a point-of-use controller between the first conductive layer and the second conductive layer, the point-of-use controller configured to provide the signal to the gate connection to control the power switch.
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 first power module, the first power module including:
a first substrate including a first conductive layer;
a second substrate including a second conductive layer;
a power switch between the first conductive layer and the second conductive layer, the power switch including a gate connection, wherein the power switch is configured to selectively electrically connect the first conductive layer to the second conductive layer based on a signal to the gate connection; and
a point-of-use controller between the first conductive layer and the second conductive layer, the point-of-use controller configured to provide the signal to the gate connection to control the power switch.
2 . The system of claim 1 , wherein the first power module further includes:
a first lead frame connection; and
a second lead frame connection,
wherein the point-of-use controller is on the first substrate between the first lead frame connection and the second lead frame connection.
3 . The system of claim 2 , wherein the first power module further includes:
an electrically conductive spacer between the first substrate and the second substrate,
wherein the first lead frame connection is connected to the first power switch via the electrically conductive spacer.
4 . The system of claim 1 , wherein the first power module further includes:
a flex layer between the first substrate and the second substrate,
wherein the point-of-use controller is connected to the gate connection via the flex layer.
5 . The system of claim 4 , wherein the first power module further includes:
a control connection,
wherein the first point-of-use controller is connected to the control connection via the flex layer.
6 . The system of claim 1 , wherein the power switch includes one or more silicon carbide dies.
7 . The system of claim 1 , wherein the inverter further includes:
a second power module; and
a third power module.
8 . 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.
9 . A system comprising:
a power module for an inverter, the power module including:
a first substrate including a first conductive region and a second conductive region;
a second substrate including a third conductive region and a fourth conductive region;
a first power switch between the first substrate and the second substrate, the first power switch including a first gate connection, wherein the first power switch is configured to selectively electrically connect the first conductive region to the third conductive region based on a first signal to the first gate connection; and
a first point-of-use controller between the first substrate and the second substrate, the first point-of-use controller configured to provide the first signal to the first gate connection to control the first power switch.
10 . The system of claim 9 , wherein the power module further includes:
a second power switch between the first substrate and the second substrate, the second power switch including a second gate connection, wherein the second power switch is configured to selectively electrically connect the second conductive region to the fourth conductive region based on a second signal to the second gate connection.
11 . The system of claim 10 , wherein the power module further includes:
a second point-of-use controller between the first substrate and the second substrate, the second point-of-use controller configured to provide the second signal to the second gate connection to control the second power switch.
12 . The system of claim 9 , wherein the power module further includes:
a first lead frame connection; and
a second lead frame connection,
wherein the first point-of-use controller is on the first substrate between the first lead frame connection and the second lead frame connection.
13 . The system of claim 12 , wherein the power module further includes:
an electrically conductive spacer between the first substrate and the second substrate,
wherein the first lead frame connection is connected to the first power switch via the electrically conductive spacer.
14 . The system of claim 9 , wherein the power module further includes:
a flex layer between the first substrate and the second substrate,
wherein the first point-of-use controller is connected to the first gate connection via the flex layer.
15 . A system comprising:
a power module for an inverter, the power module including:
a lower substrate including a lower conductive layer, the lower conductive layer including a first lower conductive region and a second lower conductive region;
an upper substrate including an upper conductive layer, the upper conductive layer including a first upper conductive region and a second upper conductive region;
a first power switch between the first lower conductive region and the first upper conductive region, the first power switch including a first gate connection, wherein the first power switch is configured to selectively electrically connect the first lower conductive region to the first upper conductive region based on a first signal to the first gate connection;
a first point-of-use controller between the lower conductive layer and the upper conductive layer, the first point-of-use controller configured to provide the first signal to the first gate connection to control the first power switch;
a second power switch between the second lower conductive region and the second upper conductive region, the second power switch including a second gate connection, wherein the second power switch is configured to selectively electrically connect the second lower conductive region to the second upper conductive region based on a second signal to the second gate connection; and
a second point-of-use controller between the lower conductive layer and the upper conductive layer, the second point-of-use controller configured to provide the second signal to the second gate connection to control the second power switch.
16 . The system of claim 15 , wherein the power module further includes:
a first lead frame connection; and
a second lead frame connection,
wherein the first point-of-use controller is on the lower substrate between the first lead frame connection and the second lead frame connection.
17 . The system of claim 16 , wherein the power module further includes:
a third lead frame connection,
wherein the second point-of-use controller is on the lower substrate between the third lead frame connection and the second lead frame connection.
18 . The system of claim 16 , wherein the power module further includes:
an electrically conductive spacer between the lower substrate and the upper substrate,
wherein the first lead frame connection is connected to the first power switch via the electrically conductive spacer.
19 . The system of claim 15 , wherein the power module further includes:
a flex layer between the lower conductive layer and the upper conductive layer,
wherein the first point-of-use controller is connected to the first gate connection via the flex layer.
20 . The system of claim 19 , wherein the power module further includes:
a control connection,
wherein the first point-of-use controller is connected to the control connection via the flex layer.