A copper bar structure for reducing stray inductance

Abstract

This invention provides a copper busbar structure for reducing stray inductance. The copper busbar is designed as a stacked, avoidance-avoidance structure, reducing stray inductance without requiring significant changes to the controller structure. It includes: a controller housing; a capacitor; two sets of IGBT elements, specifically a first IGBT element and a second IGBT element; a negative terminal connecting copper busbar, including two sets of negative terminal connecting holes, a capacitor negative terminal connecting hole, and a positive terminal avoidance notch; a positive terminal connecting copper busbar, including two sets of positive terminal connecting holes and a capacitor positive terminal connecting hole; insulating paper; and an insulating block.

Description

Technical Field

[0001] This invention relates to the technical field of coil slitting, specifically to a copper busbar structure for reducing stray inductance. Background Technology

[0002] Most existing motor controllers use a connection method where capacitors extend directly from the copper busbar and connect to the copper busbar of the IGBT. This design has two advantages: firstly, it reduces the amount of copper busbar used, lowering costs; and secondly, it reduces stray inductance. Stray inductance refers to the equivalent inductance exhibited by conductors in the circuit, such as connecting wires, component leads, and the component itself. It is caused by magnets that link with the current loop. Stray inductance can generate high voltage spikes between the collector and emitter of the IGBT, resulting in significant electromagnetic interference and even damage to the Insulated Gate Bipolar Transistor (IGBT). The more copper busbars used, the easier it is to generate high nH stray inductance.

[0003] Due to space requirements of some controllers or other design limitations, the capacitor busbar cannot directly reach the IGBT plate. An adapter busbar needs to be designed to connect them in the middle. Therefore, a reasonable structure is needed to reduce stray inductance. Summary of the Invention

[0004] To address the aforementioned problems, this invention provides a copper busbar structure for reducing stray inductance. The copper busbar is designed as a stacked, avoidance structure, which reduces stray inductance without requiring large-scale changes to the controller structure.

[0005] A copper busbar structure for reducing stray inductance, characterized in that it comprises:

[0006] Controller housing;

[0007] capacitance;

[0008] Two sets of IGBT elements, specifically a first IGBT element and a second IGBT element;

[0009] The negative electrode connection copper busbar includes two sets of negative electrode connection holes, capacitor negative electrode connection holes, and a positive electrode clearance notch;

[0010] The positive terminal connection copper busbar includes two sets of positive terminal connection holes and capacitor positive terminal connection holes;

[0011] Insulating paper;

[0012] And insulating blocks;

[0013] The transmission housing contains a capacitor and two sets of IGBT elements. The two sets of IGBT elements are identical, with a convex positive terminal and a negative terminal in the center of their long sides. The first positive terminal of the first IGBT element and the second positive terminal of the second IGBT element are staggered towards each other, as are the first negative terminal of the first IGBT element and the second negative terminal of the second IGBT element. The capacitor is located above or below the two IGBT elements arranged side by side, and there is a gap between the two sets of IGBT elements. The corresponding first positive terminal, second positive terminal, first negative terminal, and second negative terminal are all exposed within the gap. The positive and negative terminals of the capacitor are protruding towards the gap.

[0014] The negative terminal connecting copper busbar, insulating paper, and positive terminal connecting copper busbar are stacked from bottom to top. The insulating paper is used to insulate and isolate the negative terminal connecting copper busbar and the positive terminal connecting copper busbar. The insulating block covers the area directly above the positive terminal connecting copper busbar corresponding to the two sets of negative terminal connecting terminals and is provided with corresponding through connection holes. Fixing bolts connect the negative terminal connecting copper busbar to the negative terminals of the two IGBT elements, and other fixing bolts connect the positive terminal connecting copper busbar to the positive terminals of the two IGBT elements. The other end of the negative terminal connecting copper busbar is connected to the negative terminal of the capacitor, and the other end of the positive terminal connecting copper busbar is connected to the positive terminal of the capacitor.

[0015] Its further features are:

[0016] The negative electrode connection copper busbar is provided with a first negative electrode connection hole, a second negative electrode connection hole, a third negative electrode connection hole, a first clearance notch, a second clearance notch, and a third clearance notch;

[0017] The positive electrode connecting copper busbar is provided with a first positive electrode connecting hole, a second positive electrode connecting hole, a third positive electrode connecting hole, a first negative electrode through hole, a second negative electrode through hole, and a third negative electrode avoidance notch;

[0018] The first negative electrode connection hole is arranged in relation to the first negative electrode through hole, the second negative electrode connection hole is arranged in relation to the second negative electrode through hole, the first positive electrode connection hole is located directly below the first clearance notch, the second positive electrode connection hole is located directly below the second clearance notch, and the third positive electrode connection hole is located directly below the third clearance notch.

[0019] An insulating block covers the area directly above the first negative terminal connection hole and the second connection hole, and has a corresponding through connection hole. The insulating block is installed on the upper area of ​​the positive terminal connection copper busbar corresponding to the first negative terminal and the second negative terminal. After the fixing bolt passes through the corresponding through connection hole and the negative terminal through hole, it is attached to and passes through the corresponding negative terminal connection hole, and then the corresponding negative terminal of the IGBT element is fastened. The diameter of the negative terminal through hole is larger than the diameter of the fixing bolt, and it does not contact the fixing bolt.

[0020] The fixing bolt passes through the first positive terminal connection hole and the second positive terminal connection hole, then through the insulating paper below and the clearance area of ​​the negative terminal connection copper busbar, and is then fixed to the corresponding positive terminal of the corresponding IGBT element.

[0021] The fixing bolt connects the third negative terminal connection hole to the negative terminal of the capacitor;

[0022] The fixing bolt connects the third positive terminal connection hole to the positive terminal of the capacitor.

[0023] Its further characteristic is:

[0024] The insulating paper is provided with clearance holes or clearance notches at the positions where the fixing bolts pass through, to ensure the reliable passage of the fixing bolts and to ensure the insulation isolation between the negative and positive copper busbars.

[0025] When the convex electrode terminal of the capacitor and the copper busbar are not on the same plane, a first protrusion is provided on the third negative electrode connection hole of the negative electrode connection copper busbar. The protrusion fills the height difference between the negative electrode of the capacitor and the surface of the copper busbar. A second protrusion is provided on the third positive electrode connection hole of the positive electrode connection copper busbar. The second protrusion fills the height difference between the positive electrode of the capacitor and the surface of the copper busbar.

[0026] By adopting the above technical solution, the controller length can be shortened while meeting the requirements of dual IGBT integrated design. The two sets of copper busbars are simple to design and easy to install. The stacked insulating blocks, positive connection copper busbars, insulating paper, and negative connection copper busbars form an integrated busbar structure from top to bottom, which is easy to disassemble. This makes the dual IGBT arrangement more compact, reduces the size of the controller housing, and makes the controller smaller, which can better meet the needs of different motors. The controller cost will also be lower. Furthermore, the water channel part of the controller with such dual IGBT elements can be centrally designed, and the connection path from the capacitor to the IGBT element is short. Due to the thin middle insulating layer and the thin copper busbar, there is no overlapping area in the height direction of the stacked busbars, and the non-stacked path is short. In addition, the conductor width is wide, thereby reducing the stray inductance of the entire circuit and improving the safety of the product. Attached Figure Description

[0027] Figure 1 This is a three-dimensional schematic diagram of the present invention;

[0028] Figure 2 This is a top view showing the arrangement of capacitors and IGBT components without copper busbars in this invention.

[0029] Figure 3 This is a side sectional view of the present invention;

[0030] Figure 4 This is a bottom view of the negative electrode connection copper busbar of the present invention;

[0031] Figure 5 This is a bottom view of the positive electrode connection copper busbar of the present invention;

[0032] Figure 6 for Figure 3 Enlarged view of a portion at point A;

[0033] The names corresponding to the serial numbers in the diagram are as follows:

[0034] Controller housing 10, capacitor 20, capacitor positive terminal 21, capacitor negative terminal 22, negative terminal connecting copper busbar 30, first negative terminal connecting hole 31, second negative terminal connecting hole 32, third negative terminal connecting hole 33, first clearance notch 34, second clearance notch 35, third clearance notch 36, first boss 37, positive terminal connecting copper busbar 40, first positive terminal connecting hole 41, second positive terminal connecting hole 42, third positive terminal connecting hole 43, first negative terminal through hole 44, second negative terminal through hole 45, third negative terminal clearance notch 46, second boss 47, insulating paper 50, insulating block 60, through connecting hole 61, fixing bolt 70, first IGBT element 80, first positive terminal 81, first negative terminal 82, second IGBT element 90, second positive terminal 91, second negative terminal 92. Detailed Implementation

[0035] A copper busbar structure for reducing stray inductance, see Figures 1-6 It includes a controller housing 10, a capacitor 20, two sets of IGBT elements, a negative terminal connecting copper busbar 30, a positive terminal connecting copper busbar 40, insulating paper 50, an insulating block 60, and six fixing bolts 70.

[0036] The two sets of IGBT elements are specifically the first IGBT element 80 and the second IGBT element 90;

[0037] The negative electrode connecting copper busbar 30 is provided with a first negative electrode connecting hole 31, a second negative electrode connecting hole 32, a third negative electrode connecting hole 33, a first clearance notch 34, a second clearance notch 35, and a third clearance notch 36;

[0038] The positive electrode connecting copper busbar 40 is provided with a first positive electrode connecting hole 41, a second positive electrode connecting hole 42, a third positive electrode connecting hole 43, a first negative electrode through hole 44, a second negative electrode through hole 45, and a third negative electrode clearance notch 46;

[0039] The first negative electrode connection hole 31 is arranged corresponding to the first negative electrode through hole 44, the second negative electrode connection hole 32 is arranged corresponding to the second negative electrode through hole 45, the first positive electrode connection hole 41 is arranged directly below the first clearance notch 34, the second positive electrode connection hole 42 is arranged directly below the second clearance notch 35, and the third positive electrode connection hole 43 is arranged directly below the third clearance notch 36.

[0040] A capacitor 20, a first IGBT element 80, and a second IGBT element 90 are fixedly installed inside the transmission housing 10. The first IGBT element 80 and the second IGBT element 90 are identical elements, and their long sides have convex positive and negative terminals in the center area. The first positive terminal 81 of the first IGBT element 80 and the second positive terminal 91 of the second IGBT element 90 are staggered towards each other, and the first negative terminal 82 of the first IGBT element 80 and the second negative terminal 92 of the second IGBT element 90 are also staggered towards each other. The capacitor 20 is located above or below the two IGBT elements arranged side by side, and there is a gap between the two sets of IGBT elements. The corresponding first positive terminal 81, second positive terminal 91, first negative terminal 82, and second negative terminal 92 are all exposed within the gap. The capacitor positive terminal 21 and capacitor negative terminal 22 are protruding towards the gap.

[0041] The insulating block 60 covers the area directly above the first negative terminal connection hole 31 and the second negative terminal connection hole 32, and is provided with a corresponding through connection hole 61. The insulating block 60 is installed on the upper area of ​​the positive terminal connection copper busbar 40 corresponding to the first negative terminal 82 and the second negative terminal 92. After the fixing bolt 70 passes through the corresponding through connection hole and negative through hole, it is attached to and passes through the corresponding negative terminal connection hole, and then it is tightened to the corresponding negative terminal of the IGBT element. The diameter of the first negative through hole 44 and the second negative through hole 45 is larger than the diameter of the fixing bolt 70, and they do not contact the fixing bolt 70.

[0042] The fixing bolt 70 passes through the first positive terminal connection hole 41 and the second positive terminal connection hole 42, then passes through the insulating paper 50 below and the clearance area of ​​the negative terminal connection copper busbar 30, and is then fixed to the corresponding positive terminal of the corresponding IGBT element.

[0043] The fixing bolt 70 connects the third negative terminal connection hole 33 and the capacitor negative terminal 22;

[0044] The fixing bolt 70 connects the third positive terminal connection hole 43 and the positive terminal 21 of the capacitor.

[0045] In practice, the insulating paper 50 is provided with clearance holes or clearance notches at the positions where the fixing bolt 70 passes through, to ensure the reliable passage of the fixing bolt 70 and to ensure the insulation isolation between the negative terminal connecting copper busbar 30 and the positive terminal connecting copper busbar 40.

[0046] In specific implementation, when the protruding electrode terminal of capacitor 10 is lower than the copper busbar, a first protrusion 37 is provided on the lower surface of the third negative electrode connection hole 33 of the negative electrode connection copper busbar 30. The first protrusion 37 fills the height difference between the negative electrode terminal 21 of the capacitor and the surface of the negative electrode connection copper busbar 30. A second protrusion 47 is provided on the lower surface of the third positive electrode connection hole 43 of the positive electrode connection copper busbar 40. The second protrusion 47 fills the height difference between the positive electrode terminal 22 of the capacitor and the surface of the positive electrode connection copper busbar 40. A third protrusion 48 is provided on the lower surface of the first positive electrode connection hole 41 and the second positive electrode connection hole 42 of the positive electrode connection copper busbar 40. The third protrusion 48 fills the height difference between the positive electrode connection copper busbar 40 and the corresponding first positive electrode terminal 81 and second positive electrode terminal 91.

[0047] Its working principle is as follows: while meeting the requirements of dual IGBT integrated design, the controller length can be made shorter. The two sets of copper busbars are simple to design and easy to install. The insulating block, positive terminal connecting copper busbar, insulating paper, and negative terminal connecting copper busbar stacked from top to bottom form an integral busbar structure. As a whole, it is easy to disassemble, which makes the dual IGBT arrangement more compact, reduces the size of the controller housing, and makes the controller smaller to meet the needs of different motors. The controller cost will also be lower. In addition, the water channel part of the controller with such dual IGBT elements can be centrally designed, and the connection path from the capacitor to the IGBT element is short. Furthermore, due to the thin middle insulating layer and thin copper busbar, there is no remaining overlapping area in the height direction of the stacked busbar, and the non-stacked path is short. In addition, the conductor width is wide, thereby reducing the stray inductance of the entire circuit and improving the safety of the product.

[0048] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0049] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A copper busbar structure for reducing stray inductance, characterized in that, It includes: Controller housing; capacitance; Two sets of IGBT elements, specifically a first IGBT element and a second IGBT element; The negative electrode connection copper busbar includes two sets of negative electrode connection holes, capacitor negative electrode connection holes, and a positive electrode clearance notch; The positive terminal connection copper busbar includes two sets of positive terminal connection holes and capacitor positive terminal connection holes; Insulating paper; And insulating blocks; The controller housing contains a capacitor and two sets of IGBT elements. The two sets of IGBT elements are identical, with a convex positive terminal and a negative terminal in the center of their long sides. The first positive terminal of the first IGBT element and the second positive terminal of the second IGBT element are staggered towards each other, as are the first negative terminal of the first IGBT element and the second negative terminal of the second IGBT element. The capacitor is located above or below the two IGBT elements arranged side by side, and there is a gap between the two sets of IGBT elements. The corresponding first positive terminal, second positive terminal, first negative terminal, and second negative terminal are all exposed within the gap. The positive and negative terminals of the capacitor are protruding towards the gap. The negative terminal connecting copper busbar, insulating paper, and positive terminal connecting copper busbar are stacked from bottom to top. The insulating paper is used to insulate and isolate the negative terminal connecting copper busbar and the positive terminal connecting copper busbar. The insulating block covers the area directly above the positive terminal connecting copper busbar corresponding to the two sets of negative terminal connecting terminals and is provided with corresponding through connection holes. The fixing bolts connect the negative terminal connecting copper busbar to the negative terminals of the two IGBT elements, and the other fixing bolts connect the positive terminal connecting copper busbar to the positive terminals of the two IGBT elements. The other end of the negative terminal connecting copper busbar is connected to the negative terminal of the capacitor, and the other end of the positive terminal connecting copper busbar is connected to the positive terminal of the capacitor. The negative electrode connection copper busbar is provided with a first negative electrode connection hole, a second negative electrode connection hole, a third negative electrode connection hole, a first clearance notch, a second clearance notch, and a third clearance notch; The positive electrode connecting copper busbar is provided with a first positive electrode connecting hole, a second positive electrode connecting hole, a third positive electrode connecting hole, a first negative electrode through hole, a second negative electrode through hole, and a third negative electrode avoidance notch; The first negative electrode connection hole is arranged in relation to the first negative electrode through hole, the second negative electrode connection hole is arranged in relation to the second negative electrode through hole, the first positive electrode connection hole is located directly below the first clearance notch, the second positive electrode connection hole is located directly below the second clearance notch, and the third positive electrode connection hole is located directly below the third clearance notch. An insulating block covers the area directly above the first negative terminal connection hole and the second connection hole, and has a corresponding through connection hole. The insulating block is installed on the upper area of ​​the positive terminal connection copper busbar corresponding to the first negative terminal and the second negative terminal. After the fixing bolt passes through the corresponding through connection hole and the negative terminal through hole, it is attached to and passes through the corresponding negative terminal connection hole, and then the corresponding negative terminal of the IGBT element is fastened. The diameter of the negative terminal through hole is larger than the diameter of the fixing bolt, and it does not contact the fixing bolt.

2. The copper busbar structure for reducing stray inductance as described in claim 1, characterized in that: The fixing bolt passes through the first positive terminal connection hole and the second positive terminal connection hole, then through the insulating paper below and the clearance area of ​​the negative terminal connection copper busbar, and is then fixed to the corresponding positive terminal of the corresponding IGBT element.

3. The copper busbar structure for reducing stray inductance as described in claim 2, characterized in that: The fixing bolt connects the third negative terminal connection hole to the negative terminal of the capacitor; the fixing bolt connects the third positive terminal connection hole to the positive terminal of the capacitor.

4. The copper busbar structure for reducing stray inductance as described in claim 1, characterized in that: The insulating paper is provided with clearance holes or clearance notches at the positions where the fixing bolts pass through.

5. The copper busbar structure for reducing stray inductance as described in claim 1, characterized in that: When the convex electrode terminal of the capacitor and the copper busbar are not on the same plane, a first protrusion is provided on the third negative electrode connection hole of the negative electrode connection copper busbar. The first protrusion makes up the height difference between the negative electrode of the capacitor and the surface of the copper busbar. A second protrusion is provided on the third positive electrode connection hole of the positive electrode connection copper busbar. The second protrusion makes up the height difference between the positive electrode of the capacitor and the surface of the copper busbar.

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