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style="font-size:14px;">混合動(dòng)力汽車(HEV)或充電電動(dòng)汽車(PEV)通常使用電機(jī)驅(qū)動(dòng)功率模塊，例如IGBT模塊，這些模塊會(huì)產(chǎn)生非常大的熱量，通常大約為1,000W到2,000W。冷卻這些汽車電子功率模塊的唯一有效方法是水冷，而不是風(fēng)冷，因?yàn)樗臒醾鲗?dǎo)率是空氣的20倍。水還具有很高的熱量(吸收能量的能力)，是空氣的4倍。 <BR><BR>在大多數(shù)的汽車應(yīng)用中，功率模塊都具有這樣的熱挑戰(zhàn)。事實(shí)上，有專門的獨(dú)立冷卻循環(huán)來對其進(jìn)行冷卻。<a class="contentlabel" href="http://www.ex-cimer.com/news/listbylabel/label/散熱片"><em>散熱片</em></a>用來將功率模塊的熱量傳導(dǎo)到冷卻液，成為冷卻循環(huán)的重要部分。那么，如何選擇最佳的液體冷卻<a class="contentlabel" href="http://www.ex-cimer.com/news/listbylabel/label/散熱片"><em>散熱片</em></a>呢？要做出這個(gè)選擇需要在多種考慮因素之間進(jìn)行權(quán)衡，例如熱性能、重量、成本、可靠性和可制造性。讓我們看看IGBT芯片產(chǎn)生的熱量是如何通過冷卻液傳導(dǎo)。 <BR><BR>改善導(dǎo)熱性能 <BR><BR>首先，熱必須通過直接敷銅(DBC)底層轉(zhuǎn)移出來，然后經(jīng)過模塊基板(base plate)，再通過熱油脂，再進(jìn)入到栓接的<a class="contentlabel" href="http://www.ex-cimer.com/news/listbylabel/label/散熱片"><em>散熱片</em></a>(見圖1)。這部分的熱量轉(zhuǎn)移完全是通過熱傳導(dǎo)來實(shí)現(xiàn)的。 <P align=center><img onload="if(this.width>620)this.width=620;" onclick="window.open(this.src)" style="cursor:pointer" alt=newmaker.com src="http://img.newmaker.com/nmsc/u/2007/200712/art_img/2007122812483871812.jpg" border=0></P>為改善傳導(dǎo)熱轉(zhuǎn)移，你要么選擇具有最高的導(dǎo)熱系數(shù)(k)的材料，要么降低層厚度，或者減少熱源與冷卻液之間的層數(shù)。例如，氮化鋁陶瓷(k=160W/mK)用作DBC基底材料，相比于氧化鋁來說(k = 25到 35 W/mK)是一種不錯(cuò)的選擇。相對于鋁(k = 220 W/mK)或者鋁硅炭化物(AlSiC) (k = 170 - 180 W/mK)來說，銅(k = 390 W/mK)材料是用于模塊基底更好的選擇。簡言之，如果不選擇非常昂貴的材料，你所選則的材料的導(dǎo)熱性能不會(huì)超過銅。 <BR><BR>可以簡化散熱片材料的選擇，實(shí)際上就是在鋁、AlSiC和銅之間選擇。鋁很輕而且便宜，但是導(dǎo)熱性能一般，而且很重要的是，沒有合適的制造方法來獲得高的表面積。鋁鑄模不能獲得高的密度，而且容易產(chǎn)生孔隙，會(huì)導(dǎo)致冷卻液的泄漏。鋁還具有比較高的熱膨漲系數(shù)(CTE ~ 23 ppm/C)，因此不適合用作功率模塊基板材料。 <BR><BR>AlSiC很輕，但是很昂貴，被加工用來降低CTE以接近IC材料，通常做成9 - 12 ppm/C之間。而且，AlSiC的鑄造工藝難以實(shí)現(xiàn)更大的冷卻表面。而且鑄模磨損很快，導(dǎo)致更換鑄模的成本開銷。最后，材料的導(dǎo)熱率相對比較差，大約為k＝170w/mK。因?yàn)檫@些原因，AlSiC從來沒有用作栓接冷卻片材料，在實(shí)際中，只有在需要非常高的可靠性的時(shí)候，才選擇AlSiC作為基板材料。 <BR><BR>銅具有很高的導(dǎo)熱率、可接受的成本，以及最重要的是，可以利用先進(jìn)的成模技術(shù)形成帶有非常密集針翅(pin fin)形狀的散熱片(例如Amulaire Nanopins)。銅鑄模能達(dá)到的針翅密度可以實(shí)現(xiàn)超過鋁或AlSiC散熱片3倍到5倍的散熱表面積。盡管銅的CTE比較高(17 ppm/C)，但是仍然成功地應(yīng)用在高可靠性汽車應(yīng)用中，作為功率模塊的基板/散熱片，其制造工藝是基于銅基板設(shè)計(jì)的。 <BR><BR>設(shè)計(jì)實(shí)踐 <BR><BR>優(yōu)化功率模塊冷卻的一個(gè)選擇是用散熱片替代功率模塊基板。這有效地去掉了組裝中的兩個(gè)層(原來的基板和導(dǎo)熱油脂)，大大地改善了從芯片到散熱片墻的熱傳導(dǎo)。 <BR><BR>一旦熱量轉(zhuǎn)移到散熱片墻，冷卻液對散熱片的冷卻就取決于對流熱傳導(dǎo)?；镜膶α鳠醾鲗?dǎo)等式為： <BR><BR>q = h A (Tw - Tf) <BR><BR>其中q為傳導(dǎo)的熱量，單位為瓦，h是對流熱傳導(dǎo)系數(shù)，A為散熱片與冷卻液接觸的表面積，Tw是散熱片墻的溫度，Tf為流動(dòng)液體的溫度。 <BR><BR>如前面所述，Tw的大小決定于從IGBT芯片經(jīng)過功率模塊器件傳導(dǎo)到散熱片墻的熱量，Tf由冷卻系統(tǒng)的其它參數(shù)決定。 <BR><BR>更有效的導(dǎo)熱路徑可以獲得更高的Tw，以及冷卻液更佳的對流冷卻。對于液體冷卻來說，無論采用什么散熱片，h值都將比較小。那么很明顯，在任何指定的Tw下，表面積A將主要確定液體冷卻散熱片的效果。 <BR><BR>本文小結(jié) <BR><BR>為了給HEV或PEV電機(jī)驅(qū)動(dòng)功率模塊提供最佳的冷卻解決方案，首先需要確保模塊結(jié)構(gòu)以及材料、散熱片墻具有最高的導(dǎo)熱率。采用散熱片作為功率模塊基板的設(shè)計(jì)，其表現(xiàn)的性能將遠(yuǎn)遠(yuǎn)高于栓接的散熱片。 <BR><BR>其次，使散熱片與冷卻液的接觸面積最大，同時(shí)讓液體流的壓力降低在一個(gè)合理的范圍。因此，選擇一個(gè)具有大表面積以及“平整”的散熱片。粗糙的或有角的散熱片會(huì)加大壓力降，迫使采用高功率和高成本的泵。通常，最佳的結(jié)構(gòu)是圓形或卵形針翅陣列。 <BR><BR>HEV或PEV功率模塊冷卻的最佳選擇是那些用銅制成的，具有大的表面積和壓力降低小的散熱片來替代模塊的基板。這種結(jié)構(gòu)可以實(shí)現(xiàn)性能、重量、尺寸、可靠性和成本的最佳結(jié)合。 <BR><BR>在作比較時(shí)，記住要考慮散熱片的所有參數(shù)。高性能銅散熱片作為功率模塊基板，由于其卓越的性能，大多數(shù)情況下可以直接包含在汽車引擎冷卻環(huán)路中。對于<a class="contentlabel" href="http://www.ex-cimer.com/news/listbylabel/label/發(fā)動(dòng)機(jī)"><em>發(fā)動(dòng)機(jī)</em></a><a class="contentlabel" href="http://www.ex-cimer.com/news/listbylabel/label/驅(qū)動(dòng)電路"><em>驅(qū)動(dòng)電路</em></a>來說，這種結(jié)構(gòu)節(jié)省了專用冷卻環(huán)路(泵、管道和水箱等)的成本，并減小了尺寸和重量。 (end) </span>  <div class="044yaii" id="coverDiv" class="article_reg" style="width:100%;overflow:hidden;display:none;z-index:10;position:absolute;left:0;background:#fff;"> <center> <img src="https://webstorage.eepw.com.cn/images/display/reg.jpg" border="0" usemap="#Map" /> <map name="Map" id="Map"> <area shape="rect" coords="133,235,319,253" target="_blank" /> <area shape="rect" coords="132,315,319,335" /> </map> </center> </div>  <span id="oayaqiq" class="hAd8"> 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