Power assembly and preparation method thereof, motor controller, electric control assembly and vehicle

Abstract

The invention discloses a power assembly and a preparation method thereof, a motor controller, an electric control assembly and a vehicle, and relates to the field of vehicle motor control equipment, and the power assembly comprises a power module and a capacitor assembly which are stacked; the surface, facing the power module, of the capacitor assembly is connected with a first terminal and a second terminal which are mutually insulated. The first terminal and the second terminal are oppositely arranged in a first direction; the same end part of the power module is connected with a third terminal and a fourth terminal which are insulated from each other; the end part faces the first terminal and the second terminal; the third terminal comprises a first-section terminal connected with the end part, and the fourth terminal comprises a second-section terminal connected with the end part; the first section of terminal and the second section of terminal are parallel to the first direction and are oppositely arranged in the second direction; the second direction is parallel to the stacking direction of the power module and the capacitor assembly, and the first direction is perpendicular to the second direction; the first terminal is connected with the third terminal, and the second terminal is connected with the fourth terminal. The series inductance can be reduced.

Description

Technical Field

[0001] The present application relates to the field of vehicle motor control equipment, and in particular to a power component and a preparation method thereof, a motor controller, an electronic control assembly and a vehicle. Background Art

[0002] With the continuous development of science and technology, more and more vehicles are widely used in people's daily life and work, bringing great convenience to people's daily life and work, and becoming an indispensable tool for people today. Among them, the electronic control assembly is one of the important components in the vehicle. One of the core components of the electronic control assembly is the power component, which includes the capacitor component and the power module.

[0003] In conventional power components, a large series inductance (ESL) exists in the connection structure between the DC terminal of the power module and the DC terminal of the capacitor component, which affects the performance of the power component. Summary of the invention

[0004] In view of the above problems, the present application provides a power component and a preparation method thereof, a motor controller, an electric control assembly and a vehicle, so as to at least achieve the purpose of reducing the series inductance. The specific scheme is as follows:

[0005] A first aspect of the present application provides a power component, including:

[0006] A stacked power module and capacitor assembly;

[0007] A first terminal and a second terminal insulated from each other are connected to a surface of the capacitor assembly facing the power module; the first terminal and the second terminal are arranged opposite to each other in a first direction;

[0008] A third terminal and a fourth terminal insulated from each other are connected to the same end of the power module; the end faces the first terminal and the second terminal; the third terminal includes a first section terminal connected to the end, and the fourth terminal includes a second section terminal connected to the end; the first section terminal and the second section terminal are parallel to the first direction and are arranged opposite to each other in the second direction;

[0009] The second direction is parallel to the stacking direction of the power module and the capacitor assembly, and the first direction is perpendicular to the second direction; the first terminal is connected to the third terminal, and the second terminal is connected to the fourth terminal.

[0010] Optionally, in the above power component, vertical projections of the first terminal and the second terminal on the first plane at least partially overlap; the first plane is perpendicular to the first direction;

[0011] And / or, vertical projections of the third terminal and the fourth terminal on the second plane at least partially overlap; and the second plane is perpendicular to the second direction.

[0012] Optionally, in the above power component, edges of the first terminal and the second terminal located on both sides of the second direction meet a flush condition;

[0013] And / or, edges of the third terminal and the fourth terminal located on both sides of the first direction meet the alignment condition.

[0014] Optionally, in the above power assembly, the misalignment distance between the opposite edges of the first terminal and the second terminal does not exceed 0.2 mm;

[0015] The misalignment distance between opposite edges of the third terminal and the fourth terminal does not exceed 0.2 mm.

[0016] Optionally, in the above power component, the fourth terminal is located between the third terminal and the capacitor component;

[0017] The second terminal is located between the first terminal and the end portion.

[0018] Optionally, in the above power component, the fourth terminal further includes a third section terminal connected to the second section terminal; the third section terminal is parallel to the second direction and extends toward the capacitor component;

[0019] The third section terminal and the second terminal have a first overlapping area in the first direction, and the third section terminal and the second terminal are connected in the first overlapping area.

[0020] Optionally, in the above power component, the third terminal and the first terminal are connected via a transfer terminal.

[0021] Optionally, in the above power component, there is a gap between the third terminal and the first terminal exposing the first overlapping area, and the transfer terminal covers the gap.

[0022] Optionally, in the above power component, the adapter terminal and the first terminal have a second overlapping area in the first direction, and the adapter terminal is connected to the first terminal in the second overlapping area;

[0023] The adapter terminal and the third terminal have a third overlapping area, and the adapter terminal and the third terminal are connected in the third overlapping area.

[0024] Optionally, in the above power component, the first overlapping region and the second overlapping region do not overlap in the first direction.

[0025] Optionally, in the above power component, in the second direction, the distance between the first overlapping area and the capacitor component is greater than the distance between the second overlapping area and the capacitor component.

[0026] Optionally, in the above power component, the adapter terminal and the third terminal have a third overlapping area, and the adapter terminal and the third terminal are connected in the third overlapping area.

[0027] Optionally, in the above power component, the transfer terminal and the first section terminal have a third overlapping area in the second direction.

[0028] Optionally, in the above power component, the third terminal further includes a fourth terminal connected to the first terminal; the fourth terminal is parallel to the second direction and extends away from the capacitor component;

[0029] The transfer terminal and the fourth section terminal have a third overlapping area in the first direction.

[0030] Optionally, in the above power component, the third terminal further includes a fourth terminal connected to the first terminal; the fourth terminal is parallel to the second direction and extends toward the capacitor component;

[0031] The transfer terminal and the fourth section terminal have a third overlapping area in the first direction.

[0032] Optionally, in the above power component, in the second direction, the distance between the third overlapping area and the capacitor component is greater than the distance between the first overlapping area and the capacitor component; and the distance between the second overlapping area and the capacitor component is less than the distance between the first overlapping area and the capacitor component.

[0033] Optionally, in the above power component, the fourth terminal further includes a third section terminal connected to the second section terminal; the third terminal further includes a fourth section terminal connected to the first section terminal; the third section terminal and the fourth section terminal both extend away from the capacitor component;

[0034] The fourth section terminal and the first terminal are connected at one end away from the capacitor component to form a first connection area; the third section terminal and the second terminal are connected at one end away from the capacitor component to form a second connection area; in the second direction, the distance between the second connection area and the capacitor component is smaller than the distance between the first connection area and the capacitor component.

[0035] Optionally, in the above power component, the fourth section terminal and the first terminal have opposite portions in the first direction;

[0036] The third section terminal and the second terminal have a first overlapping area in the first direction; the first overlapping area includes an end of the second connection area located in the accommodation space formed by the opposite parts.

[0037] Optionally, in the above power component, in the relative portion, the fourth section terminal and the first terminal both protrude toward a side away from the first overlapping area to form an accommodation space.

[0038] Optionally, in the above power component, in the first direction, the third terminal exposes at least a portion of the third terminal segment.

[0039] Optionally, in the above power assembly, an insulating member is provided between the first terminal and the second terminal;

[0040] And / or, an insulating member is provided between the third terminal and the fourth terminal.

[0041] Optionally, in the above power component, the first terminal and the third terminal are fixedly connected by welding, and the second terminal and the fourth terminal are fixedly connected by welding.

[0042] Optionally, in the above power component, at least one of the first terminal, the second terminal, the third terminal and the fourth terminal has a thickness of 1 mm to 2 mm.

[0043] Optionally, in the above power component, the distance between the first terminal and the second terminal is 1.5 mm to 2 mm;

[0044] And / or, the distance between the third terminal and the fourth terminal is 1.5 mm to 2 mm.

[0045] Optionally, in the above power assembly, the first section terminal comprises an integrated first part and a second part, the first part is connected to the end, and the second part is located on a side of the first part away from the end;

[0046] wherein the width of the first portion is smaller than the width of the second portion;

[0047] Alternatively, the width of the first portion is equal to the width of the second portion.

[0048] Optionally, in the above power component, the first terminal and the second terminal both include an integrated third part and a fourth part; in the same terminal, the fourth part is connected to the surface, and the third part is located on a side of the fourth part away from the surface;

[0049] wherein the width of the third portion is smaller than the width of the fourth portion;

[0050] Alternatively, the width of the third portion is equal to the width of the fourth portion.

[0051] Optionally, in the above power assembly, the first section terminal includes an integrated first part and a second part, the first part is connected to the end, and the second part is located on a side of the first part away from the end;

[0052] The first terminal and the second terminal both include an integral third part and a fourth part; in the same terminal, the fourth part is connected to the surface, and the third part is located on a side of the fourth part away from the surface;

[0053] The width of the first part is smaller than the width of the second part, the width of the second part is equal to the width of the third part, and the width of the third part is smaller than the width of the fourth part.

[0054] Optionally, in the above power assembly, the power assembly includes at least one of a drive control module and a power generation control module; the drive control module is used to connect the drive motor; the power generation control module is used to connect the power generation motor;

[0055] Wherein, the driving control module and the power generation control module both include a stacked power module and a capacitor assembly.

[0056] Optionally, in the above power assembly, the power assembly includes both a drive control module and a power generation control module;

[0057] The driving control module and the power generation control module share the same capacitor component.

[0058] Optionally, in the above power assembly, the drive control module includes a plurality of first sub-power modules, each of which has an independent liner;

[0059] The power generation control module includes a plurality of second sub-power modules, and the second sub-power modules share a same liner.

[0060] Optionally, in the above power assembly, the driving control module includes three first sub-power modules; and the power generation control module includes three second sub-power modules.

[0061] Optionally, in the above power component, the first terminal and the third terminal are connected based on a transfer terminal;

[0062] The power generation control module and the drive control module share the same transfer terminal.

[0063] A second aspect of the present application provides a method for preparing the above-mentioned power component, comprising:

[0064] The power module and the capacitor assembly are stacked; the surface of the capacitor assembly facing the power module is connected with an insulated first terminal and a second terminal; the first terminal and the second terminal are arranged opposite to each other in a first direction; the same end of the power module is connected with an insulated third terminal and a fourth terminal; the end faces the first terminal and the second terminal; the third terminal includes a first section terminal connected to the end, and the fourth terminal includes a second section terminal connected to the end; the first section terminal and the second section terminal are parallel to the first direction and are arranged opposite to each other in a second direction; wherein the second direction is parallel to the stacking direction of the power module and the capacitor assembly, and the first direction is perpendicular to the second direction;

[0065] The first terminal and the third terminal are connected, and the second terminal and the fourth terminal are connected.

[0066] Optionally, in the above preparation method, connecting the first terminal and the third terminal, and connecting the second terminal and the fourth terminal, comprises:

[0067] After connecting an end of the second terminal away from the capacitor assembly and an end of the fourth terminal away from the power module, connect an end of the first terminal away from the capacitor assembly and an end of the third terminal away from the power module;

[0068] Alternatively, after the second terminal and the fourth terminal are connected in the first overlapping region, the first terminal and the third terminal are connected using a transfer terminal.

[0069] Optionally, in the above preparation method, the fourth terminal further includes a third section terminal connected to the second section terminal; the third terminal further includes a fourth section terminal connected to the first section terminal; the third section terminal and the fourth section terminal both extend away from the capacitor assembly;

[0070] The first terminal includes a fifth section terminal and a sixth section terminal, the fifth section terminal is vertically connected to the surface, and the sixth section terminal is connected to an end of the fifth section terminal away from the capacitor component;

[0071] Methods for connecting the capacitor assembly and the terminals of the power module include:

[0072] The sixth section of the terminal is bent outward and has an angle a with the first direction; the fourth end terminal is bent inward and has an angle b with the first section of the terminal; a and b are both less than 90°; based on the welding window formed by a and b, the second terminal and the fourth terminal are welded and fixedly connected;

[0073] After increasing a and b, one end of the fourth section terminal away from the first section terminal and one end of the sixth section terminal away from the fifth section terminal are brought into contact with each other and fixed by welding.

[0074] Optionally, in the above preparation method, before welding the second terminal and the fourth terminal, the values ​​of a and b are 70°~80°.

[0075] A third aspect of the present application provides a motor controller, comprising the above-mentioned power component.

[0076] A fourth aspect of the present application provides an electric control assembly, including the above-mentioned motor controller.

[0077] A fifth aspect of the present application provides a vehicle comprising the above-mentioned electronic control assembly.

[0078] By means of the above technical solution, in the technical solution of the present application, a capacitor component is provided to be connected with a first terminal and a second terminal arranged relatively in a first direction, so that the first terminal and the second terminal can be stacked in the first direction, which can reduce the series inductance of the current loop. Moreover, the first section terminal of the third terminal and the second section terminal of the fourth terminal are arranged relatively in the second direction, so that the first section terminal and the second section terminal can be stacked in the second direction, which can reduce the series inductance of the current loop. Therefore, the present application can reduce the series inductance in the power component and avoid the adverse effect of excessive series inductance on the performance of the power component.

[0079] Optionally, the first terminal and the third terminal, and the second terminal and the fourth terminal can be connected and fixed by welding, respectively, so that the contact resistance between the two terminals welded to each other is low, reducing thermal risks, and each terminal has strong vibration resistance, so that when the power component vibrates greatly or is used for a long time, the connection position between the terminals will not loosen, thereby avoiding the problem of increased contact resistance due to poor contact between the terminals and reducing the risk of abnormal temperature of the power component.

[0080] Optionally, compared with the conventional connection scheme in which the terminals are fixed by screws, the terminals in the technical scheme of the present application are fixed by welding, which does not require a separate space for screws, can greatly simplify the assembly process, improve assembly efficiency, reduce the volume of power components, and reduce material costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0081] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the related technologies, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without paying any creative work.

[0082] The structures, proportions, sizes, etc. illustrated in the drawings of this specification are only used to match the contents disclosed in the specification so as to facilitate understanding and reading by persons familiar with this technology. They are not used to limit the conditions under which this application can be implemented, and therefore have no substantive technical significance. Any structural modification, change in proportion or adjustment of size, without affecting the effects and purposes that can be achieved by this application, should still fall within the scope of the technical contents disclosed in this application.

[0083] Figure 1 A three-dimensional view of the layout of two copper bars connected in parallel and in series;

[0084] Figure 2 for Figure 1 A front view of

[0085] Figure 3 A three-dimensional view of a power component;

[0086] Figure 4 for Figure 3 A top view of

[0087] Figure 5 for Figure 3 A partial enlarged view of

[0088] Figure 6 A top view of a connection structure between a sub-power module and a capacitor component in a power component;

[0089] Figure 7 for Figure 6 a side view of the structure shown;

[0090] Figure 8 for Figure 6 a right side view of the structure shown;

[0091] Fig. 9 A schematic diagram of the structure of a power component provided in an embodiment of the present application;

[0092] Fig.10 A three-dimensional view of a power component provided in an embodiment of the present application;

[0093] Fig.11 A partial side view of a terminal connection structure of a power module and a capacitor assembly in a power assembly provided in an embodiment of the present application;

[0094] Fig.12 for Fig.11 A top view of the power assembly shown;

[0095] Fig.13 for Fig.11 The right side view of the power component before connecting the transfer terminal;

[0096] Fig.14 for Fig.11 The right side view of the power component after connecting the transfer terminal is shown;

[0097] Fig.15 A side view of a terminal connection structure of a power module and a capacitor assembly in a power assembly provided in an embodiment of the present application;

[0098] Fig.16 A side view of a terminal connection structure of a power module and a capacitor assembly in another power assembly provided in an embodiment of the present application;

[0099] Fig.17 A side view of a terminal connection structure of a power module and a capacitor assembly in another power assembly provided in an embodiment of the present application;

[0100] Fig.18 A schematic diagram of a process for preparing a power component provided in an embodiment of the present application;

[0101] Fig.19 and Fig. 20 A schematic diagram of the principle of a terminal connection method according to an embodiment of the present application;

[0102] Fig.21 A schematic diagram of the terminal structure of a capacitor assembly before being connected and assembled with a power module;

[0103] Fig. 22 A schematic diagram of the terminal structure of another capacitor assembly before being connected and assembled with a power module;

[0104] Fig.23 A topological structure diagram of an extended-range new energy vehicle provided in an embodiment of the present application;

[0105] Fig.24 An equivalent circuit diagram of a power component provided in an embodiment of the present application.

[0106] Reference numerals:

[0107] 1-power module; 2-capacitor assembly; 3-surface; 4-end; 5-insulator; 6-lining; 7-pin; 8-screw; 9-AC terminal; 10-calibration tooling; 11-electric drive unit; 12-drive motor; 13-inverter; 14-power battery; 15-power generation assembly; 16-generator motor; 17-engine; 18-range extender; 19-heat sink; 101-drive control module; 102-power generation control module; 701-first sub-power module; 702-second sub-power module; 801-first copper bus; 802-second copper bus; 901-upper bridge arm circuit; 902-lower bridge arm circuit; 903-positive bus; 904-negative Pole bus; 905-first power chip; 906-second power chip; X-first direction; Y-second direction; T1-first terminal; T2-second terminal; T3-third terminal; T4-fourth terminal; T5-transfer terminal; T01-first section terminal; T02-second section terminal; T03-third section terminal; T04-fourth section terminal; T05-fifth section terminal; T06-sixth section terminal; A1-first overlapping area; A2-second overlapping area; A3-third overlapping area; B1-first connection area; B2-second connection area; C-opposite part; D1-first area; D2-second area; D3-third area; D4-fourth area. DETAILED DESCRIPTION

[0108] The following will be combined with the drawings in the embodiments of the present application to clearly and completely describe the embodiments of the present application. It is known to those skilled in the art that with the development of technology and the emergence of new scenarios, the technical solutions provided in the embodiments of the present application are also applicable to similar technical problems.

[0109] The power component can be used to control the working state of the motor in the vehicle, and the motor is generally a three-phase motor. When the power component performs high-speed on / off control on the power module, the surge voltage V will be loaded into the current loop where the power module is located. V is proportional to the size of the series inductance Ls introduced by the terminal in the current loop. Among them, the calculation formula for the surge voltage is:

[0110] (1)

[0111] in, is the rate of change of current in the current loop.

[0112] refer to Figure 1 and Figure 2 , Figure 1 A three-dimensional view of the layout of two copper bars connected in parallel and in series. Figure 2 for Figure 1 Front view of . Figure 1 The bold one-way arrow in the figure indicates the direction of current flow in the current loop.

[0113] like Figure 1 and Figure 2 As shown, the first copper bar 801 and the second copper bar 802 are two parallel and serially connected DC terminals in the power component, such as the first copper bar 801 and the second copper bar 802 can be the positive terminal and the negative terminal of the power module, or the positive terminal and the negative terminal of the capacitor component. The first copper bar 801 and the second copper bar 802 are both set to have a width of W, a length of L, a thickness of t, and a distance d between them.

[0114] for Figure 1 and Figure 2 For the copper bar arrangement shown in the figure, the empirical calculation formula for Ls of the two copper bars in the current loop is:

[0115] (2)

[0116] Among them, L1 and L2 represent the self-inductance of the two copper bars respectively; M represents the mutual inductance between the two copper bars; k represents the coupling coefficient, which can characterize the degree of coupling between the two copper bars. When the centers of the two copper bars are not aligned, it will affect the value of k. If WS:W≠1, then k<1. The smaller the value of WS:W, the greater the degree of misalignment between the centers of the two copper bars, and the smaller the k value. WS is the overlapping width of the two copper bars.

[0117] Based on formula (2), the formula of Ls can be expressed as:

[0118] (3)

[0119] in, is the magnetic permeability in vacuum.

[0120] Based on formula (1) and formula (3), it can be seen that the smaller L is, the larger W is, and the larger t is, the smaller Ls is, and the smaller V is; the larger WS:W is, the greater the overlap ratio of the two terminals is, the larger k is, the smaller Ls is, and the smaller the surge voltage is.

[0121] refer to Figure 3-Figure 5 , Figure 3 A three-dimensional view of a power component. Figure 4 for Figure 3 A top view of Figure 5 for Figure 3 In this mode, the power component includes a stacked power module 1 and a capacitor component 2. The power component shown is a dual electric control structure, and the power module 1 includes: a drive control module 101 and a power generation control module 102.

[0122] The driving control module 101 and the power generation control module 102 can be fixed on the surface of the heat sink 19 , and the capacitor assembly 2 is located below the heat sink 19 .

[0123] The drive control module 101 is a core component that converts direct current into alternating current, and is used to connect the drive motor. The power generation control module 102 is a core component that can convert alternating current into direct current, and is used to connect the generator motor. The drive motor and the generator motor can both be three-phase motors. The drive control module 101 and the power generation control module 102 are coplanarly arranged on the surface of the capacitor assembly 2, which can reduce the size of the space occupied by the product. Among them, the capacitor assembly 2 can be used in combination with the power module 1 in the power assembly, and is a key component for balancing the DC side bus voltage.

[0124] like Figure 3-Figure 5 As shown, the capacitor assembly 2 includes a first terminal T1 and a second terminal T2, one of which is a positive terminal and the other is a negative terminal. The power module 1 includes a third terminal T3 and a fourth terminal T4, one of which is a positive terminal and the other is a negative terminal. The first terminal T1 and the third terminal T3 are connected and fixed by screws 8, and the second terminal T2 and the fourth terminal T4 are connected and fixed by screws 8, so that the positive terminals of the capacitor assembly 2 and the power module 1 are connected, and the negative terminals of the two are connected. Among them, the positive terminal is used to connect the positive electrode of the vehicle power battery through the positive DC bus, and the negative terminal is used to connect the negative electrode of the vehicle power battery through the negative DC bus.

[0125] The drive control module 101 and the power generation control module 102 each include three sub-power modules. In the same control module, the three sub-power modules can be connected to the three-phase AC terminals of the three-phase motor in a one-to-one correspondence. The connection structure between the sub-power module and the capacitor assembly 2 is shown in FIG. Figure 6-Figure 8 shown.

[0126] refer to Figure 6-Figure 8 , Figure 6 A top view of a connection structure between a sub-power module and a capacitor component in a power component. Figure 7 for Figure 6 A side view of the structure shown, Figure 8 for Figure 6 The terminal connection path between the sub-power module and the capacitor assembly 2 includes four regions, which are the first region D1, the second region D2, the third region D3 and the fourth region D4.

[0127] Combination Figure 3-Figure 8 As shown, in the sub-power module, the third terminal T3 and the fourth terminal T4 are respectively led out from the liner 6 of the sub-power module; the third terminal T3 and the fourth terminal T4 are stacked and overlapped in the first area D1, and the width is W1; in the second area D2, the third terminal T3 and the fourth terminal T4 are respectively connected to the first terminal T1 and the second terminal T2 by screws 8, and the two are in Figure 6 In the capacitor assembly 2, the first terminal T1 and the second terminal T2 are also arranged in parallel in the second region D2, with widths of W2- and W2+ respectively; the first terminal T1 and the second terminal T2 are arranged in parallel in the third region D3, with widths of W3- and W3+ respectively; the first terminal T1 and the second terminal T2 are arranged in parallel in the fourth region D4, with widths of W4.

[0128] The sub-power module includes a half-bridge circuit located on the liner 6, and the half-bridge circuit includes a power chip. Due to the limitations of factors such as chip size and quantity and the size of the liner 6, each sub-power module needs to use a separate liner 6, resulting in larger sizes of b1 and b2. The width of the single-phase sub-power module in the drive control module 101 is b1, and the width of the drive control module 101 is b01. The width of the single-phase sub-power module in the power generation control module 102 is b2, and the width of the power generation control module 102 is b02. In order to meet the terminal connection relationship between the power module 1 and the capacitor component 2 in the dual electric control structure, the six sub-power modules in the drive control module 101 and the power generation control module 102 have positive and negative terminals respectively, and a total of 6 positive terminals and 6 negative terminals are required, resulting in larger overall sizes of the two control modules b01 and b02, which in turn leads to a larger ESL of the power component and high material cost.

[0129] In addition, the first area D1 to the fourth area D4 are important areas that affect the ESL of the current loop where the power module 1 and the capacitor component 2 are located. In the first area D1, the width W1 of the terminal is large, and it is stacked up and down, and the ESL in this area is small. In the second area D2, in order to meet the connection between the positive terminal and the positive terminal of the power module 1 and the capacitor component 2 by screws 8 and the connection between the negative terminal and the negative terminal by screws 8, the widths W2- and W2+ of the terminals are relatively small, and there is no stacking area between the positive and negative terminals (in this area WS=0). Based on formula (3), the ESL between the positive and negative terminals is large. Similarly, in the third area D3, the widths W3- and W3+ of the terminals are also limited, and there is no stacking area between the positive and negative terminals (in this area WS=0). Based on formula (3), the ESL between the positive and negative terminals is large.

[0130] Since the terminals between the capacitor assembly 2 and the power module 1 need to be fixed by screws 8, the fixing scheme using screws includes at least the following shortcomings: the traditional screw scheme requires more materials, which increases the process complexity in the storage, loading, and tightening of the screws; during automatic loading, the consistency of the screws or other factors may cause occasional failures such as nail jamming, which requires manual intervention, reduces the degree of automation, and affects the production cycle; the screw fixing assembly time is long and the efficiency is low. For applications with a large number of screws, multiple batches of assembly are required to meet the production cycle, and the number of screw tightening devices increases; under high vibration or dynamic load conditions, the screws may loosen or fail, resulting in poor product reliability; the screw method has a large contact resistance (generally 20μΩ~30μΩ), and the screws need to occupy a large layout space, and a parallel staggered design of the terminals is also required, which will increase the series inductance.

[0131] Therefore, the fixing scheme using screws leads to a complicated assembly process and requires a large assembly space, and the screws 8 will occupy a large space after assembly. Moreover, the fixing method of the screws 8 is prone to loosening, increased contact resistance, and thermal overshoot after vibration.

[0132] In order to solve the above problems, the technical solution of the present application provides a power component, including:

[0133] A stacked power module and capacitor assembly;

[0134] The surface of the capacitor assembly facing the power module is connected with a first terminal and a second terminal insulated from each other; the first terminal and the second terminal are arranged opposite to each other in a first direction;

[0135] The same end of the power module is connected to a third terminal and a fourth terminal insulated from each other; the end faces the first terminal and the second terminal; the third terminal includes a first section terminal connected to the end, and the fourth terminal includes a second section terminal connected to the end; the first section terminal and the second section terminal are parallel to the first direction and are arranged opposite to each other in the second direction;

[0136] The second direction is parallel to the stacking direction of the power module and the capacitor assembly, and the first direction is perpendicular to the second direction; the first terminal is connected to the third terminal, and the second terminal is connected to the fourth terminal.

[0137] In the technical solution of the present application, a capacitor component is provided to be connected with a first terminal and a second terminal arranged relatively in a first direction, so that the first terminal and the second terminal can be stacked in the first direction, which can reduce the series inductance of the current loop. Moreover, the first section terminal of the third terminal and the second section terminal of the fourth terminal are arranged relatively in the second direction, so that the first section terminal and the second section terminal can be stacked in the second direction, which can reduce the series inductance of the current loop. Therefore, the present application can reduce the series inductance in the power component and avoid the adverse effect of excessive series inductance on the performance of the power component.

[0138] Optionally, the first terminal and the third terminal, and the second terminal and the fourth terminal are connected and fixed by welding, respectively, so that the contact resistance between the two terminals welded to each other can be low, reducing thermal risks, and each terminal has strong vibration resistance, so that when the power component vibrates greatly or is used for a long time, the connection position between the terminals will not loosen, thereby avoiding problems such as increased contact resistance and thermal tolerance due to poor contact between the terminals, and reducing the risk of abnormal temperature of the power component.

[0139] Compared with the conventional connection scheme in which the terminals are fixed by screws, the terminals in the technical solution of the present application are fixed by welding, which can realize the welding process of automated connection equipment, improve the degree of automation of the operation, reduce materials and material management, and do not need to set up the space required for screws separately. It can greatly simplify the assembly process, improve assembly efficiency, reduce the volume of power components, and reduce material costs. The welding process has a small contact resistance. If laser welding is used, the contact resistance can be reduced to about 5μΩ. In addition, the present application can also avoid the parallel design of terminal misalignment required by the screw fixing scheme, and avoid the problem of increased series inductance caused by the design reducing the area of ​​the terminal facing the area.

[0140] In order to make the above-mentioned purposes, features and advantages of the present application more obvious and easy to understand, the present application is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0141] refer to Fig. 9 , Fig. 9 A schematic diagram of a power component provided in an embodiment of the present application, wherein the power component includes:

[0142] A power module 1 and a capacitor assembly 2 are stacked.

[0143] The surface 3 of the capacitor component 2 facing the power module 1 is connected with a mutually insulated first terminal T1 and a second terminal T2 ; the first terminal T1 and the second terminal T2 are arranged opposite to each other in the first direction X; the first terminal T1 and the second terminal T2 can both be vertically led out from the surface 3 .

[0144] The same end 4 of the power module 1 is connected with a third terminal T3 and a fourth terminal T4 which are insulated from each other. The third terminal T3 and the fourth terminal T4 can be vertically led out from the end 4. The end 4 faces the first terminal T1 and the second terminal T2, that is, the first terminal T1 and the second terminal T2 are located on the same side of the end 4. The third terminal T3 includes a first section terminal T01 connected to the end 4, and the first section terminal T01 is perpendicular to the end 4. The fourth terminal T4 includes a second section terminal T02 connected to the end 4, and the second section terminal T02 is perpendicular to the end 4. The first section terminal T01 and the second section terminal T02 are parallel to the first direction X, and are arranged opposite to each other in the second direction Y.

[0145] The second direction Y is parallel to the stacking direction of the power module 1 and the capacitor assembly 2 , and the first direction X is perpendicular to the second direction Y; the first terminal T1 is connected to the third terminal T3 , and the second terminal T2 is connected to the fourth terminal T4 .

[0146] Optionally, the first terminal T1 and the third terminal T3 can be fixedly connected based on welding, and the second terminal T2 and the fourth terminal T4 can be fixedly connected based on welding. Welding can be laser welding or other welding methods, which are not limited in the embodiments of the present application. In the subsequent implementation of the present application, the connection between the terminals is achieved by fixing the terminals based on welding. In the embodiments of the present application, other fixed connection methods can also be used, which are not limited to laser welding, and can also be fixed by screws or snap-on connections.

[0147] Optionally, the sub-power modules in the power assembly may be arranged in sequence along the third direction Z.

[0148] Since the first terminal T1 and the second terminal T2 are arranged relative to each other in the first direction X, the first terminal T1 and the second terminal T2 can be stacked in the first direction X, which is equivalent to increasing the width WS of the overlapping area between the two, and the series inductance of the current loop can be reduced. Since the first section terminal T01 and the second section terminal T02 are arranged relative to each other in the second direction Y, the first section terminal T01 and the second section terminal T02 can be stacked in the second direction Y, which is equivalent to increasing the width WS of the overlapping area between the two, and the series inductance of the current loop can be reduced. Therefore, the present application can reduce the series inductance in the power component and avoid the adverse effect of excessive series inductance on the performance of the power component.

[0149] Moreover, the first terminal T1 and the third terminal T3, as well as the second terminal T2 and the fourth terminal T4 can be connected and fixed by welding, respectively, so that the contact resistance between the two terminals welded to each other can be low, reducing thermal risks, and each terminal has strong vibration resistance, so that when the power component vibrates greatly or is used for a long time, the connection position between the terminals will not loosen, thereby avoiding problems such as increased contact resistance and thermal tolerance due to poor contact between the terminals, and reducing the risk of abnormal temperature of the power component.

[0150] Compared with the connection solution in which the terminals are fixed by screws 8, the terminals in the technical solution of the present application are fixed by welding, which does not require a separate space for the screws 8, can greatly simplify the assembly process, improve assembly efficiency, reduce the volume of the power components, and reduce material costs.

[0151] Furthermore, the technical solution of the present application can also reduce the size of b1 and b2, and then reduce the size of b01 and b02, thereby reducing material costs by optimizing the size of the power chip in the power module 1 and the layout of the pins 7 used to connect to the PCB.

[0152] In the embodiment of the present application, the fourth terminal T4 is located between the third terminal T3 and the capacitor component. In the second direction Y, the fourth terminal T4 faces the capacitor component 2, and the third terminal T3 is located on the side of the fourth terminal T4 away from the capacitor component 2; the second terminal T2 is located between the first terminal T1 and the end 4. In the first direction X, the first terminal T1 faces away from the end 4, and the second terminal T2 faces the end 4. In this way, Fig. 9 As shown, the connection structure formed by the first terminal T1 and the third terminal T3 can be stacked with the connection structure formed by the second terminal T2 and the fourth terminal T4 to facilitate the connection between the capacitor assembly 2 and the positive terminal and the negative terminal of the power module 1.

[0153] refer to Fig.10 , Fig.10A three-dimensional view of a power component provided in an embodiment of the present application, the power component includes at least one of a drive control module 101 and a power generation control module 102. The drive control module 101 is used to connect the drive motor; the power generation control module 102 is used to connect the power generation motor; wherein the drive control module 101 and the power generation control module 102 both include a stacked power module 1 and a capacitor component 2. The third terminal T3 and the first terminal T1 can be as follows Fig.10 As shown, the two are connected through the transfer terminal T5, or as described below, the two are directly connected.

[0154] If the power assembly includes both the driving control module 101 and the power generation control module 102, when the first terminal T1 and the third terminal T3 are connected based on the adapter terminal T5, an implementation method may be as follows: Fig.10 As shown, the driving control module 101 and the power generation control module 102 share the same adapter terminal T5. At this time, the first terminal T1 and the third terminal T3 in the driving control module 101 and the first terminal T1 and the third terminal T3 in the power generation control module 102 are connected through the same adapter terminal T5.

[0155] In other embodiments, if the power component includes a drive control module 101 and a power generation control module 102 at the same time, when the first terminal T1 and the third terminal T3 are connected based on the adapter terminal T5, the drive control module 101 and the power generation control module 102 can also be set to use independent adapter terminals respectively. At this time, the first terminal T1 and the third terminal T3 in the drive control module 101 are connected by one adapter terminal T5, and the first terminal T1 and the third terminal T3 in the power generation control module 102 are connected by another adapter terminal T5.

[0156] In the drive control module 101, by setting the first terminal T1 and the second terminal T2 to be stacked in the first direction X, it is equivalent to increasing the width WS of the overlapping area between the two; by setting the first section terminal T01 and the second section terminal T02 to be stacked in the second direction Y, it is equivalent to increasing the width WS of the overlapping area between the two. Therefore, based on the above formula (3), the embodiment of the present application can increase WS, so the series inductance in the current loop can be reduced. Similarly, in the power generation control module 102, the series inductance in the current loop can also be reduced by increasing the width WS of the overlapping area between the first terminal T1 and the second terminal T2.

[0157] like Fig.10As shown, the power component can adopt a dual electric control structure, that is, the power component includes a driving control module 101 and a power generation control module 102 at the same time; wherein the driving control module 101 and the power generation control module 102 share the same capacitor component 2. This method integrates the driving control module 101 and the power generation control module 102 into one, so that the two share the same capacitor component 2. Compared with the solution of packaging the two control modules separately, the integration of the power component can be improved, the overall volume can be reduced, and it is easy to realize the miniaturization of the packaging of the dual electric control structure.

[0158] The driving control module 101 includes a plurality of first sub-power modules 701, and the power generation control module 102 includes a plurality of second sub-power modules 702. Optionally, the driving control module 101 includes three first sub-power modules 701, and the AC terminals 9 of the three first sub-power modules 701 are respectively used to connect to the one-phase AC terminals of the driving motor. The three first sub-power modules 701 have independent lining plates 6 respectively. The power generation control module 102 includes three second sub-power modules 702, and the AC terminals 9 of the three second sub-power modules 702 are respectively used to connect to the one-phase AC terminals of the generator motor. The three second sub-power modules 702 share the same lining plate 6. Compared with the conventional solution that the three second sub-power modules 702 in the power generation control module 102 use separate lining plates 6 respectively, the present application can improve the integration of the power generation control module 102 and reduce the product size.

[0159] The drive control module 101 is used to connect the drive motor to control the working state of the drive motor. The drive motor needs to accurately control the output torque and speed to meet the vehicle's form requirements under different working conditions. In the embodiment of the present application, each first sub-power module 701 in the drive control module 101 is fixed on the surface of the heat sink 19 using a separate liner 6, which can achieve accurate and fine control of the power chip in each first sub-power module 701, thereby more accurately controlling the amplitude, phase and frequency of the current of the drive motor, ensuring that the torque and speed output by the drive motor can accurately respond to operating instructions and the requirements of the vehicle control system.

[0160] The power generation control module 102 is used to connect the generator motor to control the working state of the generator motor. The main function of the generator motor is to convert mechanical energy into electrical energy to charge the power battery. In this process, more attention is paid to the energy conversion efficiency, so as to convert as much mechanical energy as possible into electrical energy and store it in the power battery. In the embodiment of the present application, each second sub-power module 702 in the power generation control module 102 is fixed on the surface of the heat sink 19 based on the same liner 6, which can reduce costs and improve integration while ensuring certain performance, and at the same time will not have a significant impact on the energy conversion efficiency.

[0161] In addition, compared with the drive motor, the working current characteristics of the generator motor are relatively simple. During the power generation process, the alternating current is converted into direct current through the power generation control module 102, and the frequency and amplitude of the current change are relatively stable. There is no need to perform complex control and adjustment of the current like a drive motor. Therefore, the second sub-power modules 702 in the power generation control module 102 share the same lining plate 6 to meet the basic control requirements of the generator motor.

[0162] When the power assembly includes both the driving control module 101 and the power generation control module 102 , the two control modules may respectively use separate heat sinks 19 or may share the same heat sink 19 .

[0163] Optionally, the backing plate 6 may be a double-sided copper-clad ceramic plate. The power chip in the sub-power module is fixed on the copper-clad surface of the upper surface of the backing plate 6 .

[0164] The first sub-power module 701 and the second sub-power module 702 each include a single-phase half-bridge circuit located on the liner 6, and the single-phase half-bridge circuit is a control circuit formed by interconnecting multiple power chips. Multiple single-phase half-bridge circuits in the same control module form a full-bridge circuit. The embodiment of the present application does not limit the specific circuit form of the single-phase half-bridge circuit.

[0165] As described above, Figure 3-Figure 8 As shown, in a general dual electric control structure, the screw connection will lead to a large contact resistance, there is a high risk of thermal failure, and the positive and negative terminals are misaligned and arranged in parallel in a local area, resulting in a large ESL in the area, which will lead to a large bus surge voltage, resulting in a large bus voltage fluctuation, which will seriously affect the performance of the power component. In the embodiment of the present application, by stacking the first terminal T1 and the second terminal T2 in the first direction X, and stacking the first section terminal T01 and the second section terminal T02 in the second direction Y, the width WS of the overlapping area of ​​the positive and negative terminals can be increased, the ESL in the current loop can be reduced, and the adverse effect of the large ESL on the performance of the power component can be reduced, and the performance of the power component can be improved.

[0166] As described above, in the embodiment of the present application, each second sub-power module 702 in the power generation control module 102 can be set to use the same liner 6. Compared with the solution that each second sub-power module 702 in the power generation control module 102 uses an independent liner 6, the solution of the present application can realize the miniaturization of the liner of the power generation control module 102. Moreover, each second sub-power module 702 can be integrated from multiple independent single-phase half-bridge circuits into a full-bridge circuit located on the same DBC (Direct Bonded Copper), so that each second sub-power module 702 of the power generation control module 102 can share the same third terminal T3 and the same fourth terminal T4, that is, share the same positive terminal and the same negative terminal, which can reduce the number of DC terminals, make the size of the power generation control module 102 smaller, make the size of the power component smaller, and reduce the material cost while improving product performance. At the same time, the stacking area of ​​the positive and negative terminals is maximized to reduce ESL to a greater extent.

[0167] In the embodiment of the present application, the two DC terminals of the power module 1 can also be designed to be stacked in a large area in the area facing each other in the first terminal T01 and the second terminal T02, so that the facing area of ​​the two in this area is equal to or approximately equal to 100%, which can reduce ESL, allow the current loop to have a larger terminal width, increase the width WS of the terminal overlapping area, and further reduce ESL.

[0168] In the capacitor assembly 2, the first terminal T1 and the second terminal T2 are directly led out perpendicular to the surface 3, and the structure is simple. The capacitor assembly 2 and the terminals of the power module 1 can be connected and fixed by welding, which can reduce the connection resistance between the terminals.

[0169] Moreover, the welding areas corresponding to the third terminal T3 and the fourth terminal T4 can be designed in parallel, or the welding areas corresponding to the third terminal T3 and the fourth terminal T4 can be designed in vertical direction, so that the welding area corresponding to one is located in the overlapping area of ​​the terminals in the second direction Y, and the welding area corresponding to the other is located in the overlapping area of ​​the terminals in the first direction X.

[0170] In one way, Fig.10 As shown, the first terminal T1 and the second terminal T2 of the capacitor component 2 are perpendicular to the surface 3. After the second terminal T2 is directly connected to the fourth terminal T4, the first terminal T1 and the third terminal T3 can be connected through the adapter terminal T5, so as to reserve a connection window between the second terminal T2 and the fourth terminal T4 between the first terminal T1 and the third terminal T3, which is convenient for the connection and assembly of the terminals between the capacitor component 2 and the power module 1.

[0171] Optionally, the second terminal T2 and the fourth terminal T4 can both be positive terminals, and the first terminal T1 and the third terminal T3 can both be negative terminals. In this case, the positive terminals of the power module 1 and the capacitor assembly 2 can be directly welded and fixedly connected, and the negative terminals of the two can be transferred through the transfer terminal T5, and the transfer terminal T5 can be welded and fixedly connected to the first terminal T1 and the third terminal T3 respectively. In other ways, the second terminal T2 and the fourth terminal T4 can also be set as negative terminals, and the first terminal T1 and the third terminal T3 can be set as positive terminals.

[0172] When used to control a three-phase motor, in the dual electric control structure, the drive control module 101 and the power generation control module 102 can set the three first sub-power modules 701 as three independent single-phase half-bridge circuits according to different usage requirements. Each first sub-power module 701 is packaged with a separate small-sized liner 6; three second sub-power modules 702 are set to share the same liner 6 (the liner is a full-bridge liner), using an integrated three-phase full-bridge circuit, sharing the same positive terminal, and sharing the same negative terminal. The drive control module 101 and the power generation control module 102 use a total of four liner 6. Figure 4 In this way, the present application can reduce the size of b2 while keeping the size of b1 unchanged, thereby reducing the size of b02 and reducing the overall size of the power component b01+b02. The present application embodiment does not limit the size of the liner 6 used by the drive control module 101 and the power generation control module 102.

[0173] In the embodiment of the present application, when used to control a three-phase motor, the three first sub-power modules 701 in the drive control module 101 can also be a three-phase full-bridge circuit; the three second sub-power modules 702 in the power generation control module 102 can be a three-phase full-bridge circuit. In the dual electric control structure, the drive control module 101 and the power generation control module 102 can be a six-phase full-bridge circuit structure, or each first sub-power module 701 in the drive control module 101 is a single-phase half-bridge circuit structure independently packaged with a small-size liner 6, and the three second sub-power modules 702 in the power generation control module 102 are a three-phase full-bridge circuit structure with an integrated liner 6.

[0174] It should be noted that the embodiments of the present application are not limited to Fig.10 The dual electric control structure shown, Fig.10The example of a power component including both a drive control module 101 and a power generation control module 102 is used for illustration. The power component may also include the drive control module 101 alone or the power generation control module 102 alone. These implementations can reduce the ESL of the current loop. When the power component includes one of the drive control module 101 and the power generation control module 102, it may be a three-phase full-bridge circuit structure or other circuit structures. The embodiment of the present application does not limit the circuit structure in the power module 1.

[0175] In the embodiment of the present application, the power module 1 and the capacitor assembly 2 are stacked in the second direction Y, which can reduce the area occupied by the power assembly relative to the layout mode in which the capacitor assembly 2 and the power module 1 are coplanar. The capacitor assembly 2 can be arranged above the power module 1, or the power module 1 can be arranged above the capacitor assembly 2, which is not limited in the embodiment of the present application.

[0176] refer to Figure 11-Figure 14 , Fig.11 A partial side view of a terminal connection structure of a power module and a capacitor assembly in a power assembly provided in an embodiment of the present application, Fig.12 for Fig.11 A top view of the power components shown, Fig.13 for Fig.11 The right side view of the power component before connecting the transfer terminal. Fig.14 for Fig.11 The right side view of the power component after connecting the adapter terminal is shown. In this method, the terminal connection path between the capacitor component 2 and the power module 1 also includes the first area D1 to the fourth area D4, and the spacing between the third terminal T3 and the fourth terminal T4 of the power module 1 and the spacing between the first terminal T1 and the second terminal T2 in the capacitor component 2 can both be H0.

[0177] The first section terminal T01 includes an integrated first part and a second part, the first part is connected to the end 4, and the second part is located on the side of the first part away from the end 4; the first section terminal T01 is located in the first area D1 as the first part, and is located in the second area D2 as the second part.

[0178] like Fig.12 As shown in FIG. 1 , the width W1 of the first portion is smaller than the width W2 of the second portion, wherein W1 and W2 are the lengths of the terminal in the third direction Z, which is perpendicular to the first direction X and parallel to the surface 3. If W1 is smaller than W2, Fig.12 The upper and lower ends of the first area D1 are reserved for installation space to facilitate fixing the external housing, so as to facilitate the use of the housing to encapsulate and protect the internal components of the power assembly. In other embodiments, the width W1 of the first part can be set equal to the width W2 of the second part.

[0179] The lengths of the first area D1 and the second area D2 in the first direction X can be adjusted according to the product layout requirements, and this application does not limit the lengths of the two areas. The values ​​of W1 and W2 can be designed according to performance requirements and molding requirements. In theory, the larger the values ​​of W1 and W2, the smaller the ESL.

[0180] like Fig.13 and Fig.14 As shown, the first terminal T1 and the second terminal T2 both include an integral third part and a fourth part; in the same terminal, the fourth part is connected to the surface 3, and the third part is located on the side of the fourth part away from the surface 3; wherein the width W3 of the third part is smaller than the width W4 of the fourth part. W3 and W4 are the nominal widths of the third part and the fourth part, respectively. The first terminal T1 and the second terminal T2 are partially the fourth part in the fourth area D4, and the width of the fourth part of both is W4. The first terminal T1 and the second terminal T2 are partially the third part in the third area D3, wherein the actual width of the third part of the first terminal T1 is W3-, and the actual width of the third part of the second terminal T2 is W3+, and W3+ and W3- are equal to or approximately equal to W3. In this way, W3 is smaller than W4, and it can be Fig.13 and Fig.14 The left and right sides of the third area D3 are reserved for installation space to facilitate fixing the external housing, so as to facilitate the use of the housing to encapsulate and protect the internal components of the power assembly. In other embodiments, the width W3 of the third portion may be equal to the width W4 of the fourth portion.

[0181] Optionally, setting W1<W2=W3<W4 can not only facilitate reserving housing installation space, but also ensure the relative area of ​​terminal stacking to a large extent, and reduce the ESL of the current loop.

[0182] In the embodiment of the present application, at least one of the first terminal T1, the second terminal T2, the third terminal T3 and the fourth terminal T4 has a thickness of 1 mm to 2 mm. In the embodiment of the present application, the numerical range includes the endpoint value. The thickness of each terminal can be 1.2 mm, or 1.5 mm, or 1.7 mm, or 1.9 mm, etc. Within this value range, the terminal thickness can be larger and have a smaller ESL. On the other hand, it can also avoid the excessive thickness affecting the volume of the product, and can avoid the excessive thickness of the terminal resulting in greater mechanical strength, so as to facilitate stacking connection between terminals and bending and shaping of the terminals.

[0183] Optionally, to facilitate process preparation, the first terminal T1 , the second terminal T2 , the third terminal T3 and the fourth terminal T4 may be set to have the same or similar thicknesses to facilitate preparation of the terminals in the capacitor assembly 2 and the power module 1 .

[0184] In one embodiment, the distance between the first terminal T1 and the second terminal T2 is 1.5 mm to 2 mm, and the distance may be 1.4 mm, 1.7 mm, 1.9 mm, etc.; and / or the distance between the third terminal T3 and the fourth terminal T4 is 1.5 mm to 2 mm, and the distance may be 1.4 mm, 1.7 mm, 1.9 mm, etc. When the distance between the terminals is within this value range, the distance between the terminals can be moderate. On the one hand, the spacing between the terminals can be smaller, and the ESL can be reduced. On the other hand, the short circuit problem caused by too small spacing can be avoided.

[0185] Optionally, in order to facilitate the process, the distance between the first terminal T1 and the second terminal T2 may be set to be equal to or approximately equal to the distance between the third terminal T3 and the fourth terminal T4 .

[0186] Based on other implementations, the vertical projections of the first terminal T1 and the second terminal T2 on the first surface may at least partially overlap; and the first surface is perpendicular to the first direction X. Fig.13 As shown, the first surface is Fig.13 The projection plane of the right view is shown. The vertical projections of the first terminal T1 and the second terminal T2 are arranged to at least partially overlap, so that the two can form a stacked relative area, so as to reduce the series inductance.

[0187] Based on other implementations, it is also possible to set the vertical projections of the third terminal T3 and the fourth terminal T4 on the second plane to at least partially overlap; the second plane is perpendicular to the second direction. Fig.12 As shown, the second surface is Fig.12 The vertical projections of the third terminal T3 and the fourth terminal T4 are arranged to at least partially overlap, so that the two can form a stacked relative area, so as to reduce the series inductance.

[0188] The edges of the first terminal T1 and the second terminal T2 on both sides of the second direction Y meet the flush condition, so that the vertical projections of the two overlap to a large extent, and / or the edges of the third terminal T3 and the fourth terminal T4 on both sides of the first direction X meet the alignment condition, so that the vertical projections of the two overlap to a large extent. The edges meeting the flush condition means that the edges of the two terminals are flush or approximately flush.

[0189] When the edges of the first terminal T1 and the second terminal T2 on both sides of the second direction Y meet the flush condition, such as Fig.13 and Fig.14As shown, the left edges of the first terminal T1 and the second terminal T2 are flush or approximately flush, and the right edges of the first terminal T1 and the second terminal T2 are flush or approximately flush. Within the height overlap range of the first terminal T1 and the second terminal T2, the first terminal T1 and the second terminal T2 can be 100% or approximately 100% overlapped, and the graphic structures of the two within the height overlap range can be completely consistent or approximately consistent, so that the two can have a larger overlapping area along the second direction Y, thereby greatly reducing ESL. Optionally, the offset distance between the opposite edges of the first terminal T1 and the second terminal T2 does not exceed 0.2mm, so that the edges of the first terminal T1 and the second terminal T2 on both sides of the second direction Y meet the flush condition.

[0190] When the edges of the third terminal T3 and the fourth terminal T4 located on both sides of the first direction X meet the alignment condition, such as Fig.12 As shown, the upper edges of the third terminal T3 and the fourth terminal T4 are flush or approximately flush, and the lower edges of the third terminal T3 and the fourth terminal T4 are flush or approximately flush. Within the length overlap range of the first section terminal T01 and the second section terminal T02, the fourth terminal T4 and the third terminal T3 can be 100% or approximately 100% overlapped, and the graphic structures of the two within the length overlap range can be completely consistent or approximately consistent, so that the two can have a larger overlap area along the first direction X, thereby greatly reducing ESL. Optionally, the offset distance between the opposite edges of the third terminal T3 and the fourth terminal T4 does not exceed 0.2mm, so that the edges of the third terminal T3 and the fourth terminal T4 on both sides of the first direction X meet the alignment condition.

[0191] It should be noted that in the relative areas where the edges of the first terminal T1 and the second terminal T2 meet the flush condition and the relative areas where the edges of the third terminal T3 and the fourth terminal T4 meet the flush condition, through holes penetrating the terminals can be added in the relative areas based on assembly requirements.

[0192] like Figure 11-Figure 14 As shown, the fourth terminal T4 also includes a third segment terminal T03 connected to the second segment terminal T02; the third segment terminal T03 is parallel to the second direction Y and extends toward the capacitor component 2; wherein the third segment terminal T03 and the second terminal T2 have a first overlapping area A1 in the first direction X, and the two are connected in the first overlapping area A1; the third terminal T3 and the first terminal T1 are connected via the adapter terminal T5.

[0193] The third section terminal T03 is perpendicular to the second section terminal T02. The third section terminal T03 is the outlet end of the fourth terminal T4, which is used to directly connect to the second terminal T2. With surface 3 as a reference, the third section terminal T03 is perpendicular to surface 3, so the fourth terminal T4 is a vertical outlet structure, and its welding surface faces Fig.11 The third terminal T3 can be connected to the transfer terminal T5 at the first section terminal T01. The first section terminal T01 is the outlet of the third terminal T3. With surface 3 as a reference, the first section terminal T01 is parallel to surface 3, so the third terminal T3 is a parallel outlet structure, and its welding surface faces Fig.11 In this manner, the welding surface of the third terminal T3 and the welding surface of the fourth terminal T4 are perpendicular to each other, and two more sufficient different connection positions can be formed in a limited space, which is convenient for connecting the terminals between the capacitor assembly 2 and the power module 1.

[0194] exist Figure 11-Figure 14 In the illustrated manner, the second section terminal T02 and the third section terminal T03 of the fourth terminal T4 are vertically bent structures. The fourth terminal T4 can form a first overlapping area A1 in the first direction X based on the third section terminal T03 and the second terminal T2 extending toward the capacitor assembly 2, so as to facilitate the connection of the fourth terminal T4 and the second terminal T2 in the first overlapping area A1. Moreover, a connection window for connection in the first overlapping area A1 can be formed between the first terminal T1 and the third terminal T3, so as to facilitate the connection between the fourth terminal T4 and the second terminal T2.

[0195] Optionally, in the first direction X, the third terminal T3 exposes at least part of the third section terminal T03 to form a connection window between the third section terminal T03 and the counterpart (the second terminal T2) to facilitate the connection between the third section terminal T03 and the second terminal T2. The length of the third section terminal T03 exposed by the third terminal T3 does not exceed 10 mm, and the specific value can be adjusted according to actual needs. Fig.11 In the illustrated manner, in the first direction X, the third terminal T3 exposes the entire third segment terminal T03.

[0196] like Fig.13 As shown, the width of the third terminal T03 may be W3+, and the width W3+ of the third terminal T03 may be set to be the same or approximately the same as the width W2 of the fourth terminal T4 in the second region D2.

[0197] Relative to Figure 6-Figure 8 As shown, Figure 11-Figure 14 In the manner shown, under the same size of the first area D1 to the fourth area D4 (the length of the extension path from the first area D1 to the fourth area D4 remains unchanged), the length of the current loop where the positive and negative terminals of the power module 1 and the capacitor assembly 2 are located can be unchanged, so that the terminals of the first area D1 to the fourth area D4 have a larger width, and the positive and negative terminals have a larger overlapping area in the relative area. The W1 value of the positive and negative terminals of the power module 1 in the first area D1 with the smallest width is also Figure 6-Figure 8At least twice of W1 in the manner shown. In addition, in the first region D1 to the fourth region D4, the stacked positive and negative terminals have an overlap degree close to 100%, which can have a larger coupling coefficient k. Combined with the above formula (3), when k is larger, the ESL can be effectively reduced.

[0198] In the first direction X, there is a gap between the third terminal T3 and the first terminal T1 that exposes the first overlapping area A1, and the transition terminal T5 covers the gap. Based on the gap between the third terminal T3 and the first terminal T1, a connection window can be formed for connecting the fourth terminal T4 and the second terminal T2 in the first overlapping area A1, which facilitates the connection between the fourth terminal T4 and the second terminal T2.

[0199] like Fig.11 As shown, the adapter terminal T5 and the first terminal T1 have a second overlapping area A2 in the first direction X, and the two are connected in the second overlapping area A2; the adapter terminal T5 and the third terminal T3 have a third overlapping area A3, and the two are connected in the third overlapping area A3. The adapter terminal T5 can be connected to the first terminal T1 and the third terminal T3 respectively based on the second overlapping area A2 and the third overlapping area A3, and the positions of the second overlapping area A2 and the third overlapping area A3 relative to the first overlapping area A1 can be adjusted so that the gap between the third terminal T3 and the first terminal T1 can form a connection window for connecting the fourth terminal T4 and the second terminal T2 in the first overlapping area A1, so as to facilitate the connection between the capacitor component 2 and the power module 1.

[0200] Optionally, the first overlapping area A1 and the second overlapping area A2 do not overlap in the first direction X, and the first overlapping area A1 and the second overlapping area A2 are designed to be offset in the first direction X. If the first overlapping area A1 and the second overlapping area A2 have an overlapping portion in the first direction X, the overlapping portion has a greater thickness in the first direction X, which will increase the volume of the product.

[0201] In one way, Fig.11 As shown, in the second direction Y, the distance between the first overlapping area A1 and the capacitor component 2 is greater than the distance between the second overlapping area A2 and the capacitor component 2, that is, with the surface 3 as a reference, the minimum height of the first overlapping area A1 is greater than the maximum height of the second overlapping area A2. In this way, when the length of the third segment terminal T03 is constant, the second overlapping area A2 can be arranged using the space between it and the surface 3 to avoid the product having a large thickness in the second direction Y.

[0202] In one way, Fig.11As shown, the adapter terminal T5 and the third terminal T3 have a third overlapping area A3, and the two are connected in the third overlapping area A3. This method can realize the connection between the adapter terminal T5 and the third terminal T3 in the third overlapping area A3, and can also form a larger overlapping area based on the third overlapping area A3 and the fourth terminal T4, thereby reducing ESL.

[0203] Alternatively, if Fig.11 As shown, the adapter terminal T5 and the first segment terminal T01 have a third overlapping area A3 in the second direction Y. At this time, the adapter terminal T5 can be directly connected to the first segment terminal T01, and there is no need for the third terminal T3 to set other segment terminals connected to the first segment terminal T01, so that the design of the third terminal T3 is relatively simple. In this way, the adapter terminal T5 and the third terminal T3 have a stacked portion in the second direction Y to form a third overlapping area A3, and have a stacked portion with the first terminal T1 in the first direction X to form a second overlapping area A2. The third segment terminal T03 and the second terminal T2 form a first overlapping area A1 in the first direction X, and the connection directions of the third terminal T3 and the fourth terminal T4 of the power module 1 are perpendicular to each other.

[0204] refer to Fig.15 , Fig.15 This is a side view of a terminal connection structure of a power module and a capacitor assembly in a power assembly provided in an embodiment of the present application. Based on the above implementation, Fig.15 In the illustrated embodiment, the third terminal T3 further includes a fourth terminal T04 connected to the first terminal T01; the fourth terminal T04 is parallel to the second direction Y and extends away from the capacitor assembly 2; the transfer terminal T5 and the fourth terminal T04 have a third overlapping area A3 in the first direction X. In this embodiment, the outlet end of the third terminal T3 is the fourth terminal T04, and the fourth terminal T04 is perpendicular to the surface 3. With the surface 3 as a reference, the third terminal T3 is a vertical outlet structure, and its welding surface faces Fig.15 on the right side of the screen. Fig.15 In the manner shown, the design of the positive and negative terminals in the capacitor assembly 2 can be Fig.11 This method can also increase the terminal width and the overlapping area of ​​the positive and negative terminals, and can reduce ESL.

[0205] The fourth terminal T04 is used as a connection window for connecting to the connecting counterpart (transfer terminal T5), and its length may not exceed 10 mm, and the length may be increased as required. Optionally, the fourth terminal T04 may be set to have the same or approximately the same width as the first terminal T01.

[0206] Fig.15In the illustrated manner, the connection areas in each overlapping area are indicated by shaded ellipses. The third terminal T3 and the fourth terminal T4 are both vertical outlet structures, and the graphic structures of the third terminal T3 and the fourth terminal T4 are symmetrical, which facilitates the structural design of the terminals in the power module 1. At the same time, the adapter terminal T5 can be connected to the fourth segment terminal T04 and the first terminal T1 in the same direction, which facilitates the connection and assembly of the adapter terminal T5.

[0207] In the embodiment of the present application, Fig.15 As shown, an insulating member 5 is provided between the first terminal T1 and the second terminal T2; and an insulating member 5 is provided between the third terminal T3 and the fourth terminal T4. Based on the insulating member 5, the positive and negative terminals of the capacitor assembly 2 can be insulated and isolated when the terminal spacing is small, and the positive and negative terminals of the power module 1 can be insulated and isolated when the terminal spacing is small. While ensuring the insulation isolation of the positive and negative terminals, the positive and negative terminals have a small terminal spacing in the parallel opposite parts, which can reduce ESL.

[0208] Optionally, the insulating member 5 may be an insulating layer or an insulating plastic shell covering the surface of the terminal. The embodiment of the present application does not limit the implementation of the insulating member 5.

[0209] refer to Fig.16 , Fig.16 A side view of a terminal connection structure of a power module and a capacitor assembly in another power assembly provided in an embodiment of the present application, Fig.15 The difference between the methods shown is that Fig.16 In the illustrated embodiment, the fourth terminal section T04 is parallel to the second direction Y and extends toward the capacitor assembly 2 ; the transfer terminal T5 and the fourth terminal section T04 have a third overlapping area A3 in the first direction X. Fig.16 In this way, the fourth segment terminal T04 is bent toward the capacitor component 2, which can reduce the height of the third overlapping area A3 relative to the surface 3, thereby reducing the thickness of the power component in the second direction Y. Fig.16 In the manner shown, the design of the positive and negative terminals in the capacitor assembly 2 can be Fig.11 This method can also increase the terminal width and the overlapping area of ​​the positive and negative terminals, and can reduce ESL.

[0210] exist Fig.16 In the illustrated embodiment, the third terminal T3 and the fourth terminal T4 are both vertically bent structures, and the fourth section terminal T04 and the third section terminal T03 are both bent toward the capacitor component 2, both are perpendicular to the surface 3, and both are vertical outlet structures, and the connection windows of the two are both facing Fig.16 on the right side of the screen.

[0211] The third terminal T3 includes a vertical first section terminal T01 and a fourth section terminal T04. The length and width of the first section terminal T01 and the fourth section terminal T04 can be set according to requirements. The fourth section terminal T04 is a connection window for connecting to the transfer terminal T5. The length of the fourth section terminal T04 may not exceed 10 mm. The through-hole structure in the third terminal T3 may be designed according to product assembly requirements.

[0212] The fourth terminal T4 includes a vertical second section terminal T02 and a third section terminal T03, and the length and width of the second section terminal T02 and the third section terminal T03 can be set according to requirements. The third section terminal T03 is a connection window for direct connection with the second terminal T2. The length of the third section terminal T03 may not exceed 10 mm. The fourth terminal T4 may be designed with a through-hole structure according to product assembly requirements.

[0213] like Fig.16 As shown, in the second direction Y, the distance between the third overlapping area A3 and the capacitor component 2 is greater than the distance between the first overlapping area A1 and the capacitor component 2; and the distance between the second overlapping area A2 and the capacitor component 2 is less than the distance between the first overlapping area A1 and the capacitor component 2. In other words, the height of the third overlapping area A3 is greater than the height of the first overlapping area A1, and the height of the first overlapping area A1 is greater than the height of the second overlapping area, so that a connection window exposing the first overlapping area A1 can be formed between the third overlapping area A3 and the second overlapping area A2, so that the third segment terminal T03 and the second terminal T2 can be connected in the first overlapping area A1 based on the connection window.

[0214] Alternatively, if Fig.16 As shown, in the first direction X, the first overlapping area A1 and the third overlapping area A3 have no relative parts, and have no relative parts with the second overlapping area A2, so as to avoid the connection areas in the two overlapping areas having overlapping parts in the first direction X, resulting in the need to reserve a larger spacing between the terminals in the first direction X to ensure the insulation isolation of the connection areas.

[0215] In the embodiment of the present application, the connection between the first terminal T1 and the third terminal T3 is achieved based on the adapter terminal T5, which can also achieve the technical effect of reducing ESL without increasing product cost and process complexity.

[0216] refer to Fig.17 , Fig.17A side view of a terminal connection structure of a power module and a capacitor assembly in another power assembly provided in an embodiment of the present application, based on the above embodiment, the fourth terminal T4 also includes a third segment terminal T03 connected to the second segment terminal T02; the third terminal T3 also includes a fourth segment terminal T04 connected to the first segment terminal T01; the third segment terminal T03 and the fourth segment terminal T04 both extend away from the capacitor assembly 2; the fourth segment terminal T04 and the first terminal T1 are connected at one end away from the capacitor assembly 2 to form a first connection area B1; the third segment terminal T03 and the second terminal T2 are connected at one end away from the capacitor assembly 2 to form a second connection area B2; in the second direction Y, the distance between the second connection area B2 and the capacitor assembly 2 is less than the distance between the first connection area B1 and the capacitor assembly 2. This method can also increase the terminal width and the overlapping area of ​​the positive and negative terminals, and can reduce ESL.

[0217] exist Fig.17 In the shown manner, the end of the first terminal T1 away from the capacitor assembly 2 can be directly connected to the end of the third terminal T3 away from the power module 1, and the end of the second terminal T2 away from the capacitor assembly 2 can be directly connected to the end of the fourth terminal T4 away from the power module 1. The connection between the corresponding terminals of the power module 1 and the capacitor assembly 2 can be achieved without the adapter terminal T5.

[0218] like Fig.17 As shown, the fourth section terminal T04 and the first terminal T1 have a relative portion C in the first direction X; the third section terminal T03 and the second terminal T2 have a first overlapping area A1 in the first direction X; the first overlapping area A1 includes an end of the second connection area B2 located in the accommodation space formed by the relative portion C. This method can reuse the accommodation space formed by the relative portion C to accommodate at least part of the first overlapping area A1, can reduce the space occupied by the first overlapping area A1 in the second direction Y, and can reduce the size of the product.

[0219] Alternatively, if Fig.17 As shown, in the relative portion C, the fourth terminal T04 and the first terminal T1 both protrude toward the side away from the first overlapping area A1 to form a receiving space. Based on the outwardly protruding design, the fourth terminal T04 and the first terminal T1 can form a receiving space of a sufficiently large size so that at least the end of the first overlapping area A1 can be placed in the receiving space. In other embodiments, the first terminal T1 and the third terminal T3 of the folded line structure can also form a square or triangular receiving space above the first overlapping area A1. The relative portion C is not limited to Fig.17 The arc-shaped outward protruding design shown.

[0220] It can be known from the above description that in the embodiment of the present application, if the power component includes a power generation control module 102, the three-phase sub-power modules in the power generation control module 102 can share the same positive terminal and the same negative terminal, that is, the three-phase sub-power modules share the same third terminal T3 and the same fourth terminal T4, which can reduce two positive terminals and two negative terminals relative to the solution in which the three-phase sub-power modules in the same power generation control module 102 have a set of positive and negative terminals respectively. If the power component includes a drive control module 101, the structure of the drive control module 101 is not limited to the above embodiment, and the three sub-power modules in the drive control module 101 can also be a full-bridge circuit, sharing the same positive terminal and the same negative terminal, and the three-phase sub-power modules in the drive control module 101 share the same third terminal T3 and the same fourth terminal T4. Based on the terminal sharing design, the material cost can be reduced. The drive control module 101 can also adopt other multi-phase full-bridge circuits. The embodiment of the present application does not limit the circuit structure in the power module 1.

[0221] Moreover, the technical solution of the present application can also realize a large-area stacking design between the first terminal T1 and the second terminal T2, and between the third terminal T3 and the fourth terminal T4. The entire current loop can adopt a wide-width terminal design, which functionally solves the problem of excessive ESL, reduces the bus surge voltage, and optimizes the switching loss of the module. In addition, based on the graphic structure design of the third terminal T3 and the fourth terminal T4 in the power module 1 provided in the embodiment of the present application, the first terminal T1 and the second terminal T2 led by the capacitor component 2 can be made simple in structure, reducing the material cost of the capacitor component 2.

[0222] In some implementations of the technical solution of the present application, the connection between the first terminal T1 and the third terminal T3 can also be achieved based on the adapter terminal T5, and the terminal structure of the power module 1 and the capacitor assembly 2 can be optimized by setting the shape of the adapter terminal T5.

[0223] In this application, the terminals can be connected by laser welding, and the contact resistance between the terminals is small, which reduces the risk of thermal failure. In addition, the welding method increases the connection strength of the connection position, and its vibration durability reliability is higher than that of the screw connection method, and the assembly efficiency is higher.

[0224] Based on the power components provided in the above embodiments, another embodiment of the present application further provides a preparation method for preparing the power components provided in any one of the above embodiments. The preparation method can be as follows: Fig.18 shown.

[0225] refer to Fig.18 , Fig.18 A schematic diagram of a process for preparing a power module provided in an embodiment of the present application, combined with Fig.18 As shown in the structural diagram of the power component in the above embodiment, the preparation method includes:

[0226] Step S11: stacking the power module 1 and the capacitor assembly 2; the surface 3 of the capacitor assembly 2 facing the power module 1 is connected with an insulated first terminal T1 and a second terminal T2; the first terminal T1 and the second terminal T2 are arranged opposite to each other in a first direction X; the same end 4 of the power module 1 is connected with an insulated third terminal T3 and a fourth terminal T4; the end 4 faces the first terminal T1 and the second terminal T2; the third terminal T3 includes a first section terminal T01 connected to the end 4, and the fourth terminal T4 includes a second section terminal T02 connected to the end 4; the first section terminal T01 and the second section terminal T02 are parallel to the first direction X, and are arranged opposite to each other in a second direction Y; wherein the second direction Y is parallel to the stacking direction of the power module 1 and the capacitor assembly 2, and the first direction X is perpendicular to the second direction Y;

[0227] Step S12: Connect the first terminal T1 and the third terminal T3, and connect the second terminal T2 and the fourth terminal T4.

[0228] The preparation method provided in the embodiment of the present application can be used to prepare the power components of the above embodiment, so that a larger stacking area is formed between the positive and negative terminals of the capacitor component 2 in the power component and between the positive and negative terminals of the power module 1. In the second direction Y, the positive terminal and the negative terminal can achieve 100% or approximately 100% overlap, that is, the vertical projections of the positive terminal and the negative terminal on the surface 3 can coincide with or approximately coincide with the vertical projection of the negative terminal on the surface 3, thereby reducing the ESL of the entire current loop. At the same time, the terminals are fixedly connected by a connection method, and the assembly process is simpler and more convenient.

[0229] In one embodiment, the method of connecting the first terminal T1 and the third terminal T3, and connecting the second terminal T2 and the fourth terminal T4 includes: after connecting the end of the second terminal T2 away from the capacitor component 2 and the end of the fourth terminal T4 away from the power module 1, connecting the end of the first terminal T1 away from the capacitor component 2 and the end of the third terminal T3 away from the power module 1. The second terminal T2 and the fourth terminal T4 can be directly connected. The first terminal T1 and the third terminal T3 can be connected through the transfer terminal T5, or the two can be directly connected.

[0230] If the first terminal T1 and the third terminal T3 are directly connected to prepare Fig.17 Taking the power component of the structure shown in FIG. 1 as an example, the principle of connecting the terminals of the capacitor component 2 and the power module 1 can be as follows: Fig.19 and Fig. 20 shown.

[0231] refer to Fig.19and Fig. 20 , Fig.19 and Fig. 20 The schematic diagram is a principle diagram of a terminal connection method according to an embodiment of the present application, the method comprising:

[0232] First, if Fig.19 As shown, the capacitor assembly 2 and the power module 1 are stacked and assembled. Before the terminals of the capacitor assembly 2 and the power module 1 are connected, as shown in FIG. Fig.19 As shown, the second terminal T2 located on the inner side of the capacitor component 2 is perpendicular to the surface 3, and the first terminal T1 on the outer side of the capacitor component 2 includes a fifth segment terminal T05 and a sixth segment terminal T06. The fifth segment terminal T05 is vertically connected to the surface 3. The sixth segment terminal T06 is connected to the end of the fifth segment terminal T05 away from the capacitor component 2. The sixth segment terminal T06 is bent toward the outside and has an angle a with the first direction X, and a is less than 90°. Optionally, the value of a can be 70°~80°. Before the terminals of the capacitor component 2 and the power module 1 are connected, as shown Fig.19 As shown, the fourth section terminal T04 is bent inwards and has an included angle b with the first section terminal T01, where b is less than 90°. Optionally, the value of b may be 70° to 80°.

[0233] Then, if Fig. 20 As shown, the end of the second terminal T2 away from the capacitor assembly 2 and the end of the fourth terminal T4 away from the power module 1 are connected. Due to the angles a and b, an outward-expanding bell-mouth structure can be formed between the fourth section terminal T04 and the sixth section terminal T06. The outward-expanding bell-mouth structure can serve as a welding window between the third section terminal T03 and the second terminal T2, facilitating the welding of the third section terminal T03 and the second terminal T2. Based on the welding window formed by a and b, the second terminal T2 and the fourth terminal T4 are welded and fixed. Based on the welding window formed by a and b, the second terminal T2 and the fourth terminal T4 are welded and fixed.

[0234] Finally, increase a and b, and make the end of the fourth section terminal T04 away from the first section terminal T01 and the end of the sixth section terminal T06 away from the fifth section terminal T05 contact each other and weld them to form a Fig.17 The power assembly of the structure shown. In this step, the fourth section terminal T04 and the sixth section terminal T06 can be fixed relatively at the ends by the tooling, and then the ends of the two can be connected. Optionally, the tooling can be adapted to increase a and b, and the end of the fourth section terminal T04 away from the first section terminal T01 and the end of the sixth section terminal T06 away from the fifth section terminal T05 can be brought into relative contact for welding and fixing.

[0235] For ease of illustration, Fig.19 and Fig. 20The insulating member 5 is not shown in the figure. The implementation of the insulating member 5 can refer to the above description, and this embodiment will not be repeated.

[0236] for Fig.19 and Fig. 20 In actual applications, if the sixth terminal T06 is not suitable for direct design into an external expansion structure due to factors such as assembly and sealing, it can be used Fig.21 or Fig. 22 The capacitor assembly 2 of the structure shown is connected to the power module 1 between terminals.

[0237] refer to Fig.21 , Fig.21 Schematic diagram of the terminal structure of a capacitor assembly before being connected and assembled with a power module. In this method, the first terminal T1 includes a separated fifth-segment terminal T05 and a sixth-segment terminal T06. After the main body of the capacitor assembly 2 completes the necessary assembly / potting and other processes, Fig.21 As shown, the fifth section terminal T05 and the sixth section terminal T06 are connected and fixed on the surface 3, and then Fig.19 and Fig. 20 As shown, corresponding connections are made with the terminals of the power module 1 to form a Fig.17 Power components of the structure shown.

[0238] refer to Fig. 22 , Fig. 22 FIG. 1 is a schematic diagram of another terminal structure of a capacitor assembly before being connected and assembled with a power module. In this method, the first terminal T1 is still an integrated structure. Before being connected with the power module 1, Fig. 22 As shown by the vertical dotted line in FIG. 3 , the first terminal T1 is an integral structure perpendicular to the surface 3. After the main body of the capacitor assembly 2 completes the necessary assembly / potting processes, Fig. 22 As shown, the first terminal T1 is bent into two parts, namely the fifth section terminal T05 and the sixth section terminal T06, by the correction tool 10. The specific shape and correction stroke of the correction tool 10 can be debugged and designed according to requirements, and the embodiment of the application does not limit this.

[0239] If the first terminal T1 and the third terminal T3 are connected via the adapter terminal T5, in the above text, the method of connecting the first terminal T1 and the third terminal T3 and connecting the second terminal T2 and the fourth terminal T4 includes: after connecting the second terminal T2 and the fourth terminal T4, using the adapter terminal T5 to connect the first terminal T1 and the third terminal T3.

[0240] If the first terminal T1 and the third terminal T3 can be connected via a transfer terminal T5, Fig.15Taking the power component of the structure shown in the figure as an example, when connecting the terminals of the capacitor component 2 and the power module 1, after the capacitor component 2 and the power module 1 are stacked and assembled, the third segment terminal T03 and the second terminal T2 are first connected in the first overlapping area A1 by laser welding, and then the adapter terminal T5 is assembled, and the adapter terminal T5 is connected to the first terminal T1 in the second overlapping area A2 by laser welding, and connected to the fourth segment terminal T04 in the third overlapping area A3, so that the following can be formed: Fig.15 The power component of the structure shown in FIG. The inner surface of the transfer terminal T5 is covered with an insulating member 5 to achieve insulation isolation between the second terminal T2 and the fourth terminal T4. Fig.16 The preparation process of the power module with the structure shown in the figure is similar to Fig.15 The corresponding method is the same and will not be described in detail in the embodiments of the present application.

[0241] Based on the power components provided in the above embodiments, another embodiment of the present application further provides a motor controller, including the above power components.

[0242] Based on the motor controller provided in the above embodiment, another embodiment of the present application further provides an electric control assembly, including the above motor controller.

[0243] Based on the electronic control assembly provided in the above embodiment, another embodiment of the present application further provides a vehicle, which includes the above electronic control assembly.

[0244] In the embodiment of the present application, the vehicle includes an extended-range vehicle, which has an independent motor drive requirement and an independent power generation requirement. In order to achieve these two requirements, the industry often integrates the motor drive (DC to AC) and the motor power generation (AC to DC) into an electronic control assembly with a dual-electric control structure. In this application scenario, due to the large packaging volume of the conventional full-bridge module and the constraint of the excessive size of the single unit, the pure mechanical integration size benefit of the drive control module and the power generation control module is low, and the size after integration is very large. At the same time, there are also problems such as excessive warping deformation, chip welding processability, and low application reliability, resulting in the two control modules can only be packaged separately. The technical solution of the present application can realize the integrated packaging of the two control modules, solving the above problems.

[0245] In addition, in conventional technology, there is a large ESL between the positive and negative terminals of the capacitor component and the power module. The technical solution of the present application can increase the overlapping area between the positive and negative terminals, which can greatly reduce the ESL, and thus solve the problems of large switching loss and low efficiency caused by excessive ESL.

[0246] In the embodiment of the present application, the vehicle includes a new energy vehicle, and the new energy vehicle includes an electric control assembly, so that the vehicle can be driven by electric energy. The power component in the electric control assembly can include a drive control module and a power generation control module at the same time. The new energy vehicle uses electric energy to drive the vehicle through the electric drive assembly. Taking the extended-range new energy vehicle as an example, its topological structure is as follows: Fig.23 shown.

[0247] refer to Fig.23 , Fig.23 A topological structure diagram of an extended-range new energy vehicle provided in an embodiment of the present application. Fig.23 In the figure, solid lines represent mechanical connections and dashed lines represent electrical connections.

[0248] like Fig.23 As shown, one of the core components of the extended-range new energy vehicle is the range extender 18, which includes: a generator motor 16 and a generator power assembly 15 connected thereto; the generator motor 16 is also connected to the engine 17. The generator power assembly 15 is connected to the power battery 14 and the inverter 13 respectively. The inverter 13 is connected to the drive motor 12, and the drive motor 12 is connected to the electric drive unit 11. The electric drive unit 11 includes a reducer and a differential.

[0249] Taking the extended-range new energy vehicle as an example, its core component is the range extender 18, whose main function is to start the range extender 18 when the power of the power battery 14 drops to a certain level, and the engine 17 drives the generator motor 16 to generate electricity. Part of the generated electricity can be used to supply the drive motor 12, and the other part can be used to charge the power battery 14.

[0250] Extended-range new energy vehicles have many advantages, including:

[0251] In daily commuting in the city, extended-range electric vehicles can run purely on electricity, with zero emissions, reducing tail gas pollution and meeting environmental protection requirements. At the same time, electric drive is more energy-efficient than fuel drive, reducing energy consumption and usage costs.

[0252] The extended-range electric vehicle is equipped with an engine 17 as a range extender. When the battery power is low, the engine 17 can start to generate electricity to provide continuous power for the vehicle, avoiding the additional problem of mileage anxiety caused by the limited cruising range of pure electric vehicles, making long-distance travel more convenient.

[0253] In addition, extended-range new energy vehicles also have the following advantages in driving experience:

[0254] Pure electric drive: The extended-range topology is essentially a pure electric drive system. The driving power of the vehicle is completely provided by the drive motor 12. The engine 17 does not directly participate in driving the vehicle, but plays the role of power generation. When the battery is low, it starts to convert fuel into electrical energy to power the drive motor 12 or charge the battery. This pure electric drive mode makes the vehicle's power source single and pure, which is consistent with the drive mode of pure electric vehicles, and fundamentally guarantees the comfort of the driving experience.

[0255] Rapid power response: The characteristics of the drive motor 12 determine that it can output maximum torque instantly. In a vehicle with an extended-range topology, when the driver steps on the accelerator pedal, the drive motor 12 can respond immediately and quickly output strong power to achieve fast starting and acceleration. This instant power response is far superior to traditional fuel vehicles, allowing the driver to feel a more direct and rapid push back. Whether it is frequent start-stop on urban roads or overtaking operations on highways, it can be easily handled, bringing a smooth driving experience.

[0256] No power interruption phenomenon: During the driving process of the extended-range vehicle, since it is always driven by the drive motor 12, there is no power interruption problem when shifting gears in traditional fuel vehicles. Whether driving at low speed or high speed, the power output remains continuous and stable. Even when the battery power is low and the engine starts to generate electricity, the system can ensure that the power output of the drive motor 12 is not affected through precise control strategies, and there will be no setbacks or power interruptions, thereby providing the driver with a consistent and stable driving experience and improving driving comfort and safety.

[0257] The power components of the extended-range new energy vehicle include the generator motor 16, the drive motor 12, the power components and other components. In the power components of the conventional extended-range new energy vehicle, the drive control module and the power generation control module are two independent components, each with an independent power module (for example, through diode semiconductors, IGBT semiconductors, SiC semiconductors, etc. to convert between AC and DC), current sensors, temperature sensors, motor rotor position sensors and other sensors. Its weight, volume and cost are relatively high, and optimization is urgently needed.

[0258] In the vehicle provided in the embodiment of the present application, the two control modules can be integrated into the same power component, which can reduce the overall weight and volume of the product, reduce the ESL in the current loop, and improve the performance of the electronic control assembly.

[0259] refer to Fig.24 , Fig.24An equivalent circuit diagram of a power component provided in an embodiment of the present application, the power component includes a drive control module 101 for connecting the drive motor 12 and a power generation control module 102 for connecting the power generation motor 16. The drive control module 101 includes a plurality of first sub-power modules 701, and the power generation control module 102 includes a plurality of second sub-power modules 702.

[0260] The first sub-power module 701 and the second sub-power module 702 each include a half-bridge circuit, and the half-bridge circuit includes an upper bridge arm circuit 901 and a lower bridge arm circuit 902. The upper bridge arm circuit 901 and the lower bridge arm circuit 902 each include a first power chip 905 and a second power chip 906 connected in parallel. The first power chip 905 may be an IGBT (insulated gate bipolar transistor), and may optionally be a SiC chip. The second power chip 906 may be an FRD (fast recovery diode). The collector of the IGBT is connected to the positive electrode of the FRD, and the emitter of the IGBT is connected to the negative electrode of the FRD.

[0261] For the first sub-power module 701, the two ends of the upper bridge arm circuit 901 are respectively connected to the positive bus 903 and an AC terminal of the drive motor 12, and the two ends of the lower bridge arm circuit 902 are respectively connected to the negative bus 904 and an AC terminal of the drive motor 12. In the same first sub-power module 701, the upper bridge arm circuit 901 and the lower bridge arm circuit 902 are connected to the same AC terminal of the drive motor 12. Different first sub-power modules 701 are connected to different AC terminals of the drive motor 12.

[0262] For the second sub-power module 702, the two ends of the upper bridge arm circuit 901 are respectively connected to the positive bus 903 and an AC end of the generator motor 16, and the two ends of the lower bridge arm circuit 902 are respectively connected to the negative bus 904 and an AC end of the generator motor 16. In the same second sub-power module 702, the upper bridge arm circuit 901 and the lower bridge arm circuit 902 are connected to the same AC end of the generator motor 16. Different first sub-power modules 701 are connected to different AC ends of the generator motor 16.

[0263] It should be noted that in the embodiments of the present application, the vehicle type is not limited to extended-range new energy vehicles, but can also be used for other types of vehicles, and the embodiments of the present application do not limit this.

[0264] In the specification of this application, each embodiment is described in a progressive, parallel, or progressive and parallel manner, and each embodiment focuses on the differences from other embodiments, and the same or similar parts between the embodiments can be referred to each other. The embodiments provided in the embodiments of this application can be combined with each other if there is no contradiction.

[0265] It should be noted that in the description of the present application, it should be understood that the description of the drawings and embodiments is illustrative rather than restrictive. The same reference numerals throughout the embodiments of the specification identify the same structure. In addition, for the sake of understanding and ease of description, the drawings may exaggerate the thickness of some layers, films, panels, regions, etc. It is also understood that when an element such as a layer, film, region, or substrate is referred to as "on" another element, the element may be directly on the other element or there may be an intermediate element. In addition, "on" refers to positioning an element on or below another element, but does not essentially refer to positioning on the upper side of another element according to the direction of gravity.

[0266] The terms "upper", "lower", "top", "bottom", "inner", "outer", etc. indicate positions or positional relationships based on the positions or positional relationships shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present application. When a component is considered to be "connected" to another component, it may be directly connected to the other component or there may be a centrally arranged component at the same time.

[0267] It should also be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "comprises", "comprising" or any other variants thereof are intended to cover non-exclusive inclusion, so that an article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such article or device. In the absence of further restrictions, the elements defined by the sentence "comprising a ..." do not exclude the existence of other identical elements in the article or device including the above elements.

[0268] The above description of the disclosed embodiments enables those skilled in the art to implement or use the present application. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to the embodiments shown herein, but will conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A power component, characterized in that: include: A stacked power module and capacitor assembly; The surface of the capacitor assembly facing the power module is connected with a first terminal and a second terminal insulated from each other; the first terminal and the second terminal are arranged opposite to each other in a first direction; The same end of the power module is connected to a third terminal and a fourth terminal insulated from each other; the end faces the first terminal and the second terminal; the third terminal includes a first section terminal connected to the end, and the fourth terminal includes a second section terminal connected to the end; the first section terminal and the second section terminal are parallel to the first direction and are arranged opposite to each other in the second direction; The second direction is parallel to the stacking direction of the power module and the capacitor assembly, and the first direction is perpendicular to the second direction; the first terminal is connected to the third terminal, and the second terminal is connected to the fourth terminal.

2. The power component according to claim 1, characterized in that: The vertical projections of the first terminal and the second terminal on a first plane at least partially overlap; the first plane is perpendicular to the first direction; and / or, vertical projections of the third terminal and the fourth terminal on the second plane at least partially overlap; The second plane is perpendicular to the second direction.

3. The power assembly according to claim 2, characterized in that: The edges of the first terminal and the second terminal on both sides of the second direction meet the flush condition; And / or, edges of the third terminal and the fourth terminal located on both sides of the first direction meet an alignment condition.

4. The power component according to claim 3, characterized in that: The offset distance between the edges of the first terminal and the second terminal relative to each other does not exceed 0.2 mm; The misalignment distance between the edges of the third terminal and the fourth terminal relative to each other does not exceed 0.2 mm.

5. The power component according to any one of claims 1 to 4, characterized in that: The fourth terminal is located between the third terminal and the capacitor component; The second terminal is located between the first terminal and the end portion.

6. The power component according to claim 5, characterized in that: The fourth terminal further includes a third section terminal connected to the second section terminal; the third section terminal is parallel to the second direction and extends toward the capacitor component; The third section terminal and the second terminal have a first overlapping area in the first direction, and the third section terminal and the second terminal are connected in the first overlapping area.

7. The power assembly according to claim 6, characterized in that: The third terminal and the first terminal are connected via a transfer terminal.

8. The power assembly according to claim 7, characterized in that: In the first direction, there is a gap between the third terminal and the first terminal exposing the first overlapping area, and the transfer terminal covers the gap.

9. The power assembly according to claim 7, characterized in that: The transfer terminal and the first terminal have a second overlapping area in the first direction, and the transfer terminal is connected to the first terminal in the second overlapping area; The transfer terminal and the third terminal have a third overlapping area, and the transfer terminal and the third terminal are connected in the third overlapping area.

10. The power assembly according to claim 9, characterized in that: The first overlapping region and the second overlapping region do not overlap in the first direction.

11. The power assembly according to claim 10, characterized in that: In the second direction, a distance between the first overlapping region and the capacitor component is greater than a distance between the second overlapping region and the capacitor component.

12. The power assembly according to claim 9, characterized in that: The transfer terminal and the first segment terminal have the third overlapping area in the second direction.

13. The power assembly according to claim 9, characterized in that: The third terminal further includes a fourth section terminal connected to the first section terminal; the fourth section terminal is parallel to the second direction and extends away from the capacitor component; The transfer terminal and the fourth-section terminal have the third overlapping area in the first direction.

14. The power assembly according to claim 9, characterized in that: The third terminal further includes a fourth section terminal connected to the first section terminal; the fourth section terminal is parallel to the second direction and extends toward the capacitor component; The transfer terminal and the fourth-section terminal have the third overlapping area in the first direction.

15. The power assembly according to claim 14, characterized in that: In the second direction, the distance between the third overlapping area and the capacitor component is greater than the distance between the first overlapping area and the capacitor component; and the distance between the second overlapping area and the capacitor component is less than the distance between the first overlapping area and the capacitor component.

16. The power assembly according to claim 5, characterized in that: The fourth terminal further includes a third section terminal connected to the second section terminal; the third terminal further includes a fourth section terminal connected to the first section terminal; the third section terminal and the fourth section terminal both extend away from the capacitor assembly; The fourth section terminal and the first terminal are connected at an end away from the capacitor component to form a first connection area; the third section terminal and the second terminal are connected at an end away from the capacitor component to form a second connection area; in the second direction, the distance between the second connection area and the capacitor component is smaller than the distance between the first connection area and the capacitor component.

17. The power assembly according to claim 16, characterized in that: The fourth section terminal and the first terminal have opposite parts in the first direction; The third section terminal and the second terminal have a first overlapping area in the first direction; the first overlapping area includes an end of the second connection area located in the accommodating space formed by the relative parts.

18. The power assembly according to claim 17, characterized in that: In the opposing portion, the fourth section terminal and the first terminal both protrude toward a side away from the first overlapping region to form the accommodation space.

19. The power component according to any one of claims 6 to 18, characterized in that: In the first direction, the third terminal exposes at least a portion of the third section terminal.

20. The power component according to any one of claims 1 to 18, characterized in that: An insulating member is provided between the first terminal and the second terminal; And / or, an insulating member is provided between the third terminal and the fourth terminal.

21. The power component according to any one of claims 1 to 18, characterized in that: The first terminal and the third terminal are fixedly connected by welding, and the second terminal and the fourth terminal are fixedly connected by welding.

22. The power component according to any one of claims 1 to 18, characterized in that: At least one of the first terminal, the second terminal, the third terminal and the fourth terminal has a thickness of 1 mm to 2 mm.

23. The power assembly according to any one of claims 1 to 18, characterized in that: The distance between the first terminal and the second terminal is 1.5 mm to 2 mm; And / or, the distance between the third terminal and the fourth terminal is 1.5 mm to 2 mm.

24. The power component according to any one of claims 1 to 18, characterized in that: The first section terminal comprises an integrated first part and a second part, the first part is connected to the end portion, and the second part is located on a side of the first part away from the end portion; wherein the width of the first portion is smaller than the width of the second portion; Alternatively, the width of the first portion is equal to the width of the second portion.

25. The power component according to any one of claims 1 to 18, characterized in that: The first terminal and the second terminal both include an integral third part and a fourth part; in the same terminal, the fourth part is connected to the surface, and the third part is located on a side of the fourth part away from the surface; Wherein, the width of the third portion is smaller than the width of the fourth portion; Alternatively, the width of the third portion is equal to the width of the fourth portion.

26. The power component according to any one of claims 1 to 18, characterized in that: The first section terminal comprises an integrated first part and a second part, the first part is connected to the end portion, and the second part is located on a side of the first part away from the end portion; The first terminal and the second terminal both include an integral third part and a fourth part; in the same terminal, the fourth part is connected to the surface, and the third part is located on a side of the fourth part away from the surface; The width of the first portion is smaller than the width of the second portion, the width of the second portion is equal to the width of the third portion, and the width of the third portion is smaller than the width of the fourth portion.

27. The power component according to any one of claims 1 to 26, characterized in that: The power assembly includes at least one of a drive control module and a power generation control module; the drive control module is used to connect to a drive motor; the power generation control module is used to connect to a power generation motor; Wherein, the driving control module and the power generation control module both include the power module and the capacitor assembly which are stacked.

28. The power assembly according to claim 27, characterized in that: The power assembly includes both the drive control module and the power generation control module; Wherein, the driving control module and the power generation control module share the same capacitor component.

29. The power assembly according to claim 27, characterized in that: The drive control module includes a plurality of first sub-power modules, each of which has an independent liner; The power generation control module includes a plurality of second sub-power modules, and the second sub-power modules share a same liner.

30. The power assembly according to claim 29, characterized in that The driving control module includes three of the first sub-power modules; and the power generation control module includes three of the second sub-power modules.

31. The power assembly according to claim 27, characterized in that: The first terminal and the third terminal are connected based on a transfer terminal; The power generation control module and the drive control module share the same transfer terminal.

32. A method for preparing a power component, characterized in that: include: The power module and the capacitor assembly are stacked; the surface of the capacitor assembly facing the power module is connected with a first terminal and a second terminal insulated from each other; the first terminal and the second terminal are arranged oppositely in the first direction; the same end of the power module is connected with a third terminal and a fourth terminal insulated from each other; the end faces the first terminal and the second terminal; the third terminal includes a first section terminal connected to the end, and the fourth terminal includes a second section terminal connected to the end; the first section terminal and the second section terminal are parallel to the first direction and are arranged oppositely in the second direction; wherein the second direction is parallel to the stacking direction of the power module and the capacitor assembly, and the first direction is perpendicular to the second direction; The first terminal and the third terminal are connected, and the second terminal and the fourth terminal are connected.

33. The preparation method according to claim 32, characterized in that: Connecting the first terminal and the third terminal, and connecting the second terminal and the fourth terminal, comprises: After connecting one end of the second terminal away from the capacitor assembly and one end of the fourth terminal away from the power module, connect one end of the first terminal away from the capacitor assembly and one end of the third terminal away from the power module; Alternatively, after the second terminal and the fourth terminal are connected in the first overlapping area, a transfer terminal is used to connect the first terminal and the third terminal.

34. The preparation method according to claim 33, characterized in that: The fourth terminal further includes a third section terminal connected to the second section terminal; the third terminal further includes a fourth section terminal connected to the first section terminal; the third section terminal and the fourth section terminal both extend away from the capacitor assembly; The first terminal includes a fifth section terminal and a sixth section terminal, the fifth section terminal is vertically connected to the surface; the sixth section terminal is connected to an end of the fifth section terminal away from the capacitor assembly; The method of connecting the capacitor assembly and the terminal of the power module includes: The sixth section terminal is bent toward the outside and has an included angle a with the first direction; the fourth end terminal is bent toward the inside and has an included angle b with the first section terminal; a and b are both less than 90°; based on the welding window formed by a and b, the second terminal and the fourth terminal are welded and fixedly connected; After increasing a and b, one end of the fourth section terminal away from the first section terminal and one end of the sixth section terminal away from the fifth section terminal are brought into relative contact and fixed by welding.

35. The preparation method according to claim 34, characterized in that: Before welding the second terminal and the fourth terminal, the angles of a and b are between 70° and 80°.

36. A motor controller, characterized in that: Comprising a power component as described in any one of claims 1-31.

37. An electronic control assembly, characterized in that: Comprising a motor controller as claimed in claim 36.

38. A vehicle, characterized in that: include: The electronic control assembly as claimed in claim 37.

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