US 12,348,157 B2
Systems and methods for power module for inverter for electric vehicle
David Paul Buehler, Noblesville, IN (US); Kevin M. Gertiser, Carmel, IN (US); David W. Ihms, Kokomo, IN (US); and Mark Wendell Gose, Kokomo, IN (US)
Assigned to BorgWarner US Technologies LLC, Wilmington, DE (US)
Filed by BorgWarner US Technologies LLC, Wilmington, DE (US)
Filed on Feb. 27, 2023, as Appl. No. 18/175,257.
Claims priority of provisional application 63/378,601, filed on Oct. 6, 2022.
Claims priority of provisional application 63/377,512, filed on Sep. 28, 2022.
Claims priority of provisional application 63/377,501, filed on Sep. 28, 2022.
Claims priority of provisional application 63/377,486, filed on Sep. 28, 2022.
Prior Publication US 2024/0100963 A1, Mar. 28, 2024
Int. Cl. H02P 27/06 (2006.01); B60L 3/00 (2019.01); B60L 15/00 (2006.01); B60L 15/08 (2006.01); B60L 50/40 (2019.01); B60L 50/51 (2019.01); B60L 50/60 (2019.01); B60L 50/64 (2019.01); B60L 53/20 (2019.01); B60L 53/22 (2019.01); B60L 53/62 (2019.01); B60R 16/02 (2006.01); G01R 15/20 (2006.01); G06D 1/08 (2006.01); G06F 1/08 (2006.01); G06F 13/40 (2006.01); H01L 21/48 (2006.01); H01L 23/00 (2006.01); H01L 23/15 (2006.01); H01L 23/367 (2006.01); H01L 23/373 (2006.01); H01L 23/40 (2006.01); H01L 23/467 (2006.01); H01L 23/473 (2006.01); H01L 23/495 (2006.01); H01L 23/538 (2006.01); H01L 25/00 (2006.01); H01L 25/07 (2006.01); H02J 7/00 (2006.01); H02M 1/00 (2007.01); H02M 1/08 (2006.01); H02M 1/084 (2006.01); H02M 1/088 (2006.01); H02M 1/12 (2006.01); H02M 1/32 (2007.01); H02M 1/42 (2007.01); H02M 1/44 (2007.01); H02M 7/00 (2006.01); H02M 7/537 (2006.01); H02M 7/5387 (2007.01); H02M 7/5395 (2006.01); H02P 27/08 (2006.01); H02P 29/024 (2016.01); H02P 29/68 (2016.01); H05K 1/14 (2006.01); H05K 1/18 (2006.01); H05K 5/02 (2006.01); H05K 7/20 (2006.01); H10D 64/01 (2025.01); B60L 15/20 (2006.01); H02M 3/335 (2006.01); H03K 19/20 (2006.01)
CPC H02M 7/5387 (2013.01) [B60L 3/003 (2013.01); B60L 15/007 (2013.01); B60L 15/08 (2013.01); B60L 50/40 (2019.02); B60L 50/51 (2019.02); B60L 50/60 (2019.02); B60L 50/64 (2019.02); B60L 53/20 (2019.02); B60L 53/22 (2019.02); B60L 53/62 (2019.02); B60R 16/02 (2013.01); G01R 15/20 (2013.01); G06F 1/08 (2013.01); G06F 13/4004 (2013.01); H01L 21/4882 (2013.01); H01L 23/15 (2013.01); H01L 23/3672 (2013.01); H01L 23/3675 (2013.01); H01L 23/3735 (2013.01); H01L 23/4006 (2013.01); H01L 23/467 (2013.01); H01L 23/473 (2013.01); H01L 23/49562 (2013.01); H01L 23/5383 (2013.01); H01L 24/32 (2013.01); H01L 24/33 (2013.01); H01L 25/072 (2013.01); H01L 25/50 (2013.01); H02J 7/0063 (2013.01); H02M 1/0054 (2021.05); H02M 1/08 (2013.01); H02M 1/084 (2013.01); H02M 1/088 (2013.01); H02M 1/123 (2021.05); H02M 1/32 (2013.01); H02M 1/322 (2021.05); H02M 1/327 (2021.05); H02M 1/4258 (2013.01); H02M 1/44 (2013.01); H02M 7/003 (2013.01); H02M 7/537 (2013.01); H02M 7/53871 (2013.01); H02M 7/53875 (2013.01); H02M 7/5395 (2013.01); H02P 27/06 (2013.01); H02P 27/08 (2013.01); H02P 27/085 (2013.01); H02P 29/024 (2013.01); H02P 29/027 (2013.01); H02P 29/68 (2016.02); H05K 1/145 (2013.01); H05K 1/181 (2013.01); H05K 1/182 (2013.01); H05K 5/0247 (2013.01); H05K 7/20154 (2013.01); H05K 7/2039 (2013.01); H05K 7/2049 (2013.01); H05K 7/20854 (2013.01); H05K 7/209 (2013.01); H05K 7/20927 (2013.01); H10D 64/018 (2025.01); B60L 15/20 (2013.01); B60L 2210/30 (2013.01); B60L 2210/40 (2013.01); B60L 2210/42 (2013.01); B60L 2210/44 (2013.01); B60L 2240/36 (2013.01); G06F 2213/40 (2013.01); H01L 2023/405 (2013.01); H01L 2023/4087 (2013.01); H01L 2224/32225 (2013.01); H01L 2224/32245 (2013.01); H01L 2224/33181 (2013.01); H02J 2207/20 (2020.01); H02M 1/0009 (2021.05); H02M 3/33523 (2013.01); H02P 2207/05 (2013.01); H03K 19/20 (2013.01); H05K 2201/042 (2013.01); H05K 2201/10166 (2013.01)] 19 Claims
OG exemplary drawing
 
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 substrate including a first conductive layer;
a second substrate including a second conductive layer;
a power switch between the first substrate and the second substrate; and
a flex layer between the first substrate and the second substrate, wherein the flex layer is electrically connected to the power switch, and wherein the flex layer includes a base polyimide material, an internal conductive layer, and a coverlet.