Power module, motor controller, and vehicle

Abstract

The present application relates to the technical fields of power electronics, in particular to a kind of power module, motor controller and vehicle.Power module includes at least two power units and briquetting, define two adjacent power units as first unit and second unit, first unit and second unit are all set up gap in opposite side edge, two gaps are enclosed to form mounting through-hole, briquetting includes briquetting main body and the positioning portion of protruding in the surface of briquetting main body, briquetting main body is pressed in adjacent first unit and second unit, positioning portion is positioned and fixed in external heat dissipation device through mounting through-hole.By the structural design of power unit and briquetting, power unit is installed in external heat dissipation device, without increasing overall size, improve the overall compactness of power module, and by the positioning of positioning portion, avoid not being able to be accurately installed before positioning, it is beneficial to improve the automatic assembly of power module.

Description

Technical Field

[0001] This invention relates to the field of power electronic device technology, and in particular to a power module, a motor controller, and a vehicle. Background Technology

[0002] A power module is a power drive product that combines power electronics and integrated circuit technology.

[0003] For example, the controller of a new energy electric vehicle includes several power modules, which control the rotation of the main motor.

[0004] In electrical devices such as inverters, the space available for molding power modules is becoming increasingly limited. Typically, when a power module includes a heat dissipation device, fixing components such as clamps are needed to pass through the corresponding fixing area of ​​the power module to secure the heat dissipation device. This fixing area occupies space within the power module, resulting in a larger module size. In cases requiring multiple power modules, the space occupied by these fixing components makes it impossible to arrange them compactly.

[0005] For example, during the heat dissipation packaging process, power modules are often directly fastened to the heat dissipation device by screws, or the power module is partially exposed with plastic encapsulation material for mounting blocks to press on. Screw holes are arranged on the mounting blocks for screws to connect to the water channels.

[0006] Directly screwing the power module to the heat sink requires additional screw positions on the power module, which hinders the reduction of the power module's size. Alternatively, partially exposing the power module's molding compound for mounting with clamping blocks can reduce the size issues associated with screw installation. However, the clamping blocks need to be placed in the gap between two power modules, indirectly increasing the length of the assembled power modules.

[0007] The above content is only used to help understand the technical solution of this application and does not represent an admission that the above content is prior art. Summary of the Invention

[0008] The main objective of this invention is to provide a power module that improves the overall compactness of the power module and simultaneously enhances the automated assembly of the power module.

[0009] To achieve the above objectives, the present invention provides a power module, the power module comprising:

[0010] At least two power units, defining two adjacent power units as a first unit and a second unit, each with a notch on its opposite side, the two notches forming a mounting through hole; and

[0011] The pressure block includes a pressure block body and a positioning part protruding from a surface of the pressure block body. The pressure block body is pressed against an adjacent first unit and a second unit, and the positioning part is positioned to an external heat dissipation device through the mounting through hole.

[0012] Optionally, the first unit and the second unit are provided with a first sinking groove on their opposite sides. The notch is opened at the bottom of the first sinking groove. The two first sinking grooves enclose each other to form a clearance groove. The main body of the pressing block is accommodated in the clearance groove and pressed against the bottom of the clearance groove.

[0013] Optionally, the pressing block body is further provided with pressing block teeth at the bottom of the groove corresponding to the avoidance groove, and the pressing block teeth are integrally formed with the pressing block body.

[0014] Optionally, the pressure block body has a first fixing through hole formed through the part corresponding to the mounting through hole, so as to lock the power unit to the external heat dissipation device through the first connector.

[0015] Optionally, the pressure block body has a second recessed groove formed on the other surface opposite to the positioning part, and the first fixing through hole is opened at the bottom of the second recessed groove to accommodate the first connecting member.

[0016] Optionally, the pressure block body has a second fixing groove formed on the other surface opposite to the positioning part. The second fixing groove is arranged adjacent to the first fixing through hole, and is used to fix the power unit to the external drive board through the second connector.

[0017] Optionally, the first unit and the second unit form two mounting through holes, and the power unit is defined to have a first side and a second side disposed opposite to each other, with the two mounting through holes respectively disposed near the first side and the second side of the power unit;

[0018] The pressure block includes two pressure block bodies and a connecting rod. The two pressure block bodies are symmetrically arranged at both ends of the connecting rod, and the end of the connecting rod is connected to the side of the pressure block body away from the second fixing groove.

[0019] Optionally, the power module further includes an external drive board, the projection of which overlaps with the plane of the power unit, and an opening is formed on the external drive board, the projection of which corresponds to the second fixing groove.

[0020] The external drive board extends outward toward the signal terminal of the power unit to form a signal terminal connection portion. The signal terminal connection portion has a small hole corresponding to the signal terminal. The end of the signal terminal connection portion has an avoidance notch.

[0021] The present invention also provides a motor controller, the motor controller including a liquid cooling heat dissipation device and the power module mentioned above;

[0022] The power module is mounted onto the liquid cooling heat dissipation device via the pressure block.

[0023] The present invention also provides a vehicle, the vehicle including the power module described above;

[0024] Alternatively, the vehicle may include the aforementioned motor controller.

[0025] This invention provides a power module that, by adapting the structure of the power units and the pressure block, allows for effective installation on an external heat dissipation device without increasing its size. The power module includes at least two power units and a pressure block. Two adjacent power units are defined as a first unit and a second unit. Both the first and second units have notches on their opposite sides, which together form a mounting through-hole. This creates a space within the power unit structure, eliminating the need for additional size increases. Furthermore, the mounting through-hole is formed by joining two adjacent power units, meaning each through-hole occupies only a portion of the size of one power unit, thus avoiding excessive space usage and interference with device placement on the power unit. The pressure block includes a main body and a positioning portion protruding from one surface of the main body. The main body presses against the adjacent first and second units, and the positioning portion passes through the mounting through-hole and is positioned on the external heat dissipation device. In other words, before fixing each power unit to the external heat dissipation device, the power unit is first positioned on the external heat dissipation device by passing the positioning part through the mounting through hole. This effective positioning ensures that the fixing structure used to fix the power unit to the external heat dissipation device can accurately pass through the mounting through hole during the fixing step. It is understood that this fixing structure can be formed on the positioning part, for example, a snap-fit ​​formed on the positioning part. When the positioning part is positioned, the power unit is fixed to the external heat dissipation device through the snap-fit. Alternatively, it can be understood that the pressure block body has screw holes. That is, when the fixing structure uses screws to fix the power unit to the external heat dissipation device, if the positioning is inaccurate, the screw holes are not aligned with the mounting through hole, or the screws are not aligned with the screw holes, the screws cannot be pre-tightened smoothly, directly affecting the assembly rhythm. Or, even if they are screwed in successfully, the part on the pressure block used to press the power unit does not fall on the metal pressing area of ​​the power unit, but interferes with the plastic encapsulation of the power unit, causing the brittle plastic encapsulation to crack after assembly, contaminating the inside of the power unit. Therefore, by fixing the steps, it is beneficial to improve the automated assembly of power modules, thereby increasing production efficiency and product yield. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0027] Figure 1 This is an exploded view of a motor controller according to the present invention;

[0028] Figure 2 for Figure 1 A schematic diagram of the combined structure of the motor controller in the diagram;

[0029] Figure 3 for Figure 2 A cross-sectional view of the motor controller.

[0030] Figure 4 for Figure 3 A schematic diagram of the exploded structure of the motor controller in the diagram;

[0031] Figure 5 This is a schematic diagram of the structure of a power unit according to the present invention;

[0032] Figure 6 for Figure 5 A structural schematic diagram of a medium-power unit from another perspective;

[0033] Figure 7 This is a schematic diagram of the structure of a pressure block according to the present invention;

[0034] Figure 8 for Figure 7 Another structural schematic diagram of the intermediate pressure block;

[0035] Figure 9 This is a schematic diagram of the structure of an external heat dissipation device according to the present invention.

[0036] Explanation of icon numbers:

[0037] label name label name 1000 motor controller 31 Positioning Department 100 Power Module 33 First fixing through hole 10 Power unit 331 Second settling tank 11 gap 333 Clamping screw 110 Mounting through hole 35 Second fixing groove 12 First settling tank 33 First fixing through hole 13 Power terminals 37 Pressing teeth 131 Connecting protrusions 39 Injection port clearance groove 14 First positioning pin 40 Second connector 15 Signal terminal 50 External heat dissipation device 151 First paragraph 51 positioning holes 153 Second paragraph 53 Screw hole 17 Heat dissipation area 55 Cold Night Connecting Area 171 sealing ring 70 External driver board 20 First connector 71 small hole 30 Press block 72 Signal terminal connection part 30a Compactor body 73 Opening 30b link 74 Avoiding gaps

[0038] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0039] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0040] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0041] In this invention, unless otherwise explicitly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0042] Furthermore, in this invention, descriptions involving "first," "second," etc., are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the word "and / or" throughout the text means including three parallel solutions; taking "A and / or B" as an example, it includes solution A, solution B, or a solution that simultaneously satisfies A and B. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0043] This invention proposes a power module applicable to power devices involving multiple chips connected in parallel with a compact (highly constrained) structure, such as the power module used in the motor controller of new energy vehicles.

[0044] The aim is to design a space-saving installation method for the power module 100, which can make comprehensive use of the length and vertical space during the installation of the power module 100, improve the overall compactness of the power module, and at the same time improve the automated assembly of the power module.

[0045] like Figures 1 to 4As shown in the figure, the power module 100 provided by the technical solution of the present invention is shown. By adapting the structure of the power unit 10 and the pressure block 30, the power module 100 can be effectively installed on the external heat dissipation device 50 without increasing the size.

[0046] The power module 100 includes at least two power units 10 and a pressure block 30. Two adjacent power units 10 are defined as a first unit and a second unit. Both the first and second units have notches 11 on their opposite sides, which together form a mounting through-hole 110. This creates a space within the structure of the power unit 10, eliminating the need for additional size increases, saving assembly space, and reducing the overall length of the assembled power unit 10. Furthermore, the mounting through-hole 110 is formed by splicing two adjacent power units 10, meaning each mounting through-hole 110 occupies only a portion of the size of one power unit 10, thus avoiding occupying too much space in the power unit 10 and interfering with the arrangement of components on the power unit 10. The pressure block 30 includes a pressure block body 30a and a positioning part 31 protruding from one surface of the pressure block body 30a. The pressure block body 30a is pressed against the adjacent first and second units, and the positioning part 31 passes through the mounting through-hole 110 and is positioned against the external heat dissipation device 50.

[0047] That is, before fixing each power unit 10 to the external heat dissipation device 50, the power unit 10 is first positioned to the external heat dissipation device 50 by the positioning part 31 passing through the mounting through hole 110. In this way, effective positioning is performed first, so that when the fixing step is performed, the fixing structure used to fix the power unit 10 to the external heat dissipation device 50 can accurately pass through the mounting through hole 110 to fix the power unit 10 to the external heat dissipation device 50. It is understandable that the fixing structure can be formed on the positioning part 31, for example, a buckle formed on the positioning part 31. When the positioning part 31 is positioned, the power unit 10 is fixed to the external heat dissipation device 50 by the buckle. Alternatively, it can be understood that the pressure block body 30a has a screw hole. That is, when the fixing structure uses a screw connection to fix the power unit 10 to the external heat dissipation device 50, if the positioning is inaccurate, the screw hole and the mounting through hole 110 are not aligned, or the screw is not aligned with the screw hole. In this case, the screw cannot be pre-tightened smoothly, directly affecting the assembly rhythm. Or, if it is screwed in smoothly, the part of the pressure block 30 used to press the power unit 10 does not fall on the metal pressing area of ​​the power unit 10, but interferes with the plastic encapsulation of the power unit 10, causing the brittle plastic encapsulation to crack after assembly and contaminate the inside of the power unit 10. Therefore, the positioning and fixing step is beneficial to improve the automated assembly of the power module, improve production efficiency and product yield.

[0048] Of course, the power module 100 may also include a power unit 10 and a pressure block 30. A notch 11 is formed on the opposite two sides of the power unit 10. The positioning part 31 on the pressure block 30 passes through the notch 11. The pressure block 30 presses against the side of the power unit 10 to position the power unit 10 on the external heat dissipation device 50.

[0049] like Figure 1 As shown, it can be understood that the power module 100 includes three power units 10, which are arranged adjacent to each other in one direction. From left to right, the three power units 10 are the first power unit 10, the second power unit 10, and the third power unit 10. The first power unit 10 is adjacent to the second power unit 10, and the second power unit 10 is adjacent to the third power unit 10. The adjacent power units 10 form a mounting through hole 110, and the power units 10 are fixed to the external heat dissipation device 50 by the pressure block 30.

[0050] Furthermore, such as Figure 1 , Figure 4 and Figure 5 As shown, the first unit and the second unit each have a first recessed groove 12 on their opposite sides. A notch 11 is formed at the bottom of the first recessed groove 12. The two first recessed grooves 12 enclose each other to form a clearance groove. The pressing block body 30a is accommodated in the clearance groove and pressed against the bottom of the clearance groove. This creates a space on the power unit 10 to accommodate the pressing block 30, thus preventing the pressing block 30 from protruding from the power unit 10 and avoiding increasing the size of the power module 100.

[0051] Furthermore, such as Figure 9 As shown, the pressing block body 30a is also provided with pressing block teeth 37 protruding from the bottom of the corresponding clearance groove. The pressing block teeth 37 and the pressing block body 30a are integrally formed.

[0052] like Figure 5 As shown, the surface of the pressing teeth 37 is slightly higher than the surface of the pressing body 30a, ensuring that the pressing teeth 37 first contact the bottom of the clearance groove of the power unit 10. It can be understood that the bottom of the clearance groove is a metal substrate. This design avoids the pressing teeth 37 pressing onto the plastic part. The design of the pressing teeth 37 changes the full-surface contact of the pressing body 30a to partial surface contact, reducing the adverse effect of the thickness tolerance of the metal substrate on the power unit 10 on the uniform distribution of the pressing force of the pressing teeth 30. Furthermore, while providing a reliable pressing effect, it also reduces the overall height machining tolerance requirements of the power unit 10, which helps to reduce costs.

[0053] The pressure block 30, positioned between two adjacent power units 10, directly presses against the two metal substrates, with the pressure of the pressure block 30 being evenly distributed between the two substrates. Only a mounting gap is left between the metal substrates; no space is pre-designed for the installation of the pressure block 30, further saving space. Figure 1 and Figure 4 As shown, when the pressure block 30 is arranged at the edge of the two power units 10, the pressure block 30 locks the power unit 10 onto the external heat dissipation device 50. The clamping force of the pressure block 30 is evenly distributed on the contact surface of the metal substrate of the power unit 10 and the external heat dissipation device 50, so that the sealing ring 171 provided between the power unit 10 and the external heat dissipation device 50 is pressed between the two, thereby improving the sealing effect.

[0054] Furthermore, the pressure teeth 37 and the pressure body 30a are integrally formed, meaning that the pressure teeth 37 and the pressure body 30a are integrally formed, resulting in good overall strength and high precision. The pressure teeth 37 are machined in the same step by a milling machine to ensure that the height of each pressure tooth 37 is consistent with minimal tolerance. When the power unit 10 is connected to the external heat dissipation device 50 by screwing through the pressure block 30, the use of high-torque locking screws ensures that even when both the pressure block 30 and the metal substrate of the power unit 10 undergo only elastic deformation, the minimum pressing force acting on the metal substrate is greater than the rebound force of the sealing ring. This improves the sealing performance and prevents gaps from forming at the sealing ring due to excessive elasticity and resistance to the pressing force, which would allow the coolant in the external heat dissipation device 50 to flow out through the gaps in the sealing ring.

[0055] Furthermore, such as Figure 3 , Figure 4 , Figure 7 and Figure 8 As shown, the pressure block body 30a has a first fixing through hole 33 formed through the corresponding mounting through hole 110, which is used to lock the power unit 10 to the external heat dissipation device 50 through the first connector 20. It can be understood that the first connector 20 is a screw, which passes through the first fixing through hole 33 to lock the power unit 10 to the external heat dissipation device 50. Since the power unit 10 is pre-positioned on the external heat dissipation device 50 by the positioning part 31 on one surface of the pressure block body 30a, the first fixing through hole 33 can be accurately aligned with the mounting through hole 110 and the screw hole 53 of the external heat dissipation device 50. The screw can smoothly pass through the first fixing through hole 33, the mounting through hole 110, and the screw hole 53 in sequence, improving the efficiency of screw tightening. Of course, the first connector 20 can also be a snap-fit ​​structure to lock the power unit 10 to the external heat dissipation device 50.

[0056] Furthermore, such as Figure 7 and Figure 8As shown, a second recess 331 is formed on the surface of the pressure block body 30a opposite to the positioning part 31. A first fixing through hole 33 is opened at the bottom of the second recess 331 to accommodate the first connector 20. That is, when the first connector 20 is a screw, the screw head is accommodated in the second recess 331, allowing the screw to sink into the interior of the pressure block 30, reducing the overall height of the power module 100 system and reducing the restricted area on the PCB board, because the second recess 331 provides a safe area. The shape of the second recess 331 is not limited; it can be a round hole or a square hole. Furthermore, the pressure block 30 has a completely symmetrical design, eliminating the need for error prevention and improving assembly efficiency.

[0057] Furthermore, such as Figure 4 , Figure 7 and Figure 8 As shown, a second fixing groove 35 is formed on the surface of the pressure block body 30a opposite to the positioning part 31. The second fixing groove 35 is adjacent to the first fixing through hole 33, and is used to fix the power unit 10 to the external drive plate 70 through the second connector 40. It can be understood that, as Figure 1 As shown, when the second connector 40 is a screw, the screw passes through the opening 73 of the external drive plate 70 and is screwed into the second fixing groove 35, thereby connecting the external drive plate 70 to the power unit 10. Of course, the second connector 40 can be a snap-fit ​​structure.

[0058] Furthermore, such as Figure 4 , Figure 5 and Figure 9 As shown, adjacent first and second units form two mounting through holes 110. The power unit 10 is defined with a first side and a second side arranged opposite to each other. The two mounting through holes 110 are respectively located near the first and second sides of the power unit 10. The mounting through holes 110 are located near the first and second sides, creating a larger span between them. This better fixes the edges of the power unit 10. Therefore, after installing the two pressure block bodies 30a at the positions of the two mounting through holes 110, the stability of the power unit 10 is improved. Furthermore, the edges of the external drive plate 70 mounted through the two pressure block bodies 30a are also fixed, reducing the vibration response of the external drive plate 70. And, as... Figure 9 As shown, the connection portion (positioning hole 51 and screw hole 53) adapted to the external heat dissipation device 50 is located on the side of the external heat dissipation device 50, and the space between the two sides of the external heat dissipation device 50 forms a cold water connection area 55 to facilitate the flow of cold water and reduce flow resistance. It can be understood that the water channel for cooling the power module 100 can pass through the cold water connection area 55 between the two sides.

[0059] And, as Figure 4 , Figure 7 and Figure 8As shown, the pressure block 30 includes two pressure block bodies 30a and a connecting rod 30b. The two pressure block bodies 30a are symmetrically arranged at both ends of the connecting rod 30b, and the ends of the connecting rod 30b are connected to the side of the pressure block body 30a away from the second fixing groove 35. That is, the two second fixing grooves 35 are distributed on the outermost side of the pressure block 30, ensuring the longest screw span, which can effectively reduce the vibration response of the external drive board 70 and improve the vibration reliability of the devices and signal terminal 15 pins on the external drive board 70. Furthermore, the completely symmetrical design of the pressure block bodies 30a at both ends of the pressure block 30 facilitates the quick placement of the pressure block 30 into the clearance groove around the mounting through hole 110, providing a foolproof function. The connecting rod 30b can be a reinforcing rib to improve the connection strength and overall integrity of the two pressure block bodies 30a.

[0060] And, as Figure 3 , Figure 4 ,and Figure 8 As shown, the positioning part 31 is a pressing block positioning pin that protrudes from the pressing block body 30a, such as Figure 4 As shown, the positioning pin of the pressure block passes through the mounting through hole 110 and is inserted into the positioning hole 51 of the external heat dissipation device 50, thereby positioning the power unit 10 on the external drive board 70, and as... Figure 3 and Figure 4 As shown, if the pressure block 30 lacks a positioning relationship with the power unit 10 or the external heat dissipation device 50, during automated assembly, the first fixing through hole 33 of the pressure block 30, the mounting through hole 110 of the power unit 10, and the screw hole 53 of the external heat dissipation device 50 cannot be aligned. This prevents the first connector 40 from being pre-tightened smoothly, directly affecting the assembly rhythm. Alternatively, even if it is successfully screwed in, the part of the pressure block 30 used to press the power unit 10 may not fall on the metal pressing area of ​​the power unit 10, but instead interferes with the plastic encapsulation of the power unit 10, causing the brittle plastic encapsulation to crack immediately after assembly, contaminating the interior of the power unit 10. By using a positioning-then-fixing step, the automated assembly of the power module 100 can be improved, enabling mass production and increasing production efficiency and product yield.

[0061] Furthermore, each pressure block positioning pin is adjacent to a second fixing groove 35, making the positioning more precise. This improves the positioning accuracy of the pressure block 30 to the point where it will not interfere with the external heat dissipation device 50, and facilitates the accurate passage of screws through the mounting through hole 110 and the screw hole 53 during automated assembly, enabling mass production.

[0062] Furthermore, such as Figure 1 and Figure 2As shown, the power module 100 also includes an external drive board 70. The projection of the external drive board 70 overlaps with the plane of the power unit 10, that is, the size of the external drive board 70 matches the size of the power unit 10, avoiding the external drive board 70 being too large and affecting the overall size of the power module 100, thus affecting the space adaptation for subsequent installation of the power module 100. An opening 73 is formed on the external drive board 70, and the projection of the opening 73 corresponds to the second fixing groove 35. The opening 73 is used to install the external drive board 70 into the second fixing groove 35 through the second connector 40. Considering the installation stability of the external drive board 70, since the second fixing groove 35 is located on the side of the power unit 10, the side of the external drive board 70 is fixed to the power unit 10. In this way, the external drive board 70 is installed more stably, reducing vibration response.

[0063] The external drive board 70 extends outward from the side facing the signal terminal 15 of the power unit 10 to form a signal terminal connection portion 72. The signal terminal connection portion 72 has a small hole 71 corresponding to the signal terminal 15, which is inserted into the small hole 71. Since the external drive board 70 is stably installed, the connection of the signal terminal 15 to the external drive board 70 through the small hole 71 is also more stable. Furthermore, the end of the signal terminal connection portion 72 has a clearance notch 74, which helps to avoid interference with external structures when installing the power module 100, improving installability.

[0064] Furthermore, such as Figure 5 As shown, the power unit 10 includes a circuit board, pins electrically connected to the circuit board, and a molding compound layer. The molding compound layer encapsulates the circuit board, and the pins protrude from the molding compound layer. The molding compound layer is thickened at the pins. This increases the strength of the connection between the pins and the molding compound layer, and, as... Figure 6 As shown, a first positioning pin 14 is formed at the diagonal of the plastic encapsulation layer. The first positioning pin 14 is used to adapt and position on the external heat dissipation device 50. It is used to enhance the positioning of the power unit 10 on the external heat dissipation device 50. That is, the pins are connected to the external device by soldering. If there is a positioning deviation, the soldering point cannot form a good connection. By accurately positioning the power unit 10 on the external heat dissipation device 50, the soldering accuracy is improved.

[0065] And / or, further, such as Figure 5As shown, the power unit 10 is provided with a power terminal 13. The power terminal 13 is bent and protrudes from the power unit 10. The end of the power terminal 13 away from the power unit 10 forms a connecting protrusion 131, which is used for electrical connection with external devices. For example, the connecting protrusion 131 is used to be welded to external devices by laser welding or argon arc welding. During the welding process, the connecting protrusion 131 melts to form a weld point, increasing the connection strength of the weld. In addition, the bent power terminal 13 reduces the loop that generates stray inductance. It can be understood that the power terminal 13 is connected to the adapter copper busbar, and the adapter copper busbar is attached to a bent section of the power terminal 13. This attached section can be considered to have no stray inductance. In this way, the current path between the power terminal 13 and the adapter copper busbar is shortened, the system stray inductance is reduced, and the durability and reliability of the connection are improved.

[0066] And / or, further, such as Figure 1 , Figure 2 and Figure 5 As shown, the power unit 10 is provided with a signal terminal 15. The signal terminal 15 is defined to have a first segment 151 close to the power unit 10 and a second segment 153 away from the power unit 10. The width of the first segment 151 is greater than the width of the second segment 153. The width of the second segment 153 gradually narrows from the power unit 10 in a direction from near to far. The second segment 153 is used to insert an external driver board 70. The first segment 151 is wider to increase the strength of the signal terminal 15 and prevent breakage. The second segment 153 gradually narrows to facilitate insertion into the small hole 71 of the external driver board 70, while reducing the size of the small hole 71 of the external driver board 70.

[0067] The power module 100 is controlled by a driver chip. When the power module 100 is working, the driver chip outputs a corresponding drive signal to drive the corresponding power switch to turn on / off, thereby outputting drive power to drive loads such as motors. The driver chip can be mounted on an external driver board 70, and the pins of the power module 100 are also mounted on the external driver board 70. The driver chip and the power module 100 are electrically connected through a circuit wiring layer formed on the external driver board 70. Alternatively, the driver chip can be integrated with the power module 100, that is, packaged with the power unit 10 in the same power module 100, realizing the driver-power module 100 integration.

[0068] like Figure 1 and Figure 2 As shown, the power module 100 is mounted on the external drive board 70. The external drive board 70 is connected to the power unit 10 through the pressure block 30. The external drive board 70 has a small hole 71. The signal terminal 15 passes through the small hole 71 and is electrically connected to the external drive board 70. The signal terminal 15 and the small hole 71 can also be further electrically connected and fixed by soldering.

[0069] like Figure 1 and Figure 2 As shown, after multiple power units 10 are installed on the external heat dissipation device 50, the external drive board 70 can be positioned by the positioning part on the external heat dissipation device 50 or the power unit 10, so as to ensure that the pins of the signal terminal 15 can pass through the small hole 71 of the external drive board 70 normally.

[0070] Furthermore, such as Figure 4 and Figure 8 As shown, in one embodiment, each power unit 10 is also provided with an injection port. When the power unit 10 is injection molded, the molding compound is injected into the molding die through the injection port. The force capacity of the injection port may be small. Therefore, the present invention can also form an injection port avoidance groove 39 on one side of the connecting rod 30b to avoid the connecting rod 30b pressing on the injection port.

[0071] Furthermore, in one embodiment, as Figure 1 , Figure 6 and Figure 9 As shown, the external heat dissipation device 50 includes multiple water channel cavities 52 connected sequentially through a cold water communication region 55; the power unit 10 is provided with a heat dissipation area 17, and each heat dissipation area 17 corresponds to a water channel cavity 52. ​​A sealing ring 171 is provided around the heat dissipation area 17, and the sealing ring 171 is pressed between the power unit 10 and the external heat dissipation device 50 to seal the heat dissipation area 17 within the water channel cavity 52 to prevent leakage.

[0072] The water channel cavities 52 at both ends of the external heat dissipation device 50 are also provided with inlets and outlets. The inlets and outlets are connected to each water channel cavity 52 in sequence to form a water flow path. The inlets and outlets are respectively connected to the outlet and return ends of the liquid cooling supply device. The liquid flows in through the inlet, passes through each water channel cavity, carries away the heat generated by each power unit 10, and then flows out through the outlet to achieve liquid cooling heat dissipation of the power module 100.

[0073] This application also provides a motor controller 1000, which includes a liquid cooling heat dissipation device and a power module 100; wherein the power module is mounted on the liquid cooling heat dissipation device via a pressure block 30. Since the power module 100 adopts all the technical solutions of all the above embodiments, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be described in detail here.

[0074] This application also provides a vehicle, which includes a power module 100; or, the vehicle includes a motor controller 1000. Since the power module 100 employs all the technical solutions of all the above embodiments, it possesses at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated upon here.

[0075] During the installation of the power module, the installation method includes the following steps: Multiple power units 10 are arranged sequentially along the same direction, such that the notches 11 of any two adjacent power units enclose a mounting through hole 110. Multiple pressure blocks 30 are respectively accommodated within the clearance grooves of the power units 10. The power units 10 are positioned on the external heat dissipation device 50 by a positioning part 31 passing through the mounting through hole 110. That is, when the positioning part 31 is a pressure block positioning pin, the pressure block positioning pin passes through the mounting through hole 110 and is inserted into the positioning hole 51 of the external heat dissipation device 50. At this time, the first fixing through hole 33 is aligned with the mounting through hole 110, and the first connecting member 20 passes through the first fixing through hole 33, the mounting through hole 110, and the screw hole 53 of the external heat dissipation device 50, fixing the power unit 10 to the external heat dissipation device 50. Then, the power unit 10 is fixedly installed on the external drive board 70 by passing the second connector 40 through the opening 73 and the second fixing groove 35 of the external drive board 70. The second segment 153 of the signal terminal 15 gradually narrows to facilitate insertion into the small hole 71 of the external drive board 70.

[0076] In this application, the mounting through-holes 110 on the metal substrate of the power unit 10 further compress the space required in the length direction when arranging the pressure blocks 30. This achieves a reduction in the total length when arranging the three power units 10, resulting in better installability and arrangement.

[0077] The screw heads of the first connector 20 are recessed into the pressure block 30, further saving vertical installation space for the power module 100. The external drive board 70 has a large span above the power module 100; if the power units 10 are assembled tightly, there is insufficient space to accommodate the second fixing slots 35, resulting in poor vibration resistance of the external drive board 70. This application solves this problem by arranging two second fixing slots 35 on the pressure block 30. Figure 7 As shown, the two second fixing grooves 35 on the pressure block 30 are located at both ends of the pressure block 30. The span between the two second fixing grooves 35 is relatively long, which provides space for the external drive board 70 to support the power module 100, significantly reducing the vibration risk of the devices on the external drive board 70 and improving the vibration reliability of the pins of the signal terminal 15 connected to the external drive board 70.

[0078] During mass production, the pressure block 30 presents an automated assembly problem. If the pressure block 30 lacks a positioning relationship with the power unit 10 or the external heat dissipation device 50, the first fixing through hole 33 of the pressure block 30, the mounting through hole 110 of the power unit 10, and the screw hole 53 of the external heat dissipation device 50 cannot be aligned. This prevents the first connector 40 from being pre-tightened smoothly, directly affecting the assembly rhythm. Alternatively, even if it is successfully screwed in, the part of the pressure block 30 used to press the power unit 10 (pressure block teeth 37) does not fall on the metal pressing area of ​​the power unit 10 (the bottom of the first recess 12), but interferes with the plastic encapsulation of the power unit 10, causing the brittle plastic encapsulation to crack immediately after assembly, contaminating the inside of the power unit 10. By adopting a positioning-then-fixing step, the automated assembly of the power module 100 can be improved, enabling mass production and increasing production efficiency and product yield.

[0079] In this application, the pressure block 30, through the positioning pin 31 passing through the mounting through hole 110 of the power module 100 and engaging with the positioning hole 51 on the external heat dissipation device, solves the problem of automated assembly of the pressure block 30 and realizes automated assembly of the power module 100 and the pressure block 30 during mass production. At the same time, the completely symmetrical design of the pressure block 30 also greatly reduces the error-proofing cost in the production process.

[0080] The above are merely preferred embodiments of the present invention and do not limit the scope of the patent. Any equivalent structural transformations made using the contents of the specification and drawings of the present invention under the inventive concept of the present invention, or direct / indirect applications in other related technical fields, are included within the scope of patent protection of the present invention.

Claims

1. A power module, characterized by The power module comprises: at least two power units, defining two adjacent power units as a first unit and a second unit, each of the first unit and the second unit is provided with a notch at the opposite side edge, and the two notches form a mounting through hole; a pressing block, comprising a pressing block body and a positioning portion protruding from one surface of the pressing block body, the pressing block body is pressed to the first unit and the second unit, and the positioning portion is positioned in a positioning hole of an external heat dissipation device through the mounting through hole; the opposite side edges of the first unit and the second unit are each provided with a first sink, and the notch is formed at the bottom of the first sink, and the two first sinks form an avoidance groove, and the pressing block body is accommodated in the avoidance groove and is pressed to the bottom of the avoidance groove; the pressing block body is provided with a first fixing through hole at a position corresponding to the mounting through hole, so as to lock the power unit to a screw hole of the external heat dissipation device through a first connecting piece; the pressing block body is provided with a second sink at the other surface away from the positioning portion, and the first fixing through hole is formed at the bottom of the second sink, so as to accommodate the first connecting piece; the first unit and the second unit are provided with two mounting through holes, and the power unit is defined as having a first edge and a second edge arranged opposite to each other, and the two mounting through holes are respectively arranged close to the first edge and the second edge of the power unit; the pressing block comprises two pressing block bodies and a connecting rod, and the two pressing block bodies are symmetrically arranged at the two ends of the connecting rod.

2. The power module of claim 1, wherein, the pressing block body is further provided with a pressing block tooth protruding from the bottom of the avoidance groove, and the pressing block tooth is integrally formed with the pressing block body.

3. The power module of claim 2, wherein, the pressing block body is provided with a second fixing groove at the other surface away from the positioning portion, and the second fixing groove is arranged adjacent to the first fixing through hole, so as to fixedly mount the power unit to an external driving plate through a second connecting piece.

4. The power module of claim 3, wherein, the end of the connecting rod is connected to the side of the pressing block body away from the second fixing groove.

5. The power module of claim 4, wherein, the power module further comprises an external driving plate, the projection of the external driving plate overlaps the plane of the power unit, and the external driving plate is provided with an opening, and the projection of the opening corresponds to the second fixing groove; the signal terminal connecting portion of the external driving plate extends outwardly towards the side of the power unit close to the signal terminal, and is provided with a small hole corresponding to the signal terminal, and the end of the signal terminal connecting portion is provided with an avoidance notch.

6. An electric machine controller characterized by The motor controller comprises a liquid cooling heat dissipation device and a power module as claimed in any one of claims 1-5; wherein the power module is mounted on the liquid cooling heat dissipation device through the pressing block.

7. A vehicle characterized by comprising: The vehicle comprises a power module as claimed in any one of claims 1-5; or, the vehicle comprises a motor controller as claimed in claim 6.

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