Power module assembly for a vehicle power inverter

1. A power module assembly for a power inverter of a vehicle, the power module assembly comprising:

a housing defining a cavity; and

a plurality of cards arranged side-by-side in a planar, linear array, the array being positioned within the cavity such that an inlet manifold is defined between a first longitudinal side of the array and the housing and an outlet manifold is defined between a second longitudinal side of the array and the housing; wherein

the inlet and outlet manifolds cooperate to form a fluid circuit that is in direct contact with both sides of each of the cards.

2. The power module assembly of claim 1 , wherein the housing defines a channel, and the array defines a sealing surface raised from the first longitudinal side and received in the channel.

3. The power module assembly of claim 2 further comprising a seal disposed in the channel and sealing engaged between the sealing surface of the array and the housing.

4. The power module assembly of claim 2 , wherein the housing defines a second channel, and the array defines a second sealing surface raised from the second longitudinal side and received in the second channel.

5. The power module assembly of claim 1 , wherein each of the cards is connected to an adjacent one of the cards by locating features.

6. The power module assembly of claim 5 , wherein the locating features include a pin and a receptacle.

7. The power module assembly of claim 1 , wherein the housing includes a cover and a tray, and wherein each of the cards includes opposing minor sides that each have a compression limiter projecting outwardly therefrom and disposed between the cover and the tray to maintain a gap therebetween.

8. The power module assembly of claim 1 , wherein the housing defines an inlet port opening into the inlet manifold and an outlet port opening into the outlet manifold, the inlet and outlet ports being centrically aligned with each other and located on opposing sides of the housing, and further comprising a separator connected to one end of array and disposed between the inlet and outlet ports.

9. The power module assembly of claim 8 , wherein the separator is co-planar with the array.

10. The power module assembly of claim 8 , wherein one of the separator and the array defines a projection and the other of the separator and the array defines a receptacle that receives the projection.

11. The power module assembly of claim 8 further comprising a return guide connected to the other end of the array opposite the separator and configured to direct fluid from the inlet manifold to the outlet manifold.

12. The power module assembly of claim 1 , wherein the housing defines a plurality of flow guides disposed in the inlet and outlet manifolds and projecting towards the array.

13. A power module assembly for a power inverter of a vehicle, the power module assembly comprising:

a housing including a tray and a cover connectable to define a cavity, wherein the tray defines a first seat surrounding the cavity, and the cover defines a second seat surrounding the cavity; and

a plurality of cards each having a first substrate, a second substrate, a plurality of switching units sandwiched between the substrates, and a frame, the frame including opposing ends each having a first sealing ledge projecting outwardly from the first substrate and a second sealing ledge projecting outwardly from the second substrate; wherein

the cards are arranged in a side-by-side planar, linear array that is suspended in the cavity by the first ledges being received in the first seat and the second ledges being received in the second seat such that an inlet manifold is defined between a first longitudinal side of the array and the tray and an outlet manifold is defined between a second longitudinal side of the array and the cover.

14. The power module assembly of claim 13 further comprising:

a first seal disposed in the first seat and sealingly engaging with the first ledges;

a second seal disposed in the second seat and sealingly engaging with the second ledges.

15. The power module assembly of claim 13 wherein the tray defines an inlet port opening into the inlet manifold and the cover defines an outlet port opening into the outlet manifold, wherein the ports and manifolds form a fluid path that is in direct contact with the first and second substrates.

16. The power module assembly of claim 15 further comprising a separator connected to one end of array and disposed between the inlet and outlet ports.

17. The power module assembly of claim 16 , wherein the separator is co-planar with the array.

18. The power module assembly of claim 13 , wherein one of the cards includes a projection that is received in a receptacle defined in another of the cards.

19. A power module assembly for a power inverter of a vehicle, the power module assembly comprising:

a housing including a tray defining a first fluid port and a cover defining a second fluid port, wherein the tray and the cover cooperate to define a cavity in fluid communication with the first and second ports; and

a plurality of cards each including:

opposing first and second major sides,

a first set of opposing minor sides extending between the major sides,

a second set of opposing minor sides extending between the major sides,

a frame having a plurality of sealing surfaces each raised from one of the major sides, and

compression limiters each extending outwardly from one of the minor sides of the first set; wherein

the cards are arranged side-by-side in a linear, planar array with adjacent ones of the second set of opposing minor sides abutting each other, and

the array is disposed in the cavity with the compression limiters projecting from the cavity and sandwiched between the tray and the cover.

20. The power module assembly claim 19 further comprising a separator connected to one end of the array and positioned between the first and second fluid ports.