Power electronics module
A power electronics module includes a printed circuit board populated with numerous components of the power electronics module. Power semiconductors and DC and AC connecting elements are either placed adjacently to one another on an organic insulator, and each thermally and mechanically connected to a heat sink through the organic insulator, or the DC and AC connecting elements are placed between the power semiconductors and the heat sink and are thermally and mechanically connected to the heat sink and to the power semiconductors.
1. A power electronics module, comprising:
a printed circuit board populated with a plurality of components of the power electronics module, at least some of which form discrete power semiconductors each comprising a housing, wherein a first side of the housing is configured to thermally connect to an upper surface of a heat sink, and wherein another side of the housing are configured to be attached to the printed circuit board and brought into electrical contact;
the heat sink opposite the first side of the housings of the power semiconductors, the upper surface of which is thermally connected to a first side of each power semiconductor;
electrically conductive DC and AC connecting elements configured to obtain electric contact to the power semiconductors; and
an insulator located between the printed circuit board and the heat sink, wherein the insulator comprises an insulated metal substrate between the power semiconductors and the heat sink, wherein the insulated metal substrate comprises a metal core, an insulating layer, and a metal layer, wherein the insulated metal substrate is placed such that the metal layer is connected to the heat sink, and the metal core is connected to the power semiconductors, and is structured such that it functions as the DC and AC connecting elements.
2. The power electronics module according to claim 1 , wherein a surface area of the DC and AC connecting elements is larger than a surface area of the power semiconductors placed thereon in the cases in which the DC and AC connecting elements are between the power semiconductors and the heat sink.
3. The power electronics module according to claim 1 , wherein the metal core or the lead frame is structured such that a part thereof functions as a ground connection.
4. The power electronics module according to claim 1 , wherein the metal core is structured such that there is a trough reaching to the insulating layer between the DC and AC connecting elements.
5. The power electronics module according to claim 1 , wherein an electrical and/or mechanical connection is a soldered or sintered connection.
6. The power electronics module according to claim 1 , wherein thermal contact by the housings of the power semiconductors is formed as a surface area contact.
7. The power electronics module according to claim 1 , wherein the power semiconductors comprise semiconductor switches.
8. The power electronics module according to claim 1 , wherein the power electronics module comprises a DC/DC converter, an inverter, or a charger.
9. The power electronics module according to claim 1 , comprising:
an electrically insulating compound placed in spaces between the printed circuit board and the heat sink.
10. An inverter or DC/DC converter, comprising the power electronics module according to claim 1 .
11. An electric drive or fuel cell drive for a motor vehicle, comprising the inverter or DC/DC converter according to claim 10 .
12. The motor vehicle, comprising an electric motor driven by the electric drive or the fuel cell drive according to claim 11 .
13. A method for producing a power electronics module, comprising:
structuring a metal core in an insulated metal substrate in advance, and connecting a metal layer in the insulated metal substrate to a heat sink, and subsequently connecting discrete power semiconductors to the insulated metal substrate, wherein the insulated metal substrate also includes an insulating layer;
bringing a plurality of discrete power semiconductors and other components of the power electronics module into electrical contact with a printed circuit board; and, wherein the discrete power semiconductors each comprise a housing;
thermally connecting a first side of the housing to an upper surface of the heat sink, and attaching another side of the housing to the printed circuit board and brought into electrical contact;
electrically connecting electrically conductive DC and AC connecting elements to the power semiconductors; and
locating the insulated metal substrate between the printed circuit board and the heat sink such that the metal layer is connected to the heat sink and the metal core is connected to the power semiconductors, and so that it functions as the DC and AC connecting elements.