Electric vehicle control device and electric vehicle

Abstract

The application is suitable for the technical field of electric vehicle control device, and provides an electric vehicle control device and an electric vehicle.The first shell and the second shell of the electric vehicle control device are assembled together, and a plurality of power tubes are welded on the circuit board.The metal back plate of the power tube is in thermal connection with the heat relay body, and the first pressing structure is arranged on the first shell.When the first shell and the second shell are assembled into one, the first pressing structure abuts against the power tube and / or the heat relay body to generate pressure, so that the heat relay body and the second shell form a stable insulating thermal connection.In this way, the electric vehicle control device can directly rely on the pressure generated by the first pressing structure when the first shell and the second shell are assembled to hold and compress the heat relay body, so that a stable insulating thermal connection is formed between the heat relay body and the second shell, and the implementation and assembly methods are relatively simple, and the assembly efficiency is higher.

Description

Technical Field

[0001] This application relates to the field of electric vehicle technology, and more particularly to an electric vehicle control device and an electric vehicle. Background Technology

[0002] Electric vehicles are equipped with three-phase motor controllers to control the three-phase motors. Currently, the power device technology used in three-phase motor controllers has enabled the individual device chips to withstand relatively large currents. Relatively speaking, larger currents mean more heat generation.

[0003] In related technologies, in order to improve the heat dissipation efficiency of power transistors, heat dissipation structures are usually set on the metal backplate of the power transistor to dissipate heat. For example, a heat sink is set on the metal backplate of the power transistor to dissipate heat. The heat sink is positioned and installed using additional fastening and positioning elements to thermally connect the positioning elements to the housing to dissipate heat. Then the housing is assembled. This implementation and assembly method is relatively complex. Summary of the Invention

[0004] This application provides an electric vehicle control device and an electric vehicle, aiming to solve the technical problem that the heat sink positioning and assembly method of the power tube in the existing electric vehicle control device is relatively complex.

[0005] This application is implemented as follows: the electric vehicle control device in the embodiments of this application includes:

[0006] First shell;

[0007] A second housing assembled with the first housing;

[0008] A circuit board disposed between the first housing and the second housing, wherein multiple power transistors are soldered onto the circuit board; and

[0009] A thermal relay, which is thermally connected to the metal backplate of the power transistor;

[0010] A first pressing structure is provided on the first housing;

[0011] When the first housing and the second housing are assembled as a single unit, the first pressing structure abuts against the power transistor and / or the thermal relay to generate pressure, thereby forming a stable insulating thermal connection between the thermal relay and the second housing.

[0012] Furthermore, when the first housing and the second housing are assembled as a single unit, the first pressing structure abuts against the power tube to form a stable thermal connection between the metal backplate and the thermal relay.

[0013] Furthermore, the metal backplate of the power transistor forms a stable thermal connection with the thermal relay via a first fixing device.

[0014] Furthermore, the electric vehicle control device also includes a buffer, wherein the first pressing structure abuts against the buffer to apply pressure to the power transistor, thereby forming a robust insulating thermal connection between the thermal relay and the second housing.

[0015] Furthermore, the buffer is an insulating component.

[0016] Furthermore, the thermal relay includes:

[0017] A back-side thermal repeater is thermally connected to the back of the metal backplate of the power transistor and thermally insulated from the second housing.

[0018] A front-side thermal relay is thermally connected to the front of the metal backplate of the power transistor and thermally insulated from the first housing.

[0019] The first pressing structure abuts against the front thermal relay to form a solid thermal connection between the front thermal relay and the front side of the metal backplate of the power transistor, and to form a solid thermal connection between the back side of the metal backplate of the power transistor and the back thermal relay, and to form a solid insulating thermal connection between the back thermal relay and the second housing.

[0020] Furthermore, the thermal relay includes:

[0021] A back-side thermal repeater is thermally connected to the back of the metal backplate of the power transistor and thermally insulated from the second housing.

[0022] A front-side thermal relay is thermally connected to the front of the metal backplate of the power transistor and thermally insulated from the first housing.

[0023] The back heat relay and the back of the metal back plate of the power tube form a stable thermal connection through the second fixing device.

[0024] The front thermal relay and the front of the metal backplate of the power tube form a stable thermal connection through the second fixing device or the third fixing device.

[0025] The first pressing structure abuts against the front thermal relay to form a solid, insulating thermal connection between the back thermal relay and the second housing.

[0026] Furthermore, the first housing also includes a second pressing structure;

[0027] When the first housing and the second housing are assembled as a single unit, the second pressing structure abuts against the signal pin sealing gasket to form a solid insulating thermal connection between the extension and the second housing, and to seal the signal pin portion out of the electric vehicle control device.

[0028] Furthermore, a terminal block is connected to the extension portion;

[0029] The first housing also includes a third pressing structure;

[0030] The third pressing structure generates pressure on the terminal and terminal sealing gasket when the first housing and the second housing are assembled as a whole, so that the extension forms a solid insulating thermal connection with the second housing, and the terminal portion is led out of the electric vehicle control device in a sealed manner.

[0031] Furthermore, the first housing also includes a fourth pressing structure;

[0032] The fourth pressing structure exerts pressure on the housing sealing gasket when the first housing and the second housing are assembled as a whole.

[0033] Furthermore, the first housing is provided with multiple wire grooves;

[0034] The multiple cable trays are configured with two different external wiring directions, one of which is for external power input and the other is for three-phase motor output.

[0035] This application also provides an electric vehicle, which includes the electric vehicle control device described in any of the above claims, and the electric vehicle is equipped with a three-phase motor, wherein the three-phase line interface of the three-phase motor is electrically connected to the three-phase output terminal of the motor of the electric vehicle control device.

[0036] The beneficial effects achieved by this application are: the electric vehicle control device can directly rely on the pressure generated by the first pressing structure during the assembly of the first and second housings to hold and press the thermal relay, thereby forming a stable insulating thermal connection between the thermal relay and the second housing. The implementation and assembly methods are relatively simple, and the assembly efficiency is also higher.

[0037] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0038] Figure 1 This is a schematic diagram of the electric vehicle module provided in an embodiment of this application;

[0039] Figure 2This is a schematic diagram of the electric vehicle control device provided in the embodiments of this application;

[0040] Figure 3 This is an exploded view of the electric vehicle control device provided in the embodiments of this application;

[0041] Figure 4 This is a schematic diagram of the planar structure of the electric vehicle control device provided in the embodiments of this application;

[0042] Figure 5 yes Figure 4 A cross-sectional schematic diagram of the electric vehicle control device along line VV.

[0043] Figure 6 yes Figure 4 A cross-sectional schematic diagram of the electric vehicle control device along line VI-VI.

[0044] Figure 7 This is a partial structural schematic diagram of the electric vehicle control device provided in the embodiments of this application;

[0045] Figure 8 This is a schematic diagram of the structure of each rear thermal relay of the electric vehicle control device provided in the embodiments of this application;

[0046] Figure 9 yes Figure 8 A schematic diagram of the exploded structure in the image;

[0047] Figure 10 This is a schematic diagram of the structure of the thermal relay in the embodiments of this application;

[0048] Figure 11 yes Figure 10 thermal relay along Figure 10 A schematic diagram of the projection along direction A in the diagram;

[0049] Figure 12 yes Figure 10 thermal relay along Figure 10 A schematic diagram of the projection along direction B in the diagram;

[0050] Figure 13 This is another structural schematic diagram of the electric vehicle control device provided in the embodiments of this application;

[0051] Figure 14 This is a schematic diagram of the structure of the electric vehicle control device provided in the embodiments of this application, which has a rear thermal relay and a front thermal relay;

[0052] Figure 15 This is an exploded view of the electric vehicle control device provided in the embodiments of this application, which has a rear thermal relay and a front thermal relay.

[0053] Figure 16This is an assembly diagram of the power transistor, the rear thermal relay, and the front thermal relay of the electric vehicle control device provided in this application embodiment;

[0054] Figure 17 This is a cross-sectional schematic diagram of the electric vehicle control device provided in the embodiments of this application, which has a rear thermal relay and a front thermal relay.

[0055] Figure 18 yes Figure 4 A cross-sectional schematic diagram of the electric vehicle control device along line XVIII-XVIII.

[0056] Figure 19 This is a schematic diagram of the structure of the first housing of the electric vehicle control device provided in the embodiments of this application;

[0057] Figure 20 This is another structural schematic diagram of the first housing of the electric vehicle control device provided in the embodiments of this application;

[0058] Figure 21 This is a schematic diagram of the structure of each sealing gasket and buffer component of the electric vehicle control device provided in the embodiments of this application;

[0059] Figure 22 This is another structural schematic diagram of the electric vehicle controller provided in the embodiments of this application;

[0060] Figure 23 This is a schematic diagram of another part of the structure of the electric vehicle controller provided in the embodiments of this application;

[0061] Figure 24 This is a schematic diagram of the structure of the second housing of the electric vehicle control device provided in the embodiments of this application. Detailed Implementation

[0062] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application. Furthermore, it should be understood that the specific embodiments described herein are merely for explaining this application and are not intended to limit this application.

[0063] In the description of this application, it should be understood that the orientations or positional relationships indicated in the description of directions and positional relationships are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of the stated features. In the description of this application, "a plurality of" means two or more, unless otherwise explicitly specified.

[0064] The following disclosure provides numerous different embodiments or examples for implementing various structures of this application. To simplify the disclosure, specific examples of components and arrangements are described below. These are merely examples and are not intended to limit the scope of this application. Furthermore, reference numerals and / or letters may be repeated in different examples; such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed. In addition, various specific examples of processes and materials are provided in this application, but those skilled in the art will recognize the application of other processes and / or the use of other materials.

[0065] In this application, by providing a first pressing structure on the first housing, the electric vehicle control device can directly rely on the pressure generated by the first pressing structure during the assembly of the first housing and the second housing to hold and press the thermal relay, thereby forming a stable insulating thermal connection between the thermal relay and the second housing. The implementation and assembly methods are relatively simple, and the assembly efficiency is also higher.

[0066] Example 1

[0067] Please see Figure 1 In this embodiment, the electric vehicle 1000 can be a two-wheeled electric vehicle or a three-wheeled electric vehicle. The electric vehicle 1000 may include a three-phase motor 200 and an electric vehicle controller 100 as described in this embodiment. The three-phase motor 200 has a three-phase wire interface (not shown in the figure), and the three-phase wire interface of the three-phase motor 200 is connected to the three-phase output of the electric vehicle controller 100. The external power input of the electric vehicle controller 100 is connected to a power source, and the three-phase output of the electric vehicle controller 100 is connected to the three-phase motor 200.

[0068] Please see Figures 2 to 5 The electric vehicle control device 100 in this embodiment may include a housing 10, a circuit board 20, a plurality of power transistors 30 and a thermal relay 40, which can be used to dissipate heat from the power transistors 30.

[0069] The outer casing 10 may include a first casing 11 and a second casing 12, which can be stacked and assembled together to form a complete outer casing 10. The second casing 12 may be made of metal, and the first casing 11 may be made of insulating material (such as plastic) or metal, without any specific limitation.

[0070] The circuit board 20 can be installed inside the housing 10 and disposed between the first housing 11 and the second housing 12. The circuit board 20 may be provided with signal pin headers 21.

[0071] The number of power transistors 30 is at least 6, and the power transistors 30 are soldered onto the circuit board 20. The power transistors 30 can be through-hole visible metal package power transistors, for example, the power transistors 30 can be metal package power transistors of model TO220.

[0072] The power transistor 30 has a metal backplate 31 and a plastic package located on the front of the metal backplate 31. Multiple pins 32 extend from the plastic package. Preferably, there are three pins 32. The metal backplate 31 is located on the back of the power transistor 30. The three pins 32 of the power transistor 30 are the gate, drain, and source, respectively. The multiple pins 32 of the power transistor 30 are arranged at intervals in the same direction. The metal backplate 31 is electrically connected to the drain.

[0073] like Figure 6 and Figure 7 As shown, the multiple power transistors 30 can be configured as upper bridge arm power transistors of three phases A, B, and C, and lower bridge arm power transistors of three phases A, B, and C, namely, A-phase upper bridge arm power transistor 301, A-phase lower bridge arm power transistor 302, B-phase upper bridge arm power transistor 303, B-phase lower bridge arm power transistor 304, C-phase upper bridge arm power transistor 305, and C-phase lower bridge arm power transistor 306. The number of each of the following power transistors 30 is at least one: A-phase upper bridge arm power transistor 301, A-phase lower bridge arm power transistor 302, B-phase upper bridge arm power transistor 303, B-phase lower bridge arm power transistor 304, C-phase upper bridge arm power transistor 305, and C-phase lower bridge arm power transistor 306.

[0074] The number of thermal relays 40 can also be multiple. The thermal relays 40 are also arranged in the space formed by the first housing 11 and the second housing 12. The thermal relays 40 are thermally connected to the metal back plate 31 of the power transistor 30 to dissipate heat from the power transistor 30.

[0075] Please see Figure 5 In embodiments of this application, a first pressing structure 112 may be provided on the first housing 11. When the first housing 11 and the second housing 12 are assembled as one unit, the first pressing structure 112 abuts against the power transistor 30 and / or the thermal relay 40 to generate pressure, thereby forming a stable insulating thermal connection between the thermal relay 40 and the second housing 12. Figure 5In the example shown, the first pressing structure 112 abuts against the plastic package of the power transistor 30. It is understood that in other embodiments, the first pressing structure 112 may also abut against the thermal relay 40 or against the metal backplate 31 of the power transistor 30 or against both the power transistor 30 and the thermal relay 40. No specific limitation is made here.

[0076] In the electric vehicle control device 100 and electric vehicle 1000 of this application embodiment, a first pressing structure 112 is provided on the first housing 11. When the first housing 11 and the second housing 12 are assembled as one unit, the first pressing structure 112 abuts against the power transistor 30 or the thermal relay 40 to generate pressure, thereby forming a stable insulating thermal connection between the thermal relay 40 and the second housing 12. In this way, the electric vehicle control device 100 can directly rely on the pressure generated by the first pressing structure 112 when assembling the first housing 11 and the second housing 12 to hold and press the thermal relay 40, thereby forming a stable insulating thermal connection between the thermal relay 40 and the second housing 12. The implementation and assembly methods are relatively simple, and the assembly efficiency is also higher.

[0077] It should be noted that "abutment" can be understood as direct contact or indirect contact through other components; no specific restrictions are made here.

[0078] In this document, "insulating thermal connection" can be understood as two components that are insulated from each other but can transfer heat between them through other thermally conductive elements. That is to say, in this application, the thermal relay 40 and the second housing 12 of the electric vehicle controller 100 are insulated from each other and thermally connected. If the same description appears below, it can also be understood here.

[0079] It should also be noted that in this article, "thermal connection" can be understood as either the insulating thermal connection or the conductive thermal connection mentioned above, while "conductive thermal connection" can be understood as two things that are in direct contact, can conduct electricity and conduct heat between each other, or can be understood as two things that are indirectly connected and conduct heat indirectly through other components. If the same description appears in the following text, please refer to this section for understanding.

[0080] Specifically, please refer to Figure 2 and Figure 3 In some embodiments, snap-fit ​​portions 111 may be formed on the four sides of the first housing 11, and snap-fit ​​grooves 1111 may be formed on the snap-fit ​​portions 111. Snap-fit ​​protrusions 122 may be correspondingly formed on the four sides of the second housing 12. The first housing 11 and the second housing 12 are snapped together by the snap-fit ​​protrusions 122 and the snap-fit ​​grooves 1111 to achieve overlapping assembly.

[0081] like Figure 5As shown, in some embodiments, the first pressing structure 112 may be a first abutting portion disposed on the first housing 11, for example, in Figure 5 In this configuration, the first pressing structure 112 can be a protruding rib on the first housing 11. When the first housing 11 and the second housing 12 are fastened together by the snap-fit ​​protrusion 122 and the snap-fit ​​part 111, the first abutting part on the first housing 11 can abut against the power tube 30 or the thermal relay 40 to generate pressure, thereby tightly abutting the thermal relay 40 and the second housing 12 together to form a stable insulating thermal connection.

[0082] Further, please refer to Figures 5 to 9 In this application, the thermal relay 40 may include a heat-absorbing part 41 and an extension part 42. The heat-absorbing part 41 may be thermally connected to the metal back plate 31 of the power tube 30, and the extension part 42 is connected to the heat-absorbing part 41. Both the heat-absorbing part 41 and the extension part 42 are thermally insulated from the second housing 12. The surface of the heat-absorbing part 41 that contacts the metal back plate 31 is the surface of the thermal relay 40 that absorbs heat, while the surface of the thermal relay 40 that is thermally insulated from the second housing 12 (e.g., the bottom surface of the heat-absorbing part 41 and the bottom surface of the extension part 42) is the surface that conducts heat to the second housing 12.

[0083] In the embodiments of this application, each thermal repeater 40 is preferably electrically and thermally connected to the back side of the metal backplate 31 of each power transistor 30. That is, at least one plane of the thermal repeater 40 can be directly attached to the metal backplate 31. Of course, it is understood that in some possible embodiments, a conductive element with good thermal conductivity can be provided between the thermal repeater 40 and the metal backplate 31 to achieve the conductive thermal connection between the two. For example, the conductive thermal connection between the two can be achieved by using a silicone grease with good thermal conductivity and conductive properties. The specific method is not limited here. In this case, the thermal relay 40 can be used to connect to the positive power input or the three-phase output of the motor of the electric vehicle controller 100. For example, the extension 42 and / or heat absorption part 41 of the thermal relay 40 corresponding to each upper bridge arm power transistor can be connected to the positive power input, while the extension 42 and / or heat absorption part 41 of the thermal relay 40 corresponding to the lower bridge arm power transistor can be connected to the three-phase input of the motor. For example, the thermal relay 40 corresponding to the A-phase lower bridge arm power transistor 302 is connected to the A-phase output, the thermal relay 40 corresponding to the B-phase lower bridge arm power transistor 304 is connected to the B-phase output, and the thermal relay 40 corresponding to the C-phase lower bridge arm power transistor 306 is connected to the C-phase output.

[0084] In this way, the positive power input and three-phase motor output of the electric vehicle controller 100 can be electrically connected to the corresponding power transistors 30 through each thermal relay 40, eliminating the need for wiring on the circuit board 20 to connect these terminals and reducing the heat generated by the circuit board 20. The heat generated by the current flowing through each thermal relay 40 can be directly transferred to the outer casing 10 and dissipated to the outside of the electric vehicle controller 100, thus solving the technical problem of heat generation due to the conductivity of the thermal relay 40. It is easy to understand that when the power transistor 30 is working, the heat generated by the power transistor 30 can be quickly transferred to the outer casing 10 of the electric vehicle controller 100 through the thermal relay 40 to absorb the instantaneous heat generated by the power transistor 30, thereby ensuring that the power transistor 30 remains within a safe temperature range.

[0085] Further, please refer to Figures 10 to 12 In some embodiments, the extension 42 and the heat-absorbing portion 41 are aligned in the same direction as the pins 32 of the power transistor 30 (i.e., ...). Figure 10 The orthographic projection regions on direction A in the diagram do not overlap at least partially, that is, as shown in the diagram. Figure 11 As shown, in Figure 10 In direction A, the projection area Y2 formed by the orthogonal projection of the heat-absorbing part 41 and the projection area Y1 formed by the orthogonal projection of the extension part 42 do not overlap at least partially.

[0086] Furthermore, the extension 42 and the heat absorption portion 41 are arranged in a direction perpendicular to the pin 32 of the power tube 30 (i.e., Figure 10 The orthographic projection regions on the B direction (in the image) do not overlap at least partially, that is, as shown in the image. Figure 12 As shown, in Figure 10 In direction A, the projection area Y2+Y3 formed by the orthographic projection of the heat-absorbing part 41 and the projection area Y1+Y3 formed by the orthographic projection of the extension part 42 do not overlap at least partially. This is understandable. Figure 12 In the diagram, the projection area Y2+Y3 is the projection area formed by the orthogonal projection of the heat-absorbing part 41 in the B direction, while Y1+Y3 is the projection area formed by the orthogonal projection of the heat-absorbing part 41 in the B direction. The projection area Y3 is the overlapping area of ​​the orthogonal projections of the extension part 42 and the heat-absorbing part 41 in the B direction.

[0087] Thus, the projection areas of the extension 42 and the heat absorption part 41 in both directions do not overlap. On the one hand, this can increase the heat dissipation area and thus improve the heat dissipation performance of the power tube 30. On the other hand, the arrangement of the extension 42 allows for more flexible arrangement of the wiring terminals of the electric vehicle controller 100 (such as the power positive input terminal 81, A-phase output terminal 821, B-phase output terminal 822 and C-phase output terminal 823 described below). The wiring terminals can be placed in any position simply by changing the extension direction and extension shape of the extension 42.

[0088] Of course, it is understood that in other embodiments, each thermal relay 40 may only be thermally connected to the metal backplate 31 of the power transistor 30 without being electrically connected. In this case, the thermal relay 40 is only used for heat dissipation and not for conduction, and each terminal may be set on the circuit board 20 or the corresponding power transistor 30.

[0089] In addition, in some embodiments, a portion of the thermal relays 40 may be electrically and thermally connected to the corresponding power transistors 30 and connected to terminals, while another portion of the thermal relays 40 may only be thermally connected to the corresponding power transistors 30. In such cases, some of the terminals may be located on the circuit board 20 or on the metal backplate 31 of the corresponding power transistors 30. No specific restrictions are imposed here. In the following description, each thermal relay 40 may be electrically and thermally connected to the metal backplate 31 of the corresponding power transistors 30 as an example.

[0090] Please see Figure 3 and Figure 5 In some embodiments, in order to achieve an insulating thermal connection between each thermal relay 40 and the second housing 12, the electric vehicle controller 100 may further include an insulating element 50, which may be disposed within the second housing 12, and each thermal relay 40 may abut against the insulating element 50.

[0091] Thus, the insulation component 50 can enable rapid heat transfer to the second housing 12 while also preventing leakage caused by conduction between each thermal relay 40 and the second housing 12. It can also prevent conduction between the thermal relay 40 connected to the upper bridge arm power transistor and the thermal relay 40 connected to the lower bridge arm power transistor, as well as prevent mutual conduction between each thermal relay 40 connected to the lower bridge arm power transistor.

[0092] Specifically, in such embodiments, the insulating element 50 may be a sheet-like body made of insulating thermal interface materials, such as a metal substrate (e.g., an aluminum substrate), a silicon wafer, an imide film, an insulating cloth, or a high thermal conductivity interface material.

[0093] It is understood that in some embodiments, the shape of the insulating element 50 may be configured to correspond to the geometry of the thermal relay 40, or the insulating element 50 may be directly configured to cover the entire surface of the second housing 12 that abuts against the thermal relay 40.

[0094] In some embodiments, the insulating member 50 may preferably be an aluminum substrate. The aluminum substrate may include an aluminum base layer, an insulating layer stacked on the aluminum base layer, and a copper foil layer disposed on the insulating layer. The area covered by the copper foil layer may correspond to each thermal relay 40. That is, except for the area corresponding to each thermal relay 40, other areas on the aluminum substrate do not have copper foil layers. Each thermal relay 40 may be soldered to the corresponding copper foil layer. In this way, the aluminum substrate can be used to position and limit each thermal relay 40 while ensuring heat transfer efficiency.

[0095] In addition, Figure 5 and Figure 6 In the illustrated embodiment, the thermal relay 40 is disposed below the circuit board 20. The heat-absorbing part 41 of the thermal relay 40 is located below the metal back plate 31 of the power tube 30 and is electrically and thermally connected to the back side of the metal back plate 31. When the first housing 11 and the second housing 12 are assembled and stacked together, the first pressing device 112 can abut against the power tube 30, thereby making the metal back plate 31 tightly abut against the heat-absorbing part 41, and thus making the thermal relay 40 tightly abut against the insulating member 50 to achieve a stable insulating thermal connection with the second housing 12.

[0096] It is understood that in other embodiments, the first pressing device 112 may also directly abut against the thermal relay 40, or simultaneously abut against the thermal relay 40 and the power tube 30, so that the heat transfer surface 421 of the thermal relay 40 is tightly abutted against the insulating member 50 to form a solid insulating thermal connection with the second housing 12, and no specific limitation is made here.

[0097] Furthermore, it can be understood that when the first housing 11 is made of insulating material such as plastic, the first pressing structure 112 on the first housing 11 can directly abut against the metal back plate 31 or the thermal relay 40. When the first housing 11 is made of conductive material such as metal, the first pressing structure 112 on the first housing 11 can abut against the plastic package of the power transistor 30, or indirectly abut against the metal back plate 31 or the thermal relay 40 through other insulating elements. No specific limitations are made here.

[0098] Please see Figures 5 to 9 In some embodiments, the thermal relay 40 may include a back thermal relay 43 that is electrically and thermally connected to the back of the metal back plate 31, and the number of back thermal relays 43 is at least four.

[0099] Specifically, the back thermal relay 43 may include an upper bridge arm thermal relay that is electrically and thermally connected to the metal backplate 31 of the upper bridge arm power transistor and a lower bridge arm thermal relay that is electrically and thermally connected to the metal backplate 31 of the lower bridge arm power transistor. The number of upper bridge arm thermal relays is at least one, and the number of lower bridge arm thermal relays is at least three.

[0100] At least one upper bridge arm thermal relay is electrically and thermally connected to the metal backplate 31 of at least two phases of the upper bridge arm power transistors, and the metal backplate 31 of each phase of the lower bridge arm power transistor is electrically and thermally connected to at least one lower bridge arm thermal relay. The upper bridge arm thermal relays can be connected to the positive power input of the electric vehicle controller 100, and the lower bridge arm thermal relays are connected to the three-phase motor output of the electric vehicle controller 100.

[0101] Thus, the upper bridge arm thermal repeater can dissipate heat from the upper bridge arm power transistors while also providing the positive input to the electric vehicle controller 100, and the lower bridge arm thermal repeater can dissipate heat from the lower bridge arm power transistors while also providing the three-phase output to the electric vehicle controller 100. Furthermore, the fact that one upper bridge arm thermal repeater corresponds to at least two phases of the upper bridge arm power transistors on the metal backplate 31 reduces the number of upper bridge arm thermal repeaters required, lowers manufacturing costs, and facilitates installation.

[0102] Specifically, it can be understood that in the electric vehicle controller 100, the number of power transistors 30 is at least 6. In this article, we will use the example of 6 power transistors 30 for illustration. Figures 5 to 7 As shown, there are 6 power transistors 30, namely 1 A-phase upper arm power transistor 301, 1 A-phase lower arm power transistor 302, 1 B-phase upper arm power transistor 303, 1 B-phase lower arm power transistor 304, 1 C-phase upper arm power transistor 305, and 1 C-phase lower arm power transistor 306.

[0103] It is understandable that in the electric vehicle controller 100, since the drains of all the upper arm power transistors in the three-phase half-bridge drive circuit need to be connected to the positive input of the power supply, all the upper arm power transistors can be installed in the same upper arm thermal relay. It is only necessary to provide at least three heat-absorbing parts 41 on this upper arm thermal relay for conductive thermal connection with the metal backplates 31 of different upper arm power transistors to connect all the upper arm power transistors together to the positive input of the power supply. For example... Figure 8 and Figure 9 As shown in the embodiments of this application, the upper bridge arm thermal relay may be a single piece, and three spaced heat-absorbing parts 41 may be formed on the upper bridge arm thermal relay. The three heat-absorbing parts 41 are connected together by the connecting part 45 and connected to the extension part 42. Each heat-absorbing part 41 is provided with at least one upper bridge arm power tube.

[0104] Furthermore, in a three-phase half-bridge drive circuit, since the drain of the lower bridge arm power transistor is electrically connected to the source of the upper bridge arm power transistor and requires simultaneous three-phase output, to avoid mutual conduction between the two lower bridge arm power transistors, each phase's corresponding lower bridge arm power transistor needs to have at least one separate lower bridge arm thermal relay. For example... Figure 8 and Figure 9As shown in the embodiments of this application, the number of lower arm thermal relays is at least 3. The lower arm thermal relay corresponding to the A-phase lower arm power transistor 302 can be connected to the A-phase output of the electric vehicle control device 100, the lower arm thermal relay corresponding to the B-phase lower arm power transistor 304 can be connected to the B-phase output of the electric vehicle control device 100, and the lower arm thermal relay corresponding to the C-phase lower arm power transistor 306 can be connected to the C-phase output of the electric vehicle control device 100.

[0105] In this article, we will use 6 power transistors (40), 1 upper bridge arm thermal repeater, and 3 lower bridge arm thermal repeaters as examples. Specifically, as... Figure 8 and Figure 9 As shown, the upper bridge arm thermal relay may include three heat-absorbing parts 41 and one extension part 42. The three lower bridge arm thermal relays may be the A-phase lower bridge arm thermal relay, the B-phase lower bridge arm thermal relay, and the C-phase lower bridge arm thermal relay, respectively. The extension part 42 of the upper bridge arm thermal relay is connected to the positive input of the power supply, and the upper bridge arm thermal relay is thermally insulated from the housing 10. The metal backplates 31 of the A-phase upper bridge arm power transistor 301, the B-phase upper bridge arm power transistor 303, and the C-phase upper bridge arm power transistor 305 are respectively electrically and thermally connected to the three heat-absorbing parts 41 of the three upper bridge arm thermal relays. The extension part 42 of each lower bridge arm thermal relay is connected to the three output terminals of the three-phase output of the motor. At the same time, each lower bridge arm thermal relay is also thermally insulated from the second housing 12.

[0106] More specifically, the three lower bridge arm thermal relays are respectively electrically and thermally connected to the metal backplate 31 of the lower bridge arm power transistors 302 (phase A), 304 (phase B), and 306 (phase C), and are as follows:

[0107] The heat-absorbing part 41 on the thermal relay of the lower bridge arm of phase A is electrically and thermally connected to the back of the metal back plate 31 of the power tube 301 of the lower bridge arm of phase A, and the extension part 42 on the thermal relay of the lower bridge arm of phase A is connected to the output of the three-phase output phase A.

[0108] The heat-absorbing part 41 on the thermal relay of the lower bridge arm of phase B is electrically and thermally connected to the back of the metal back plate 31 of the power tube 301 of the lower bridge arm of phase B, and the extension part 42 on the thermal relay of the lower bridge arm of phase B is connected to the output of the three-phase output of phase B.

[0109] The heat-absorbing part 41 on the C-phase lower arm thermal relay is electrically and thermally connected to the back of the metal backplate 31 of the C-phase lower arm power tube 301, and the extension part 42 on the C-phase lower arm thermal relay is connected to the C-phase output of the three-phase output.

[0110] like Figure 6 and Figure 7 As shown, in Figure 6 and Figure 7In the illustrated embodiment, six power transistors 30 are arranged in a row, with the upper bridge arm power transistors and the lower bridge arm power transistors alternating sequentially. In this case, as... Figure 8 and Figure 9 As shown, preferably, the spacing between two adjacent heat-absorbing parts 41 on the upper bridge arm thermal relay can be set to be greater than the width of the heat-absorbing part 41 of the lower bridge arm thermal relay, so that the heat-absorbing part 41 of the lower bridge arm thermal relay corresponding to the lower bridge arm power tube can be arranged between two adjacent heat-absorbing parts 41 of the upper bridge arm thermal relay to optimize the layout between each thermal relay 40, that is, so that the heat-absorbing parts 41 of each thermal relay 40 can also be arranged in a row.

[0111] Furthermore, the heat-absorbing portions 41 of the rear thermal repeaters 43 can be located below the metal backplate 31 of the corresponding power transistors 30, and the extension portions 42 of each rear thermal repeater 43 can be bent relative to their respective heat-absorbing portions 41 and extend in a plane parallel to the circuit board 20. The three heat-absorbing portions 41 of the upper bridge arm thermal repeater are connected together by the connecting portion 45 and then connected to the extension portion 42, which extends relative to the connecting portion 43 in a plane parallel to the circuit board 20.

[0112] In this way, by setting the extension 42 of each rear heat relay 43 to be bent relative to the heat absorption part 41 of each rear heat relay 43, the length of each extension 42 can be increased within a fixed space to increase the heat dissipation area and improve the heat dissipation efficiency.

[0113] In the embodiments of this application, in order to save manufacturing processes and reduce installation processes, it is preferable that all upper arm power transistors share a single upper arm thermal relay. That is, the metal backplate 31 of all upper arm power transistors is electrically and thermally connected to a single upper arm thermal relay.

[0114] Of course, it is understandable that in some embodiments, the number of upper bridge arm thermal relays can also be multiple, such as 2 or 3. When there are 2, one of them may have two heat absorption parts 41 corresponding to two upper bridge arm power transistors, and the other may have one heat absorption part 41 corresponding to one upper bridge arm power transistor. Alternatively, each upper bridge arm power transistor may correspond to multiple upper bridge arm thermal relays, and then all the upper bridge arm thermal relays may be connected together with the positive input of the power supply. No specific restrictions are imposed here.

[0115] In addition, in some embodiments, the number of lower arm thermal repeaters may be greater than three. For example, each lower arm power transistor may correspond to one or more lower arm thermal repeaters, and there is no specific limitation here.

[0116] Furthermore, in the illustrated example, the electric vehicle controller 100 has six power transistors 30. Taking the six power transistors 30 arranged in a row as an example, the six power transistors 30 can be set at the edge of the circuit board 20, and the three pins 32 of the power transistors 30 are soldered to the edge of the circuit board 20.

[0117] Furthermore, this article only uses 6 power transistors 30 as an example for explanation. It is understood that in some embodiments, the number of power transistors 30 may also be 9, 12, 18, etc., and no specific limitation is made here.

[0118] Furthermore, in the illustrated embodiment, the power tubes 30 may be arranged in a row, and the heat-absorbing portions 41 of each rear thermal relay 43 may also be arranged in a row. It is understood that in other embodiments, the power tubes 30 may also be arranged in two rows, four rows, six rows, etc., and no specific limitation is made here.

[0119] It is easy to understand that in the embodiments of this application, regardless of the number of power transistors, all upper bridge arm power transistors can be disposed together on one upper bridge arm thermal relay. It is only necessary to form multiple corresponding heat absorption parts 41 on the upper bridge arm thermal relay. Alternatively, each upper bridge arm power transistor can correspond to one upper bridge arm thermal relay, or one upper bridge arm thermal relay can correspond to two or more upper bridge arm power transistors. No specific limitation is made here.

[0120] For the lower arm power transistors, when there are more than one corresponding lower arm power transistor, all A-phase lower arm power transistors 302 can be connected in parallel and correspond to one lower arm thermal relay, or each A-phase lower arm power transistor 302 can correspond to one lower arm thermal relay; all B-phase lower arm power transistors 304 can be connected in parallel and correspond to one lower arm thermal relay, or each B-phase lower arm power transistor 304 can correspond to one lower arm thermal relay; all C-phase lower arm power transistors 306 can be connected in parallel and correspond to one lower arm thermal relay, or each C-phase lower arm power transistor 306 can correspond to one lower arm thermal relay, and no specific restrictions are imposed here.

[0121] Furthermore, it is understood that in some embodiments, only the upper bridge arm thermal relay can be connected to the positive power input of the electric vehicle controller 100, while the three-phase motor output of the electric vehicle controller 100 can be configured on the circuit board 20. Alternatively, the lower bridge arm thermal relay can be connected to the three-phase motor output of the electric vehicle controller 100, while the positive power input can be configured on the circuit board 20. The specific configuration method is not limited here.

[0122] Example 2

[0123] Please see Figure 5 In some embodiments, when the first housing 11 and the second housing 12 are assembled as a single unit, the first pressing structure 112 abuts against the power tube 30 to form a stable thermal connection between the metal backplate 31 and the thermal relay 40.

[0124] Thus, the first pressing structure 112 can form a stable insulating thermal connection between the thermal relay 40 and the second housing 12, and also form a stable thermal connection between the metal backplate 31 of the power tube 30 and the thermal relay 40, without the need to use other pressing structures or other structures to form a stable thermal connection between the metal backplate 31 and the thermal relay 40 separately.

[0125] Please see Figure 5 When the first housing 11 and the second housing 12 are fastened together by the snap-fit ​​protrusion 122 and the snap-fit ​​part 111, the first abutting part on the first housing 11 can abut against the plastic package of the power tube 30 to generate continuous pressure, thereby pressing the metal back plate 31 of the power tube 30 tightly against the thermal relay 40 to form a solid thermal connection. At the same time, the pressure transmitted from the power tube 30 to the thermal relay 40 can also make the thermal relay 40 and the second housing 12 tightly abut against each other to form a solid insulating thermal connection.

[0126] Taking a configuration of 6 power transistors as an example, in the illustrated embodiment, there is one first abutment, which extends along the arrangement direction of the 6 power transistors 30 on the circuit board 20. In this case, when the first housing 11 and the second housing 12 are assembled and stacked together, all the power transistors 30 can be held together by the same first abutment, thereby enabling each thermal relay 40 to achieve a stable and insulating thermal connection with the second housing 12 under the action of the same abutment.

[0127] Of course, it is understood that in other embodiments, each thermal repeater 40 and each power tube 30 may correspond to a first abutment, and no specific limitation is made here.

[0128] In addition, in some embodiments, the first pressing structure 112 may also use a pressure strip or elastic element to hold the power tube 30, thereby forming a stable thermal connection between the metal back plate 31 of the power tube 40 and the thermal relay 40, and forming a stable insulating thermal connection between the thermal relay 40 and the second housing 12. The specific configuration is not limited here.

[0129] Of course, it is understood that in other embodiments, the first pressing structure 112 may only generate pressure when the first housing 11 and the second housing 12 are assembled together to form a stable insulating thermal connection between the thermal relay 40 and the second housing 12. For example, the first pressing device 112 may only hold the thermal relay 40, while the stable thermal connection between the thermal relay 40 and the metal back plate 31 of the power tube 30 may be achieved in other ways, such as by screws or welding.

[0130] Example 3

[0131] In some embodiments, the metal backplate 31 of the power transistor 30 can form a stable thermal connection with the thermal relay 40 through a first fixing device. Thus, the first fixing device ensures stable assembly between the metal backplate 31 and the thermal relay 40 to form a stable thermal connection, improving reliability.

[0132] Specifically, please refer to Figure 2 , Figure 8 and Figure 9 In such an embodiment, in order to achieve a stable thermal connection between the metal backplate 31 and the thermal relay 40, mounting holes 311 may be formed on the metal backplate 31 of each power tube 30, and fixing holes 411 for connecting with the metal backplate 31 of the power tube 30 may be provided on the heat-absorbing part 41 of the thermal relay 40. The first fixing device may be a fastening element such as a screw and bolt, and the fixing hole 411 may be a threaded hole.

[0133] During installation, the fixing hole 411 can be aligned with the mounting hole 311 on the metal back plate 31 first, and then the first fixing device can be inserted through the mounting hole 311 and fixedly engaged with the fixing hole 411. In this way, the metal back plate 31 can achieve thermal connection while being fixed to the thermal relay 40. The method is relatively simple and the installation is relatively convenient and quick.

[0134] It is understood that in some embodiments, threaded connectors such as screws can be made of metal. On the one hand, this can improve the structural strength of the connection between the thermal relay 40 and the metal back plate 31. On the other hand, the metal back plate 31 and the heat-absorbing part 41 can also be electrically connected by screws, which simplifies the assembly process.

[0135] Of course, it is understood that in other embodiments, the conductive and thermal connection between the metal back plate 31 and the heat-absorbing part 41 can also be achieved by welding and / or riveting, or by making the metal back plate 31 of each power tube 30 and the heat-absorbing part 41 of each thermal relay conductive and thermally connected. No specific limitation is made here.

[0136] Example 4

[0137] Please see Figure 5 and Figure 13 To avoid direct hard contact between the first pressing structure 112 on the first housing 11 and the power transistor 30 and / or the thermal relay 40, which could easily lead to damage during assembly, in some embodiments, the electric vehicle control device 100 may also include a buffer 60, with the first pressing structure 112 abutting against the buffer 60 to apply pressure to the power transistor 30 so that the thermal relay 40 forms a stable insulating thermal connection with the second housing 12.

[0138] Specifically, in such an embodiment, the buffer 60 can be an insulating component. For example, the buffer 60 can be a rubber pad, foam pad, or other element that can deform under external force to absorb the impact force. The buffer 60 can cover the power transistor 30 and / or the thermal relay 40. When the first housing 11 and the second housing 12 are assembled together, the first pressing structure 112 on the first housing 11 can abut against the buffer 60, thereby indirectly abutting against the power transistor 30 and / or the thermal relay 40.

[0139] Example 5

[0140] Please see Figures 14 to 17 In some embodiments, in addition to the aforementioned back thermal relay 43, the thermal relay 40 may also include a front thermal relay 44. The back thermal relay 43 is thermally connected to the back of the metal backplate 31 of the power transistor 30 and is thermally insulated from the second housing 12. The front thermal relay 44 is thermally connected to the front of the metal backplate 31 of the power transistor 30 and is thermally insulated from the first housing 11.

[0141] Please see Figure 17 The first pressing structure 112 can abut against the front thermal relay 44 to form a solid thermal connection between the front thermal relay 44 and the front of the metal back plate 31 of the power tube 30, and to form a solid thermal connection between the back of the metal back plate 31 of the power tube 30 and the back thermal relay 43, and to form a solid insulating thermal connection between the back thermal relay 43 and the second housing 12.

[0142] Thus, by providing a back thermal relay 43 and a front thermal relay 44 on the back and front of the metal backplate 31 respectively, the heat dissipation efficiency of the power transistor 30 can be improved. The front thermal relay 44 is abutted by the same first pressing structure 112, which allows the front thermal relay 44 to form a solid thermal connection with the front of the metal backplate 31 and the back of the metal backplate 31 to form a solid insulating thermal connection with the second housing 12, without the need for additional structures to achieve a solid connection of the four parts.

[0143] It should be noted that, in this article, the back side of the metal backplate 31 refers to the surface of the metal backplate 31 that is opposite to the surface on which the plastic encapsulation is disposed, while the front side of the metal backplate 31 refers to the surface of the metal backplate 31 that is the same as the surface on which the plastic encapsulation is disposed.

[0144] Specifically, please refer to Figures 14 to 17 The front thermal relay 44, the metal back plate 31, and the back thermal relay 43 are stacked sequentially from top to bottom. When the first housing 11 and the second housing 12 are assembled together, the first pressing structure 112 on the first housing 11 can abut against the front thermal relay 44. Thus, the pressing force generated by the first pressing structure 112 can tightly press the front thermal relay 44, the metal back plate 31, the back thermal relay 43, and the second housing 12 together, thereby achieving a stable connection between the two adjacent components without the need to use other fixing and connecting structures to fix the two adjacent components to form a stable connection.

[0145] Furthermore, in this embodiment, the arrangement of the rear thermal repeater 43 is consistent with that described in the previous embodiments, and will not be repeated here. For the front thermal repeater 44, in one possible embodiment, the number of front thermal repeaters 44 may correspond to the number of power transistors 30, with each power transistor 30 corresponding to one front thermal repeater 44. The shape of the front thermal repeater 44 is complementary to the shape of the power transistor 30, for example, as... Figure 16 As shown, the front thermal relay 44 can be L-shaped and cover the metal backplate 31 and plastic package of the power transistor 30, and the first pressing structure 112 can abut against the front thermal relay 44.

[0146] In some embodiments, the front thermal relay 44 may be used solely for heat dissipation and not for connecting the positive power input and the three-phase motor output. Of course, it is understood that in other embodiments, the front thermal relay 44 may connect the positive power input and the three-phase motor output, while the rear thermal relay 43 may be used solely for heat dissipation. In this case, the front thermal relay 44 corresponding to the upper bridge arm power transistors may share a common power connection to the positive power input, while the front thermal relay 44 corresponding to the lower bridge arm power transistors may be connected to the A-phase output, B-phase output, and C-phase output, respectively. Similarly to the rear thermal relay 43, in this application, all upper bridge arm power transistors may share a common power connection to the same front thermal relay 44; that is, the number of front thermal relays 44 may be at least four.

[0147] Furthermore, in some embodiments, the back thermal relay 43 can also form a stable thermal connection with the back of the metal backplate 31 of the power transistor 30 through a second fixing device, while the front thermal relay 44 can form a stable thermal connection with the front of the metal backplate 31 of the power transistor 30 through a second fixing device or a third fixing device. The first pressing structure 112 abuts against the front thermal relay 44 to make the back thermal relay 43 form a stable insulating thermal connection with the second housing 112.

[0148] Specifically, the second and third fixing devices can be fastening elements such as screws and bolts. In this case, the front thermal relay 44, the metal back plate 31, and the back thermal relay 43 can be directly fixed together by the same screw or bolt (i.e., the second fixing device). Alternatively, the back thermal relay 43 can be connected to the metal back plate 31 by one screw or bolt (i.e., the second fixing device), and the front thermal relay 44 and the metal back plate 31 can be connected by another screw or bolt (i.e., the third fixing device). After the three are connected together, the first pressing structure 112 abutting against the front thermal relay 44 can apply pressure to the three as a whole, thereby making the back thermal relay 43 and the second housing 12 form a stable insulating thermal connection.

[0149] Example 6

[0150] Please see Figure 3 , Figure 5 and Figure 20 In some embodiments, the thermal relay 40 includes a heat-absorbing portion 41 and an extension portion 42 extending from the heat-absorbing portion 41, the heat-absorbing portion 41 being thermally connected to the metal backplate 31 of the power transistor 30. For example... Figure 5 and Figure 20 As shown, the first housing 11 may also include a second pressing structure 116. When the first housing 11 and the second housing 12 are assembled as one unit, the second pressing structure 116 abuts against the signal pin sealing gasket 70, so that the extension 42 forms a solid insulating thermal connection with the second housing 12, and the signal pin 21 is partially led out of the electric vehicle control device 100 in a sealed manner.

[0151] Thus, by forming a second pressing structure 116 on the first housing 11 to hold the signal pin sealing gasket 70, the signal pin 21 can be sealed. At the same time, by holding the signal pin sealing gasket 70 with the second pressing structure 116, the extension 42 of the thermal repeater 40 can form a solid insulating thermal connection with the second housing 12.

[0152] Specifically, such as Figure 3 and Figure 5As shown, a signal pin 21 is provided on the circuit board 20, and a signal pin sealing gasket 70 passes through the signal pin 21. The signal pin sealing gasket 70 is used to seal the signal pin 21, so that the signal pin 21 can be partially led out of the electric vehicle control device 100 in a sealed manner. Figure 5 As shown, when assembling the first housing 11 and the second housing 12, the second pressing structure 116 abuts against the pin header sealing gasket 70, thereby applying pressure to the thermal relay 40 through the circuit board 20 and the power transistor 30, so that the extension 42 of the thermal relay 40 forms a solid insulating thermal connection with the second housing 12.

[0153] Further, please refer to Figure 5 and Figure 20 In the illustrated embodiment, the second pressing structure 116 can be a second abutment provided on the first housing 11. When the first housing 11 and the second housing 12 are tightly closed together by the snap-fit ​​protrusion 122 and the snap-fit ​​part 111, the second abutment on the first housing 11 can abut against the signal pin sealing gasket 70 to seal the signal pin 21. At the same time, the signal pin sealing gasket 70 exerts pressure on the circuit board 20. After being subjected to force, the circuit board 20 will exert pressure on the thermal relay 40 through the metal backplate 31 of the power tube 30, thereby making the extension 42 tightly abut against the insulating part 50 on the second housing 12 to form a stable insulating thermal connection.

[0154] Additionally, it is understood that in some embodiments, the second pressing structure 116 may also use a pressure strip or elastic element to support the signal pin sealing gasket 70, thereby forming a stable thermal connection between the extension 42 and the second housing 12. The specific configuration is not limited here.

[0155] Example 6

[0156] Please see Figure 3 , Figures 7 to 9 as well as Figure 13 and Figure 18 In some embodiments, the extension 42 is connected to a terminal 80, and the first housing 11 further includes a third pressing structure 117. The third pressing structure 117 generates pressure on the terminal 80 and the terminal sealing gasket 90 when the first housing 11 and the second housing 12 are assembled together, so that the extension 42 and the second housing 12 form a solid insulating thermal connection, and the terminal 80 is partially led out of the electric vehicle control device 100 in a sealed manner.

[0157] Thus, by forming a third pressing structure 117 on the first housing 11 to hold the terminal sealing gasket 90, the terminal 80 can be sealed. At the same time, by holding the terminal 80 and the terminal sealing gasket 90 together with the third pressing structure 117, the extension 42 of the thermal relay 40 can form a solid insulating thermal connection with the second housing 12.

[0158] Specifically, such as Figures 7 to 9 as well as Figure 13 and Figure 18 As shown, terminal 80 may include a positive power input terminal 81 and a three-phase motor output terminal 82. In this article, the connection between the extension 42 of the rear thermal relay 43 and terminal 80 is used as an example for illustration.

[0159] The three-phase output terminal 82 of the motor may include an A-phase output terminal 821, a B-phase output terminal 822, and a C-phase output terminal 823. The positive power input terminal 81 is electrically connected to the extension 42 of the upper arm thermal relay in the rear thermal relay 43, thereby being electrically connected to each upper arm power transistor 30 of the electric vehicle control device 100.

[0160] Phase A output terminal 821 is electrically connected to the extension 42 of the lower bridge arm thermal relay corresponding to the lower bridge arm power transistor 302 of phase A, thus being electrically connected to the lower bridge arm power transistor 302 of phase A. Phase B output terminal 822 is electrically connected to the extension 42 of the lower bridge arm thermal relay corresponding to the lower bridge arm power transistor 304 of phase B, thus being electrically connected to the lower bridge arm power transistor 304 of phase B. Phase C output terminal 823 is electrically connected to the extension 42 of the lower bridge arm thermal relay corresponding to the lower bridge arm power transistor 306 of phase C, thus being electrically connected to the lower bridge arm power transistor 306 of phase C. Phase A output terminal 821, phase B output terminal 822 and phase C output terminal 823 can be arranged in parallel at intervals on the same side of the electric vehicle control device 100.

[0161] For example, in the illustrated embodiment, the extension 42 of the upper bridge arm thermal relay can be bent and extended toward one side of the circuit board 20 relative to the heat absorption part 41, while the extension 42 of each lower bridge arm thermal relay can be bent and extended toward the other side of the circuit board 20 relative to the heat absorption part 41, so that the power positive input terminal 81 and the motor three-phase output terminal 82 can be located in two different directions of the circuit board 20 to facilitate wiring by the user.

[0162] In addition, in some embodiments, the electric vehicle control device 100 also includes a negative power input terminal 83, which is arranged side by side with the positive power input terminal 81. The bottom of the negative power input terminal 83 is connected to a negative terminal connector 84. A negative copper foil is formed on the circuit board 20. One end of the negative terminal connector 84 is provided with the negative power input terminal 83, and the other end is soldered to the negative copper foil on the circuit board 20 or connected together by screws or fasteners to achieve electrical connection.

[0163] Furthermore, the terminal sealing gasket 90 can be made of rubber material, such as... Figure 13 and Figure 21 As shown, the terminal sealing gasket 90 may include a power input terminal sealing gasket 91 and a three-phase output terminal sealing gasket 92.

[0164] A first through hole 911 and a second through hole 912 may be formed on the power input terminal sealing gasket 91. The positive power input terminal 81 passes through the first through hole 911, and the negative power input terminal 83 passes through the second through hole 912. Both the positive power input terminal 81 and the negative power input terminal 83 have stepped surfaces, and the power input terminal sealing gasket 92 is supported on the stepped surfaces.

[0165] The three-phase output terminal sealing gasket 92 has a third through hole 921, a fourth through hole 922 and a fifth through hole 923. The A-phase output terminal 821 passes through the third through hole 921, the B-phase output terminal 822 passes through the fourth through hole 922 and the C-phase output terminal 823 passes through the fifth through hole 923. The three output terminals A-phase output terminal 821, B-phase output terminal 822 and C-phase output terminal 823 also have stepped surfaces, and the three-phase output terminal sealing gasket 92 is supported on the stepped surfaces.

[0166] like Figure 18 As shown, the third pressing structure 117 can be a third abutment provided on the first housing 11. When the first housing 11 and the second housing 12 are fastened together by the snap-fit ​​protrusion 122 and the snap-fit ​​part 111, the third abutment on the first housing 11 can abut against the power input terminal sealing gasket 91 and the three-phase output terminal sealing gasket 92, thereby applying pressure to the corresponding terminals through these two sealing gaskets, and further applying pressure to the extension 42 of the thermal relay 40 connected to each terminal so that the extension 42 forms a stable insulating thermal connection with the second housing 12.

[0167] Additionally, it is understood that in some embodiments, the third pressing structure 117 may also use a pressure strip or elastic element to support the terminal sealing gasket 90, thereby forming a stable insulating thermal connection between the extension 42 and the second housing 12. The specific configuration is not limited here.

[0168] Example 7

[0169] Please see Figure 5 , Figure 13 as well as Figure 17 and Figure 18 In some embodiments, the first housing 11 may further include a fourth pressing structure 118. The fourth pressing structure 118 generates pressure on the housing gasket 110 when the first housing 11 and the second housing 12 are assembled together.

[0170] Thus, the housing gasket 110 seals the gap between the first housing 11 and the second housing 12 when they are fitted together, thereby improving waterproof and moisture-proof performance.

[0171] Specifically, please refer to Figure 21 In some embodiments, the housing gasket 110 may be integrally formed with the buffer 60, signal pin gasket 70 and terminal gasket 90 described above. For example, these gaskets may all be made of rubber and may be integrally formed by the same mold to improve processing efficiency and assembly efficiency.

[0172] Example 8

[0173] Please see Figure 2 , Figure 4 , Figure 5 as well as Figure 19 and Figure 20 In some embodiments, the first housing 11 may also be provided with wire slots 115, and the number of wire slots 115 is multiple. The multiple wire slots 115 are configured with two different external wiring directions, one of which is for external power input and the other is for three-phase motor output.

[0174] Thus, by providing multiple wire grooves 115 on the first housing 11 to form different external wiring directions, the external power input and the three-phase output of the motor can be located in different directions of the electric vehicle control device 100, thereby facilitating wiring by the user.

[0175] Specifically, in the illustrated embodiment, there are five wire slots 115, namely positive terminal slot 1151, negative terminal slot 1152, A-phase slot 1161, B-phase slot 1162 and C-phase slot 1163.

[0176] Positive terminal wiring slot 1151 and negative terminal wiring slot 1152 are arranged side by side on one side of the electric vehicle control device 100. A-phase wiring slot 1161, B-phase wiring slot 1162 and C-phase wiring slot 1163 are arranged side by side on the other side of the electric vehicle control device. The top of each wiring slot is open and a wire slot is formed on the side wall. The wire slots of positive terminal wiring slot 1151 and negative terminal wiring slot 1152 are opened in the same direction, while the wire slots of A-phase wiring slot 1161, B-phase wiring slot 1162 and C-phase wiring slot 1163 are opened in opposite directions to achieve appearance on both sides.

[0177] The positive input terminal 81 of the power supply can pass through the bottom of the positive terminal wiring slot 1151 and extend into the positive terminal wiring slot 1151, while the negative input terminal 83 of the power supply passes through the bottom of the negative terminal wiring slot 1152 and extends into the negative terminal wiring slot 1152.

[0178] Phase A output terminal 821 can pass through and extend into Phase A wiring slot 1161, Phase B output terminal 822 can pass through and extend into Phase B wiring slot 1162, and Phase C output terminal 823 can pass through and extend into Phase C wiring slot 1163.

[0179] The third pressing structure 117 can be formed at the bottom of each wire groove 115, such as Figure 18 As shown, when the first housing 11 and the second housing 12 are stacked together, each terminal extends into the corresponding terminal groove after passing through the terminal sealing gasket 90. The third pressing structure 117 at the bottom of the terminal groove abuts against the terminal sealing gasket 90 and each terminal, thereby applying pressure to the extension 42 of each thermal relay 40 so that the heat transfer surface 421 of the extension 42 forms a solid insulating thermal connection with the second housing 12.

[0180] Example 9

[0181] In the embodiments of this application, each thermal relay 40 may be made of a material with a thermal conductivity greater than 50 W / m·K. For example, the thermal relay 40 may be made of at least one of the metal materials with good thermal conductivity, such as copper, aluminum, and copper-aluminum composites (e.g., copper-aluminum alloys), and it is preferably made of aluminum.

[0182] In some embodiments, the heat-absorbing portion 41 may be integrally formed with the extension portion 42.

[0183] Thus, the integral molding of the heat-absorbing part 41 and the extension part 42 simplifies the manufacturing process of the metal connectors, eliminating the need to manufacture the two parts separately and then connect them, thereby simplifying the manufacturing process. Furthermore, the integral molding eliminates the need for subsequent installation of the extension part 42, saving labor costs and improving production efficiency.

[0184] Specifically, in such an embodiment, the heat-absorbing portion 41 and the extension portion 42 can preferably be manufactured together using a casting process, which enables the extension portion 42 and the heat-absorbing portion 41 to be manufactured together using a casting process. Figure 7 The projection areas formed by the orthographic projections in directions A and B are at least partially non-overlapping. In this way, the extension 42 can be bent relative to the heat-absorbing part 41 to increase the extension length of the extension 42 within the effective space of the housing 10, thereby increasing the heat dissipation area.

[0185] In a preferred embodiment, the metal connector is preferably made of aluminum casting, but this is not a limitation. Furthermore, it is understood that in some embodiments, the metal connector may also be partially or entirely manufactured using a casting process, without limitation, as long as it can smoothly form the heat-absorbing portion 41 and the extension portion 42.

[0186] Example 10

[0187] In some embodiments, the terminal 80 may be integrally formed with the extension 42.

[0188] In this way, the terminal 80 and the extension 42 are integrally formed, eliminating the need to manufacture the two components separately before connecting them, thus saving costs. At the same time, the integral forming eliminates the need for subsequent installation of the terminal 80, saving labor installation costs and improving production efficiency.

[0189] Specifically, in such an embodiment, the heat-absorbing part 41, the extension part 42 and the terminal 80 can be die-cast into one piece by die-casting process. This can effectively improve production efficiency and eliminate the need to install a separate terminal 80 on the extension part 42, reducing the investment in the terminal 80 and the manual assembly steps, thus effectively reducing production costs.

[0190] More specifically, taking the connection of each terminal 80 to the rear thermal relay 43 as an example, the positive power input terminal 81 can be integrally formed with the extension 42 of the upper bridge arm thermal relay of the rear thermal relay 43, and the A-phase output terminal 821, the B-phase output terminal 822 and the C-phase output terminal 823 can be integrally formed with the extension 42 of the lower bridge arm thermal relay of the corresponding rear thermal relay 43, respectively.

[0191] Of course, it is understood that in other embodiments, the terminal 80 and the extension 42 can also be detachably connected. For example, they can be plugged together by a plug-in structure to achieve electrical connection, or the terminal 80 can be snapped onto the extension 42 by a snap-fit ​​structure, or the terminal 80 can be detachably fixed onto the extension 42 by fastening elements such as screws or bolts. In particular, the connection method between the terminal 80 and the extension 42 is not specifically limited here, and it can be selected according to actual needs.

[0192] Example 11

[0193] Please refer to the following: Figure 3 , Figure 22 and Figure 23 In some embodiments, the electric vehicle controller 100 may further include a positioning structure, which can be used to position and assemble the heat-absorbing part 41 of each rear thermal relay 43 with the metal back plate 31 of the corresponding power tube 30, and / or to position and assemble the rear thermal relay 43 with the second housing 12.

[0194] Thus, the positioning structure can limit the relative positions of each rear thermal relay 43, the metal back plate 31 of the power tube 30, and the second housing 12, thereby ensuring the stability of the conductive thermal connection between each heat-absorbing part 41 and the metal back plate 31, as well as the installation stability of each rear thermal relay 43 and the second housing, thereby improving the reliability of the electric vehicle controller 100.

[0195] It is understandable that in this document, "the positioning structure can be used to position and assemble the heat-absorbing part 41 of each back heat relay 43 with the metal back plate 31 of the corresponding power tube 30, and / or to position and assemble the back heat relay 43 with the second housing 12" can be understood as the positioning structure can position and limit the heat-absorbing part 41 of each back heat relay 43 to ensure that the heat-absorbing part 41 can maintain a stable conductive thermal connection with the metal back plate 31 of the corresponding power tube 30 and / or ensure the stability of the relative position between each back heat relay 43 and the second housing 12, thereby avoiding the positional displacement of each back heat relay 43, which would cause the heat-absorbing part 41 to fail to achieve a stable conductive thermal connection with the back of the metal back plate 31.

[0196] Specifically, in the embodiments of this application, the positioning structure can be disposed inside the second housing 12. The positioning structure can be an insulating bracket 71, which can be made of insulating and heat-resistant materials such as plastic.

[0197] like Figure 22 and Figure 23 As shown, multiple limiting grooves 711 can be formed on the insulating bracket 71. Each back heat relay 43 can be disposed in each limiting groove 711 on the insulating bracket 71. The limiting grooves 711 can contact the outer edge contour of each back heat relay 43 respectively, thereby positioning and limiting each back heat relay 43.

[0198] In other words, in the embodiments of this application, the presence of the positioning structure can position and limit each back heat relay 43. During installation, after each back heat relay 43 is installed, the circuit board 20 with the power tube 30 can be directly covered on the positioning structure to achieve the conductive thermal connection between each heat absorption part 41 and the metal back plate 31 of each power tube 30.

[0199] Furthermore, the outer contour of the insulating bracket 71 can correspond to the inner contour of the second housing 12 so that the insulating bracket 71 can be installed in the second housing 12 in a perfectly fitting manner.

[0200] Please see Figures 22 to 24In some embodiments, a first positioning protrusion 712 may be formed on the insulating bracket 71, and a first positioning hole 123 may be formed at the bottom of the second housing 12. The first positioning protrusion 712 and the first positioning hole 123 cooperate to position the insulating bracket 71 on the second housing 12.

[0201] In this way, the position of the insulating bracket 71 is fixed, and the positions of each back heat relay 43 are also relatively fixed. During the assembly process, the insulating bracket 71 only needs to be positioned and installed on the second housing 12 through the first positioning protrusion 712 and the first positioning hole 123. Then, each back heat relay 43 is placed in the corresponding limiting groove 711. Subsequently, the circuit board 20 with the power tube 30 is placed on the second housing 12 so that the metal back plate 31 can contact the corresponding heat-absorbing part 41 to achieve conductive thermal connection.

[0202] Of course, it is understood that in some embodiments, the first positioning hole may be formed on the insulating bracket 71 and the first positioning protrusion may be formed on the second housing 12, or the first positioning hole and the first positioning protrusion may be formed on the insulating bracket 71 and the first positioning protrusion and the first positioning hole may also be formed on the second housing 12, with the positioning holes and positioning protrusions on both corresponding one-to-one. No specific limitations are imposed here.

[0203] Furthermore, please refer to Figure 22 and Figure 23 In some embodiments, a second positioning protrusion 713 may be formed on the insulating bracket 71, and a second positioning hole 22 may be formed on the circuit board 20. The second positioning hole 22 and the second positioning protrusion 713 cooperate to position and install the circuit board 20 on the insulating bracket 71, so that the metal back plate 31 of each power tube 30 on the circuit board 20 corresponds to the heat absorption part 41 of the corresponding back heat relay 43 to achieve conductive thermal connection.

[0204] In this case, during assembly, the insulating bracket 71 can first be installed in the second housing 12 through the first positioning protrusion 712 and the first positioning hole 123. Then, each back heat relay 43 is placed in the limiting groove 711 on the corresponding insulating bracket 71 and in contact with the insulating component 50. Subsequently, the circuit board 20 with the power tube 30 can be installed on the insulating bracket 71 through the second positioning protrusion 713 and the second positioning hole 22 to directly realize the alignment and conductive thermal connection between the heat-absorbing part 41 of each back heat relay 43 and the metal back plate 31 of the corresponding power tube 30, resulting in high assembly efficiency.

[0205] Of course, it is understood that in some embodiments, a second positioning protrusion may be formed on the circuit board 20 and a second positioning hole may be formed on the insulating bracket 71, or a second positioning hole and a second positioning protrusion may be formed on the insulating bracket 71 and a second positioning protrusion and a second positioning hole may also be formed on the circuit board 20, with the positioning holes and positioning protrusions on both corresponding one-to-one. No specific limitations are imposed here.

[0206] Furthermore, it is understood that in some embodiments, the positioning structure is not limited to the insulating bracket 71 shown in the figure. It may also include positioning posts, positioning grooves, positioning buckles, etc., provided on the second housing 12. No specific limitations are made here, as long as it can position and limit each back heat relay 43 so that it can maintain a stable conductive and thermal connection with the metal back plate 31.

[0207] For example, in some embodiments, multiple insulating posts can be formed on the second housing 12, and positioning holes corresponding to the insulating posts can be formed on each back thermal relay 43. When installing each back thermal relay 43, the positioning and limiting of each back thermal relay 43 can be achieved by the cooperation of the insulating posts and the positioning holes.

[0208] For example, in some embodiments, the metal substrate (aluminum substrate) described above can also be used to achieve insulating thermal connection, while the copper foil layer on the metal substrate can be used to position each back thermal relay 43.

[0209] In the description of this specification, references to terms such as "some embodiments," "illustrative embodiments," "examples," "specific examples," or "other embodiments," etc., indicate that a specific feature, structure, material, or characteristic described in connection with the described embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0210] Furthermore, the above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. An electric vehicle control device characterized by comprising: The electric vehicle control device comprises: a first shell; a second shell assembled with the first shell; a circuit board arranged between the first shell and the second shell, and a plurality of power tubes are welded on the circuit board; and a heat relay body, which is in thermal connection with a metal back plate of the power tube, and the heat relay body comprises a heat absorbing part and an extension part extending from the heat absorbing part, the heat absorbing part is in electrically conductive and thermal connection with the metal back plate of the power tube, and a wiring terminal is connected to the extension part, the wiring terminal is in electrically conductive connection with the power tube through the extension part and the heat absorbing part; the first shell is provided with a first pressing structure; when the first shell and the second shell are assembled into one, the first pressing structure abuts against the power tube and / or the heat relay body to generate pressure, so that the heat absorbing part abuts against the metal back plate of the power tube, and the heat relay body forms a stable insulating thermal connection with the second shell.

2. The electric vehicle control device according to claim 1, characterized by when the first shell and the second shell are assembled into one, the first pressing structure abuts against the power tube to make the metal back plate form a stable thermal connection with the heat relay body.

3. The electric vehicle control device according to claim 1, characterized by the metal back plate of the power tube forms a stable thermal connection with the heat relay body through a first fixing device.

4. The electric vehicle control device according to claim 1, characterized by The electric vehicle control device further comprises a buffer, and the first pressing structure abuts against the buffer to apply pressure to the power tube, so that the heat relay body forms a stable insulating thermal connection with the second shell.

5. The electric vehicle control device according to claim 4, characterized by The buffer is an insulating piece.

6. The electric vehicle control device according to claim 1, characterized by The heat relay body comprises: a back heat relay body, which is in thermal connection with a back of the metal back plate of the power tube and forms an insulating thermal connection with the second shell; a front heat relay body, which is in thermal connection with a front of the metal back plate of the power tube and forms an insulating thermal connection with the first shell; the first pressing structure abuts against the front heat relay body to make the front heat relay body form a stable thermal connection with the front of the metal back plate of the power tube, the back of the metal back plate of the power tube form a stable thermal connection with the back heat relay body, and the back heat relay body forms a stable insulating thermal connection with the second shell.

7. The electric vehicle control device according to claim 1, characterized by The heat relay body comprises: a back heat relay body, which is in thermal connection with a back of the metal back plate of the power tube and forms an insulating thermal connection with the second shell; a front heat relay body, which is in thermal connection with a front of the metal back plate of the power tube and forms an insulating thermal connection with the first shell; the back of the metal back plate of the power tube forms a stable thermal connection with the back heat relay body through a second fixing device; the front of the metal back plate of the power tube forms a stable thermal connection with the front heat relay body through the second fixing device or a third fixing device; the first pressing structure abuts against the front heat relay body to make the back heat relay body form a stable insulating thermal connection with the second shell.

8. The electric vehicle control device according to claim 1, wherein the first shell further comprises a second pressing structure; The second pressing structure abuts against the signal pin gasket when the first shell and the second shell are assembled into one, so that the extension part forms a stable insulating thermal connection with the second shell, and the signal pin part is sealedly led out of the electric vehicle control device.

9. The electric vehicle control device according to claim 1, characterized by The extension part is connected with a terminal; The first shell further comprises a third pressing structure; The third pressing structure exerts pressure on the terminal and the terminal gasket when the first shell and the second shell are assembled into one, so that the extension part forms a stable insulating thermal connection with the second shell, and the terminal part is sealedly led out of the electric vehicle control device.

10. The electric vehicle control device of claim 1, wherein The first shell further comprises a fourth pressing structure; The fourth pressing structure exerts pressure on the shell gasket when the first shell and the second shell are assembled into one.

11. The electric vehicle control apparatus according to claim 1, characterized by The first shell is provided with a plurality of wire grooves; The plurality of wire grooves are configured in two different external wiring directions, one of which is external power input, and the other of which is motor three-phase output.

12. An electric vehicle, characterized by The electric vehicle comprises the electric vehicle control device of any one of claims 1-11, and is configured with a three-phase motor, the three-phase line interface of the three-phase motor being electrically connected to the three-phase output of the electric vehicle control device.

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