Motor controller and vehicle
By directly encapsulating and installing the capacitor module in the first cavity of the housing within the motor controller, and utilizing a combination of cooling water channels and heat dissipation holes in the thermal pad, the thermal resistance and heat dissipation problems caused by the capacitor fixing method are solved, achieving lower thermal resistance and better heat dissipation, thus improving the safety and reliability of the motor controller.
Patent Information
- Application Number
- CN202422861959.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-22
- Publication Date
- 2025-10-31
- Estimated Expiration
- 2034-11-22
AI Technical Summary
The way capacitors are fixed in existing motor controllers makes the plastic housing prone to cracking, increases thermal resistance and reduces heat dissipation. Traditional thermal pads cannot directly contact the capacitor copper busbars, affecting heat dissipation.
The capacitor module is directly encapsulated and installed in the first cavity of the housing. The capacitor module is cooled by cooling water channels. A thermal pad and heat dissipation holes are set on the inner side of the cover plate. Combined with a heat dissipation adhesive with a high thermal conductivity, the effects of bolt fixing stress and thermal resistance of traditional thermal pads are eliminated.
It effectively reduces thermal resistance, improves heat dissipation, enhances the safety and reliability of the motor controller, reduces the risk of plastic housing cracking, and extends the life of the capacitor module.
Smart Images
Figure CN223503234U_ABST
Abstract
Description
Technical Field
[0001] This disclosure relates to the field of motor controllers, and more specifically, to a motor controller and a vehicle. Background Technology
[0002] In related technologies, the assembly of capacitors in motor controllers typically involves first connecting the positive and negative copper busbars of the capacitor to the core and then encapsulating them in a plastic housing with potting compound. The plastic housing is then bolted to the inside of the motor controller housing, and a thermal pad is placed at the bottom of the plastic housing for heat dissipation. However, this method increases the risk of cracking in the plastic housing due to the stress generated by the bolt assembly. Furthermore, the thermal pad, located at the bottom of the plastic housing, cannot directly contact the positive or negative copper busbars of the capacitor, increasing thermal resistance and hindering effective heat dissipation. Additionally, the plastic housing itself also increases thermal resistance, further impeding heat dissipation. Utility Model Content
[0003] The purpose of this disclosure is to provide a motor controller and vehicle that can effectively reduce thermal resistance and is safer and more reliable, thereby at least partially solving the above-mentioned technical problems.
[0004] To achieve the above objectives, a first aspect of this disclosure provides a motor controller, comprising:
[0005] The housing includes a first receiving cavity and cooling water channels; and
[0006] A capacitor module includes a core assembly and conductive elements connected to the core assembly. The core assembly and a portion of the conductive elements are potted and installed within a first receiving cavity, such that the cooling water channel can cool the core assembly and / or the conductive elements.
[0007] Optionally, the motor controller further includes a cover plate detachably connected to the housing, the cover plate and the housing together forming an accommodating space, the first accommodating cavity, the cooling water channel and the capacitor module are all located within the accommodating space.
[0008] Optionally, a thermal pad corresponding to the position of the first receiving cavity is provided on the inner side wall of the cover plate, and the thermal pad is used to dissipate heat for the capacitor module.
[0009] Optionally, the cover plate has heat dissipation holes on the side opposite to the thermal pad.
[0010] Optionally, the housing further includes a second receiving cavity arranged adjacent to the first receiving cavity; the second receiving cavity is used to install the power module of the motor controller, the power module and the second receiving cavity forming the cooling water channel, and / or,
[0011] At least a portion of the cooling water channel flows between the first and second receiving cavities for cooling the capacitor module and the power module.
[0012] Optionally, the cooling water channel includes an inlet pipe disposed on the outer wall of the housing and communicating with the second receiving cavity, and an outlet pipe disposed on the bottom wall of the housing and communicating with the second receiving cavity.
[0013] Optionally, the core assembly includes a plurality of core bodies arranged side by side;
[0014] The conductive element includes a positive copper busbar and a negative copper busbar connected to the core assembly and located on opposite sides of the core assembly.
[0015] Optionally, an insulating film is provided on the inner wall of the first receiving cavity.
[0016] Optionally, the core assembly and some of the conductive components are encapsulated and installed in the first receiving cavity using a heat-dissipating adhesive.
[0017] A second aspect of this disclosure is to provide a vehicle including the motor controller described in any of the above alternatives.
[0018] Through the above technical solution, the motor controller of this disclosure, by directly encapsulating and installing the capacitor module within the first receiving cavity of the housing, eliminates the stress caused by traditional bolt fixing methods compared to traditional capacitor module fixing methods. It also reduces the thermal resistance caused by the plastic housing of the capacitor module itself and the thermal pad between the plastic housing and the motor controller housing, effectively lowering thermal resistance. Furthermore, the cooling channels within the housing allow for effective heat dissipation of the capacitor module, resulting in better performance. Therefore, the motor controller provided by this disclosure has lower thermal resistance, better heat dissipation, and is safer and more reliable.
[0019] Other features and advantages of this disclosure will be described in detail in the following detailed description section. Attached Figure Description
[0020] The accompanying drawings are provided to further illustrate the present disclosure and form part of the specification. They are used together with the following detailed description to explain the present disclosure, but do not constitute a limitation thereof. In the drawings:
[0021] Figure 1 This is a schematic diagram of the overall structure of the motor controller provided in the exemplary embodiments of this disclosure. Figure 1 ;
[0022] Figure 2 This is a schematic diagram of the overall structure of the motor controller provided in the exemplary embodiments of this disclosure. Figure 2 ;
[0023] Figure 3 This is a schematic diagram of the overall structure of the motor controller provided in the exemplary embodiments of this disclosure. Figure 3 Among them, the cover plate and capacitor module were not installed;
[0024] Figure 4 This is a schematic diagram of the overall structure of the motor controller provided in the exemplary embodiments of this disclosure. Figure 4 In one case, no cover was installed.
[0025] Figure 5 This is a schematic diagram of the overall structure of the capacitor module provided in the exemplary embodiments of this disclosure;
[0026] Figure 6 This is a schematic diagram of the overall structure of the cover plate provided in an exemplary embodiment of this disclosure.
[0027] Explanation of reference numerals in the attached figures
[0028] 1. Housing; 10. First receiving cavity; 100. Insulating film; 11. Second receiving cavity;
[0029] 2. Capacitor module; 20. Core assembly; 21. Conductive component; 21a. Positive copper busbar; 21b. Negative copper busbar;
[0030] 3. Cover plate; 30. Heat dissipation holes;
[0031] 4. Thermal pad;
[0032] 50. Inlet pipe; 51. Outlet pipe;
[0033] 6. Capacity space. Detailed Implementation
[0034] The specific embodiments of this disclosure will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit this disclosure.
[0035] In this disclosure, unless otherwise stated, "inner" and "outer" refer to the inner and outer contours of the corresponding components. Furthermore, the terms "first" and "second" used in this disclosure are for distinguishing one element from another and are not sequential or significant. In addition, when the following description relates to the accompanying drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements.
[0036] according to Figures 1 to 6As shown, in a first aspect, this disclosure provides a motor controller, which may include a housing 1 and a capacitor module 2. The housing 1 may include a first receiving cavity 10 and a cooling channel. The capacitor module 2 may include a core assembly 20 and a conductive element 21 connected to the core assembly 20. The core assembly 20 and at least a portion of the conductive element 21 are potted and installed in the first receiving cavity 10, such that the cooling channel can cool the core assembly 20 and the conductive element 21, or the cooling channel can cool one of the core assembly 20 and the conductive element 21.
[0037] Through the above technical solution, the motor controller disclosed herein, by directly encapsulating and installing the capacitor module 2 in the first receiving cavity 10 of the housing 1, eliminates the stress influence caused by the traditional bolt fixing method compared with the traditional capacitor module fixing method. It also reduces the thermal resistance caused by the plastic housing of the capacitor module 2 itself and the thermal pad 4 between the plastic housing and the housing 1 of the motor controller, effectively reducing thermal resistance. Furthermore, the capacitor module 2 can be effectively dissipated through the cooling water channel of the housing 1, resulting in better performance and greater safety and reliability.
[0038] In some feasible ways, for example, refer to Figure 1 and Figure 6 As shown, the motor controller may also include a cover plate 3 detachably connected to the housing 1. The cover plate 3 and the housing 1 together form an accommodating space 6. The first accommodating cavity 10, the cooling water channel and the capacitor module 2 are all located in the accommodating space 6, so that the operator can disassemble, install and repair the components in the accommodating space 6 by removing the cover plate 3.
[0039] The detachable connection method between the cover plate 3 and the housing 1 can be adapted to the actual needs. For example, it can be achieved by bolts and screw holes, pins and holes, or snap-fits and slots. This disclosure does not make specific limitations in this regard.
[0040] In some feasible ways, for example, refer to Figure 1 and Figure 6 As shown, a thermal pad 4 corresponding to the position of the first receiving cavity 10 can be provided on the inner wall of the cover plate 3. The thermal pad 4 is used to dissipate heat for the capacitor module 2. By placing the thermal pad 4 on the inner wall of the cover plate 3, it is easy to replace the thermal pad 4. Moreover, compared with traditional capacitors, the external thermal pad 4 makes the thermal resistance of the capacitor module 2 disclosed in this invention smaller and the heat dissipation effect better.
[0041] Optionally, a heat dissipation hole 30 can be provided on the side of the cover plate 3 away from the heat dissipation pad 4. The heat dissipation hole 30 is connected to the receiving space 6. The heat dissipation pad 4 is arranged corresponding to the heat dissipation hole 30. When the cover plate 3 and the housing 1 are assembled, the heat dissipation pad 4 is located inside the receiving space 6, so that the heat dissipation pad 4 can exchange the heat generated by the capacitor module 2 with the outside through the heat dissipation hole 30, further enhancing the heat dissipation effect and making it more reliable in use.
[0042] The number of heat dissipation holes 30 can be adjusted according to actual needs. For example, there can be multiple heat dissipation holes 30, which can be arranged in an array. The direction of the array arrangement can be the same as the arrangement direction of the thermal pad 4. The number of heat dissipation holes 30 can also be five, six, or more, and can be designed according to heat dissipation requirements. This disclosure does not make specific limitations in this regard.
[0043] In some feasible ways, for example, refer to Figure 3 and Figure 4 As shown, the housing 1 may further include a second receiving cavity 11 arranged adjacent to the first receiving cavity 10. The second receiving cavity 11 is used to install the power module of the motor controller. The power module and the second receiving cavity 11 together form a cooling water channel, and / or, at least part of the cooling water channel flows between the first receiving cavity 10 and the second receiving cavity 11 for cooling the capacitor module 2 and the power module.
[0044] It should be noted that the power module can be detachably connected to the second receiving cavity 11. For example, the power module may include a base plate with through holes corresponding to the threaded holes of the second receiving cavity 11. The operator can fix the power module and the second receiving cavity 11 by connecting bolts.
[0045] Optionally, heat dissipation fins may also be provided on the side of the base plate facing the second receiving cavity 11 to further dissipate heat from the power module. This disclosure does not impose specific limitations on this, and those skilled in the art can make adaptive adjustments according to actual needs.
[0046] In some feasible ways, for example, refer to Figures 1 to 4 As shown, the cooling water channel may include an inlet pipe 50 disposed on the outer wall of the housing 1 and communicating with the second receiving cavity 11, and an outlet pipe 51 disposed on the bottom wall of the housing 1 and communicating with the second receiving cavity 11. By disposing of the outlet pipe 51 on the bottom wall of the housing 1, when the motor controller and the motor are assembled, the outlet pipe 51 disposed on the bottom wall of the housing 1 can flow through the motor, thereby cooling the motor, which is more convenient.
[0047] In some feasible ways, for example, refer to Figure 4 and Figure 5As shown, the core assembly 20 may include multiple core bodies arranged side by side, and the conductive element 21 may include a positive copper busbar 21a and a negative copper busbar 21b connected to the core assembly 20 and located on opposite sides of the core assembly 20. In this way, the plastic housing 1 and thermal pad 4 required by traditional capacitors are eliminated, further reducing thermal resistance, enhancing the heat dissipation of the capacitor module 2, and extending the service life of the capacitor module 2.
[0048] The connection method between the conductive element 21 and the core body can be adapted to meet the actual needs. For example, the positive copper busbar 21a and the negative copper busbar 21b of the conductive element 21 can be connected to the core assembly 20 by welding, or a buckle can be provided on the core body, and slots can be opened on the positive copper busbar 21a and the negative copper busbar 21b to achieve initial fixation of the conductive element 21 and the core body. This disclosure is not limited thereto.
[0049] In some feasible ways, for example, refer to Figure 3 As shown, an insulating film 100 can be provided on the inner sidewall of the first receiving cavity 10. The insulating film 100 can realize the functions of insulation and voltage resistance, so as to further improve the safety of the capacitor module 2.
[0050] In some feasible ways, for example, refer to Figure 4 As shown, the core assembly 20 and some conductive components 21 can be potted and installed in the first receiving cavity 10 using thermally conductive adhesive. Compared with the low thermal conductivity potting adhesive used in traditional capacitors, the thermally conductive adhesive with a high thermal conductivity has better thermal conductivity, and the thermal conductivity of the thermally conductive adhesive can be flexibly adjusted according to the needs of product design, which is more convenient.
[0051] The heat-dissipating adhesive can be a synthetic epoxy resin filled with metal or inorganic filler materials, depending on the actual needs. This disclosure does not impose any limitations on it.
[0052] A second aspect of this disclosure is to provide a vehicle including a motor controller that has all the beneficial effects of the above-described embodiments, which will not be repeated here.
[0053] The preferred embodiments of this disclosure have been described in detail above with reference to the accompanying drawings. However, this disclosure is not limited to the specific details of the above embodiments. Within the scope of the technical concept of this disclosure, various simple modifications can be made to the technical solutions of this disclosure, and these simple modifications all fall within the protection scope of this disclosure.
[0054] It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, this disclosure will not describe the various possible combinations separately.
[0055] Furthermore, various different embodiments of this disclosure can be combined in any way, as long as they do not violate the spirit of this disclosure, they should also be regarded as the content disclosed in this disclosure.
Claims
1. A motor controller, characterized in that, include: The housing includes a first receiving cavity and cooling water channels; and A capacitor module includes a core assembly and a conductive element connected to the core assembly, wherein the core assembly and at least a portion of the conductive element are potted and mounted within a first receiving cavity, such that the cooling water channel can cool the core assembly and / or the conductive element.
2. The motor controller according to claim 1, characterized in that, The motor controller also includes a cover plate detachably connected to the housing, the cover plate and the housing together forming an accommodating space, the first accommodating cavity, the cooling water channel and the capacitor module are all located within the accommodating space.
3. The motor controller according to claim 2, characterized in that, A thermal pad corresponding to the position of the first receiving cavity is provided on the inner side wall of the cover plate, and the thermal pad is used to dissipate heat for the capacitor module.
4. The motor controller according to claim 3, characterized in that, The cover plate has heat dissipation holes on the side opposite to the heat-conducting pad.
5. The motor controller according to any one of claims 1-4, characterized in that, The housing further includes a second receiving cavity arranged adjacent to the first receiving cavity; the second receiving cavity is used to install the power module of the motor controller, the power module and the second receiving cavity forming the cooling water channel, and / or, At least a portion of the cooling water channel flows between the first and second receiving cavities for cooling the capacitor module and the power module.
6. The motor controller according to claim 5, characterized in that, The cooling water channel includes an inlet pipe disposed on the outer wall of the housing and communicating with the second accommodating cavity, and an outlet pipe disposed on the bottom wall of the housing and communicating with the second accommodating cavity.
7. The motor controller according to claim 1, characterized in that, The core assembly includes multiple core bodies arranged side by side; The conductive element includes a positive copper busbar and a negative copper busbar connected to the core assembly and located on opposite sides of the core assembly.
8. The motor controller according to claim 1, characterized in that, An insulating film is provided on the inner wall of the first receiving cavity.
9. The motor controller according to claim 1, characterized in that, The core assembly and some of the conductive components are encapsulated and installed in the first receiving cavity using a heat-dissipating adhesive.
10. A vehicle, characterized in that, Includes the motor controller described in any one of claims 1-9.