INTRODUCTION

The information provided in this section is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.

The present disclosure relates to vehicle propulsion systems and more particularly to cooling of switches of an inverter module.

Some types of vehicles include only an internal combustion engine that generates propulsion torque. Electric vehicles may not include an internal combustion engine and may rely on one or more electric motors for propulsion.

Hybrid vehicles include both an internal combustion engine and one or more electric motors. Some types of hybrid vehicles utilize the electric motor and the internal combustion engine in an effort to achieve greater fuel efficiency than if only the internal combustion engine was used. Some types of hybrid vehicles utilize the electric motor and the internal combustion engine to achieve greater torque output than the internal combustion could achieve by itself.

Some example types of hybrid vehicles include parallel hybrid vehicles, series hybrid vehicles, and other types of hybrid vehicles. In a parallel hybrid vehicle, the electric motor works in parallel with the engine to combine power and range advantages of the engine with efficiency and regenerative braking advantages of electric motors. In a series hybrid vehicle, the engine drives a generator to produce electricity for the electric motor, and the electric motor drives a transmission. This allows the electric motor to assume some of the power responsibilities of the engine, which may permit the use of a smaller and possibly more efficient engine.

SUMMARY

In a feature, a switch cooling system includes: a coolant channel; a switch of an inverter module that is disposed in the coolant channel, that is configured to be immersed in coolant in the coolant channel, and that includes: a first terminal disposed on a first plane and configured to connect to a direct current (DC) reference potential; a second terminal disposed on a second plane and configured to connect to an alternating current (AC) reference potential; a gate, an emitter, and a collector; first cooling features that extend away from the first and second planes, that directly contact the first terminal, and that are configured to allow coolant flow therethrough; and second cooling features that extend away from the first cooling features, the first plane, and the second plane, that directly contact the second terminal, and that are configured to allow coolant flow therethrough.

In further features, the first and second planes are parallel.

In further features, the first cooling features extend perpendicularly away from the first and second planes.

In further features, the second cooling features extend perpendicularly away from the first and second planes.

In further features a second switch of the inverter module is disposed in the coolant channel, is configured to be immersed in the coolant in the coolant channel, and includes: a third terminal disposed on a third plane and configured to connect to a second DC reference potential; a second gate, a second emitter, and a second collector that are disposed between the second and third planes; and third cooling features that extend away from the second and third planes, that directly contact the third terminal, and that are configured to allow coolant flow therethrough.

In further features, an electrical insulator is disposed between (a) the gate, the emitter, and the collector and (b) the second gate, the second emitter, and the second collector.

In further features, first, second, and third electrical conductors are electrically connected to the first, second, and third terminals and extend through the coolant channel to outside of the coolant channel.

In further features, the first cooling features include members that extend perpendicularly to the first and second planes.

In further features, the first features include: a plurality of parallel plates; and posts that are separate the plates from each other.

In further features, the posts extend perpendicularly to the parallel plates.

In further features, the posts are cylindrical.

In further features, the posts all have the same diameter.

In further features, the posts all have the same pitch.

In further features, the posts include first posts having a first diameter and second posts having a second diameter.

In further features, the first posts have a first pitch and the second posts have a second pitch, wherein the first pitch is different than the second pitch.

In further features, the first cooling features include: a first layer including an inlet, an outlet, a first portion that is fluidly connected to the inlet, and a second portion that is fluidly connected to the outlet; a second layer including a third portion that is fluidly connected to the first and second portions of the first layer; and a third layer including a fourth portion that is fluidly connected to the first and second portions.

In further features, the first cooling features: two parallel plates; and a helical member having a first direction of rotation and disposed between the two parallel plates.

In further features, the first cooling features further include: a second helical member having a second direction of rotation and disposed between the two parallel plates.

In further features, the second direction of rotation is different than the first direction of rotation.

In further features, the first cooling features include: a first material having uniform openings configured to allow coolant flow therethrough; and a second material having non-uniform openings configured to allow coolant flow therethrough.

Further areas of applicability of the present disclosure will become apparent from the detailed description, the claims and the drawings. The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.

