Power assembly and preparation method thereof, power module and equipment comprising power module

Abstract

The invention discloses a power assembly and a preparation method thereof, a power module and equipment comprising the power module, and relates to the field of vehicle motor control equipment, and the power assembly comprises the power module and a capacitor assembly which are stacked; the capacitor assembly is connected with a first terminal and a second terminal; the power module comprises a plurality of sub power modules; the power module comprises at least one third terminal and at least one fourth terminal; at least two sub power modules are connected with a third terminal and a fourth terminal; the first terminal is connected with the third terminal, and the second terminal is connected with the fourth terminal. According to the technical scheme, the power module and the capacitor assembly are arranged in the stacked mode, compared with a conventional scheme that the power module and the capacitor assembly are connected in a coplanar mode, the layout area of the power assembly can be reduced, and miniaturization design of the power assembly is facilitated; and the at least two sub-power modules share the third terminal and the fourth terminal, so that the number of terminals and 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 power module, and a device including the power module. Background Art

[0002] In conventional power assemblies, the power module and capacitor assembly are typically placed on the same plane, with the positive DC terminal of the power module connected to the positive DC terminal of the capacitor assembly, and the negative DC terminal of the power module connected to the negative DC terminal of the capacitor assembly. In this approach, because the capacitor assembly and power module are placed on the same plane, the power assembly occupies a larger layout area. Summary of the Invention

[0003] In view of the above problems, the present application provides a power component and its preparation method, a power module, and a device including the power module, to at least achieve the purpose of reducing the layout area of ​​the power component. The specific solution is as follows:

[0004] A first aspect of the present application provides a power component, including:

[0005] A stacked power module and capacitor assembly;

[0006] The capacitor assembly is connected to a first terminal and a second terminal;

[0007] The power module includes a plurality of sub-power modules;

[0008] The power module includes at least one third terminal and at least one fourth terminal;

[0009] At least two sub-power modules are connected to a third terminal and a fourth terminal;

[0010] The first terminal and the third terminal are connected, and the second terminal and the fourth terminal are connected.

[0011] Optionally, in the above power component, a surface of the capacitor component facing the power module is connected to a first terminal and a second terminal.

[0012] Optionally, in the above power assembly, the first end of the power module is connected to a third terminal and a fourth terminal.

[0013] Optionally, in the above power component, the first end faces the first terminal and the second terminal.

[0014] Optionally, in the above power component, the first terminal and the second terminal are arranged opposite to each other in the first direction.

[0015] Optionally, in the above power component, the third terminal and the fourth terminal are arranged opposite to each other in the second direction.

[0016] Optionally, in the above power component, the third terminal includes a first-section terminal connected to the first end, and the fourth terminal includes a second-section terminal connected to the first end.

[0017] Optionally, in the above power component, the first section of terminals and the second section of terminals are parallel to the first direction and are arranged opposite to each other in the second direction.

[0018] Optionally, in the above power component, the first direction is parallel to a stacking direction of the power module and the capacitor component.

[0019] Optionally, in the above power component, the second direction is parallel to the stacking direction.

[0020] Optionally, in the above power component, 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;

[0021] 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.

[0022] Optionally, in the above power component, edges of the first terminal and the second terminal on both sides of the second direction meet a flush condition;

[0023] And / or, edges of the third terminal and the fourth terminal located on both sides of the first direction meet an alignment condition.

[0024] Optionally, in the above power component, the offset distance between the opposite edges of the first terminal and the second terminal does not exceed 0.2 mm;

[0025] The misalignment distance between opposite edges of the third terminal and the fourth terminal does not exceed 0.2 mm.

[0026] Optionally, in the above power component, the fourth terminal is located between the third terminal and the capacitor component;

[0027] The second terminal is located between the first terminal and the first end.

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

[0029] 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.

[0030] Optionally, in the above power component, the third terminal and the first terminal are connected via a transfer terminal.

[0031] Optionally, in the above power component, in the first direction, there is a gap between the third terminal and the first terminal, exposing the first overlapping area, and the transition terminal covers the gap.

[0032] 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;

[0033] 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.

[0034] Optionally, in the above power component, the first overlapping region and the second overlapping region do not overlap in the first direction.

[0035] 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.

[0036] Optionally, in the above power component, the transfer terminal and the first section terminal have a third overlapping area in the second direction.

[0037] 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;

[0038] The transfer terminal and the fourth-section terminal have a third overlapping area in the first direction.

[0039] 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;

[0040] The transfer terminal and the fourth-section terminal have a third overlapping area in the first direction.

[0041] Optionally, in the above-mentioned 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.

[0042] 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;

[0043] 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.

[0044] Optionally, in the above power component, the fourth section terminal and the first terminal have opposing portions in the first direction;

[0045] 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.

[0046] Optionally, in the above power component, 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 an accommodating space.

[0047] Optionally, in the above power component, in the first direction, the third terminal exposes at least a portion of the third section terminal.

[0048] Optionally, in the above power component, an insulating member is provided between the first terminal and the second terminal;

[0049] And / or, an insulating member is provided between the third terminal and the fourth terminal.

[0050] 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.

[0051] 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.

[0052] Optionally, in the above power component, the distance between the first terminal and the second terminal is 1.5 mm to 2 mm;

[0053] And / or, the distance between the third terminal and the fourth terminal is 1.5 mm to 2 mm.

[0054] Optionally, in the above power component, the first section terminal includes an integrated first part and a second part, the first part is connected to the first end, and the second part is located on a side of the first part away from the first end;

[0055] wherein the width of the first portion is smaller than the width of the second portion;

[0056] Alternatively, the width of the first portion is equal to the width of the second portion.

[0057] Optionally, in the above power component, the first terminal and the second terminal each include an integral third portion and a fourth portion; in the same terminal, the fourth portion is connected to the surface, and the third portion is located on a side of the fourth portion facing away from the surface;

[0058] wherein the width of the third portion is smaller than the width of the fourth portion;

[0059] Alternatively, the width of the third portion is equal to the width of the fourth portion.

[0060] Optionally, in the above power component, the first section terminal includes an integrated first part and a second part, the first part is connected to the first end, and the second part is located on a side of the first part away from the first end;

[0061] The first terminal and the second terminal each include an integral third portion and a fourth portion; in the same terminal, the fourth portion is connected to the surface, and the third portion is located on a side of the fourth portion facing away from the surface;

[0062] The width of the first part is smaller than that 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 that of the fourth part.

[0063] 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 to the drive motor; the power generation control module is used to connect to the power generation motor;

[0064] The driving control module and the power generation control module both include a stacked power module and a capacitor assembly.

[0065] Optionally, in the above power assembly, the power assembly includes both a drive control module and a power generation control module;

[0066] The drive control module and the power generation control module share the same capacitor component.

[0067] Optionally, in the above power component, the first terminal and the third terminal are connected based on a transfer terminal;

[0068] The power generation control module and the drive control module share the same transfer terminal.

[0069] Optionally, in the above power assembly, the sub-power module in the drive control module is a first sub-power module, the drive control module includes a plurality of first sub-power modules, and each of the first sub-power modules has an independent liner;

[0070] The sub-power module in the power generation control module is a second sub-power module. The power generation control module includes a plurality of second sub-power modules. The second sub-power modules share the same liner.

[0071] 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.

[0072] Optionally, in the above power assembly, the sub-power module in the drive control module is a first sub-power module, the drive control module includes a plurality of first sub-power modules, and the first sub-power modules are connected to the same third terminal and the same fourth terminal;

[0073] The sub-power module in the power generation control module is a second sub-power module. The power generation control module includes a plurality of second sub-power modules. The second sub-power modules are connected to the same third terminal and the same fourth terminal.

[0074] If the power assembly includes both a driving control module and a power generation control module, the first sub-power module and the second sub-power module are connected to different third terminals and different fourth terminals, respectively.

[0075] A second aspect of the present application provides a method for preparing any of the above-mentioned power components, comprising:

[0076] The power module and the capacitor assembly are stacked; the capacitor assembly is connected to a first terminal and a second terminal; the power module includes a plurality of sub-power modules; the power module includes at least one third terminal and at least one fourth terminal; at least two sub-power modules are connected to a third terminal and a fourth terminal;

[0077] The first terminal and the third terminal are connected, and the second terminal and the fourth terminal are connected.

[0078] Optionally, in the above preparation method, connecting the first terminal and the third terminal, and connecting the second terminal and the fourth terminal, includes:

[0079] After connecting the end of the second terminal away from the capacitor assembly and the end of the fourth terminal away from the power module, connect the end of the first terminal away from the capacitor assembly and the end of the third terminal away from the power module;

[0080] 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.

[0081] Optionally, in the above preparation method, a first terminal and a second terminal 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; a third terminal and a fourth terminal are connected to a first end portion of the power module; the first end portion faces the first terminal and the second terminal; the third terminal includes a first segment terminal connected to the first end portion, and the fourth terminal includes a second segment terminal connected to the first end portion; the first segment terminal and the second segment terminal are parallel to the first direction and are arranged opposite to each other in a 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 and the third terminal are connected, and the second terminal and the fourth terminal are connected;

[0082] 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 being vertically connected to the surface; the sixth section terminal being connected to an end of the fifth section terminal away from the capacitor assembly;

[0083] Methods for connecting the capacitor assembly to the terminals of the power module include:

[0084] The sixth section of terminals is bent outward and forms an angle a with the first direction; the fourth terminal is bent inward and forms an angle b with the first section of terminals; both a and b are less than 90°; the second terminal and the fourth terminal are welded and fixedly connected based on the welding window formed by a and b;

[0085] After increasing a and b, an end of the fourth section terminal away from the first section terminal and an end of the sixth section terminal away from the fifth section terminal are brought into contact with each other and fixed by welding.

[0086] Optionally, in the above preparation method, before welding the second terminal and the fourth terminal, the angles of a and b are 70° to 80°.

[0087] A third aspect of the present application further provides a power module, including:

[0088] a plurality of sub-power modules, wherein the sub-power modules are connected to the third terminal and the fourth terminal;

[0089] At least two sub-power modules are connected to a third terminal and a fourth terminal.

[0090] Optionally, in the above power module, the first end of the power module is connected to a third terminal and a fourth terminal.

[0091] Optionally, in the above power module, the third terminal includes a first section terminal connected to the first end, and the fourth terminal includes a second section terminal connected to the first 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.

[0092] Optionally, in the above power module, the second direction is perpendicular to the plane where the power module is located, and the first direction is perpendicular to the second direction.

[0093] Optionally, in the above power module, 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 along the second direction;

[0094] The third section terminal and the fourth section terminal are bent toward the same side and are arranged opposite to each other in the first direction; or, the third section terminal and the fourth section terminal are bent toward opposite directions.

[0095] Optionally, in the above power module, at least two sub-power modules share the same liner.

[0096] Optionally, in the above power module, at least two sub-power modules each have a separate liner.

[0097] Optionally, in the above power module, at least two sub-power modules share the same liner;

[0098] At least two sub-power modules each have a separate liner.

[0099] A fourth aspect of the present application provides a motor controller comprising the above-mentioned power component.

[0100] A fifth aspect of the present application provides an electronic control assembly, including the above-mentioned motor controller.

[0101] A sixth aspect of the present application provides a vehicle comprising the above-mentioned electronic control assembly.

[0102] By utilizing the above-described technical solution, the power assembly of the present application stacks the power module and capacitor assembly. Compared to conventional solutions in which the power module and capacitor assembly are connected in the same plane, the present application reduces the layout area of ​​the power assembly and facilitates the miniaturization of the power assembly. Furthermore, at least two sub-power modules are connected to a third terminal and a fourth terminal, allowing the at least two sub-power modules to share the third terminal and the fourth terminal, thereby reducing the number of terminals and series inductance. BRIEF DESCRIPTION OF THE DRAWINGS

[0103] In order to more clearly illustrate the technical solutions in the embodiments of the present application or related technologies, the following briefly introduces the drawings required for use in the embodiments or descriptions of the prior art. Obviously, the drawings described below are merely embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without any creative work.

[0104] The structures, proportions, sizes, etc. depicted 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 intended to limit the conditions under which this application can be implemented, and therefore have no substantive technical significance. Any structural modifications, changes in proportional relationships, or adjustments in size, without affecting the efficacy and objectives that can be achieved by this application, should still fall within the scope of the technical contents disclosed in this application.

[0105] Figure 1 A three-dimensional view of the layout of two copper busbars connected parallel to each other and in series;

[0106] Figure 2 for Figure 1 Front view of

[0107] Figure 3 A three-dimensional view of a power component;

[0108] Figure 4 for Figure 3 A top view of

[0109] Figure 5 for Figure 3 A partial enlarged view of

[0110] Figure 6 A top view of a connection structure between a sub-power module and a capacitor component in a power component;

[0111] Figure 7 for Figure 6 a side view of the structure shown;

[0112] Figure 8 for Figure 6 a right side view of the structure shown;

[0113] Figure 9 A side view of a power component provided in an embodiment of the present application;

[0114] Figure 10 for Figure 9 A top view of a power module in the power assembly shown;

[0115] Figure 11 A three-dimensional view of a power component provided in an embodiment of the present application;

[0116] Figure 12 for Figure 11 A three-dimensional view of the power modules in the power assembly shown;

[0117] Figure 13 A three-dimensional view of a power module in a power assembly;

[0118] Figure 14A three-dimensional view of another power component provided in an embodiment of the present application;

[0119] Figure 15 for Figure 14 A three-dimensional view of the power modules in the power assembly shown;

[0120] Figure 16 A three-dimensional view of a power component provided in an embodiment of the present application;

[0121] Figure 17 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;

[0122] Figure 18 for Figure 17 A top view of the power assembly shown;

[0123] Figure 19 for Figure 17 The right side view of the power component before connecting the transfer terminal;

[0124] Figure 20 for Figure 17 The right side view of the power component after connecting the transfer terminal;

[0125] Figure 21 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;

[0126] Figure 22 A side view of a terminal connection structure between a power module and a capacitor assembly in another power assembly provided in an embodiment of the present application;

[0127] Figure 23 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;

[0128] Figure 24 A schematic diagram of a process for preparing a power module according to an embodiment of the present application;

[0129] Figure 25 and Figure 26 A schematic diagram showing the principle of a terminal connection method according to an embodiment of the present application;

[0130] Figure 27 This is a schematic diagram of the terminal structure of a capacitor assembly before being connected and assembled with a power module;

[0131] Figure 28 A schematic diagram of the terminal structure of another capacitor assembly before being connected and assembled with a power module;

[0132] Figure 29A topological structure diagram of an extended-range new energy vehicle provided in an embodiment of the present application;

[0133] Figure 30 An equivalent circuit diagram of a power component provided in an embodiment of the present application.

[0134] Reference numerals:

[0135] 1-Power module; 2-Capacitor assembly; 3-Surface; 4-First end; 5-Insulator; 6-Liner; 7-Sub-power module; 70-Pin; 8-Screw; 9-AC terminal; 10-Correction tool; 11-Electric drive unit; 12-Drive motor; 13-Inverter; 14-Power battery; 15-Generation power assembly; 16-Generation motor; 17-Engine; 18-Range extender; 19-Heat sink; 101-Drive control module; 102-Generation control module; 701-First sub-power module; 702-Second sub-power module; 801-First copper busbar; 802-Second copper busbar; 901-Upper bridge arm circuit; 902-Lower bridge arm circuit; 903-Positive busbar; 904 -Negative busbar; 905-first power chip; 906-second power chip; X-first direction; Y-second direction; Z-third 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

[0136] 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. Those skilled in the art will know 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.

[0137] 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.

[0138] In conventional power components, the power module and capacitor assembly are typically placed on the same plane, with the positive DC terminal of the power module connected to the positive DC terminal of the capacitor assembly, and the negative DC terminal of the power component connected to the negative DC terminal of the capacitor assembly. In this approach, because the capacitor assembly and power module are placed on the same plane, the power component occupies a larger layout area.

[0139] In order to solve the above problems, a power component is provided in an embodiment of the present application. The power component can be as follows: Figure 9 Shown, including:

[0140] A stacked power module 1 and a capacitor assembly 2;

[0141] The capacitor component 2 is connected to a first terminal T1 and a second terminal T2;

[0142] The power module 1 includes a plurality of sub-power modules 7;

[0143] The power module 1 includes at least one third terminal T3 and at least one fourth terminal T4;

[0144] At least two sub-power modules 7 are connected to a third terminal T3 and a fourth terminal T4;

[0145] The first terminal T1 and the third terminal T3 are connected, and the second terminal T2 and the fourth terminal T4 are connected.

[0146] In the technical solution of the present application, the power assembly stacks the power module 1 and the capacitor assembly 2. Compared to the conventional solution in which the power module 1 and the capacitor assembly 2 are connected on the same plane, the technical solution of the present application can reduce the layout area of ​​the power assembly and facilitate the miniaturization design of the power assembly. In addition, at least two sub-power modules 7 are connected to a third terminal T3 and a fourth terminal T4, so that at least two sub-power modules 7 share the third terminal T3 and the fourth terminal T4, which can reduce the number of terminals and increase the size of the third terminal T3 and the size of the fourth terminal T4. In addition, the area of ​​the area facing the third terminal T3 and the fourth terminal T4 can be increased, which can reduce the series inductance.

[0147] Optionally, a first terminal T1 and a second terminal T2 are connected to a surface 3 of the capacitor assembly 2 facing the power module 1. When the capacitor assembly 2 and the power module 1 are stacked, the first terminal T1 and the second terminal T2 are led out from the side surface 3 of the capacitor assembly 2 facing the power module 1. This allows the first terminal T1 and the second terminal T2 to be closer to the power module 2, facilitating the connection between the first terminal T1 and the third terminal T3, the second terminal T2 and the fourth terminal T4, and the terminal connection between the power module 1 and the capacitor assembly 2.

[0148] Alternatively, in one approach, Figure 9 As shown, the first end of the power module 1 (such as Figure 9The third terminal T3 and the fourth terminal T4 are connected to the right end of the power module 1. In this case, the third terminal T3 and the fourth terminal T4 are connected from the same end of the power module 1, which facilitates the extraction of the two terminals in the power module 1 and the circuit connection with the corresponding terminals in the capacitor assembly 2. In other embodiments, the third terminal T3 and the fourth terminal T4 can also be connected to different ends of the power module 1.

[0149] Alternatively, in one approach, Figure 9 As shown, the first end faces the first terminal T1 and the second terminal T2. This method allows the third terminal T3 and the fourth terminal T4 to be led out from the same end of the power module 1 toward the first terminal T1 and the second terminal T2, facilitating the lead-out of the two terminals in the power module 1 and facilitating the circuit connection between the corresponding terminals in the power module 1 and the capacitor assembly 2. In other methods, the third terminal T3 and the fourth terminal T4 can also be led out at other ends of the power module 1, and the circuit connection between the corresponding terminals in the power module 1 and the capacitor assembly 2 can be achieved by bending the terminals in the power module 1 and / or bending the terminals in the capacitor assembly 1.

[0150] Alternatively, in one approach, Figure 9 As shown, the first terminal T1 and the second terminal T2 are arranged relative to each other in the first direction X, that is, the first terminal T1 and the second terminal T2 at least partially overlap in the first direction X. The first terminal T1 and the second terminal T2 are arranged relative to each other in the first direction X, so that there is an overlapping relative area between the first terminal T1 and the second terminal T2, which can reduce the equivalent series inductance (ESL).

[0151] Alternatively, in one approach, Figure 9 As shown, the first direction X is perpendicular to the stacking direction of the power module 1 and the capacitor assembly 2 ( Figure 9 In other embodiments, the first direction X may be non-perpendicular to the stacking direction, that is, the first direction X may be inclined relative to the surface 3, and the first direction X and the stacking direction may have an angle greater than 0° and less than 90°.

[0152] Alternatively, in one approach, Figure 9 As shown, the third terminal T3 and the fourth terminal T4 are arranged opposite to each other in the second direction Y, that is, the third terminal T3 and the fourth terminal T4 at least partially overlap in the second direction Y. The third terminal T3 and the fourth terminal T4 are arranged opposite to each other in the second direction Y, so that there is an overlapping relative area between the third terminal T3 and the fourth terminal T4, which can reduce the series inductance.

[0153] Alternatively, in one approach, Figure 9As shown, the second direction Y is parallel to the stacking direction. In this case, the third terminal T3 and the fourth terminal T4 are arranged opposite each other in this stacking direction, and the third terminal T3 and the fourth terminal T4 can be horizontally extended from the first end 4. In other embodiments, the second direction Y can also be set to have an angle greater than 0° and less than 90° with respect to the stacking direction. In this case, the third terminal T3 and the fourth terminal T4 can be extended obliquely upward or obliquely downward from the first end 4.

[0154] Alternatively, in one approach, Figure 9 As shown, the third terminal T3 includes a first section terminal T01 connected to the first end 4 , and the fourth terminal T4 includes a second section terminal T02 connected to the first end 4 .

[0155] 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. The two may have a stacked opposite area in the second direction Y, which can reduce the series inductance.

[0156] The first section terminal T01 and the second section terminal T02 can extend along the first direction X. If the first direction X is perpendicular to the stacking direction, the first section terminal T01 and the second section terminal T02 can be Figure 9 In the manner shown, it extends horizontally.

[0157] Power modules control the operating state of a vehicle's motors, which are typically three-phase. When the power module switches the power module on and off at high speed, a surge voltage, V, is applied to the current loop containing the power module. V is proportional to the series inductance, Ls, introduced by the terminals in the current loop. The surge voltage is calculated as follows:

[0158]

[0159] in, is the rate of change of current in the current loop.

[0160] refer to Figure 1 and Figure 2 , Figure 1 A three-dimensional view of the layout of two copper busbars connected parallel to each other and in series. Figure 2 for Figure 1 Front view of . Figure 1 The bold unidirectional arrow in the figure indicates the direction of current flow in the current loop. In the embodiment of the present application, each terminal is not limited to being a copper busbar, but may also be a structural member made of other metal materials.

[0161] like Figure 1 and Figure 2As shown, the first copper bar 801 and the second copper bar 802 are two parallel and series-connected DC terminals in a power assembly. For example, the first copper bar 801 and the second copper bar 802 can respectively serve as the positive and negative terminals of a power module, or the positive and negative terminals of a capacitor assembly. The first copper bar 801 and the second copper bar 802 are both assumed to have a width of W, a length of L, a thickness of t, and a distance d between them.

[0162] for Figure 1 and Figure 2 For the copper busbar arrangement shown in the figure, the empirical calculation formula for Ls of the two copper busbars in the current loop is:

[0163]

[0164] Where L1 and L2 represent the self-inductance of the two copper busbars, respectively; M represents the mutual inductance between the two copper busbars; and k represents the coupling coefficient, which characterizes the degree of coupling between the two copper busbars. Misalignment of the centers of the two copper busbars affects the value of k. If WS:W ≠ 1, then k < 1. The smaller the WS:W value, the greater the misalignment of the centers of the two copper busbars, and the smaller the k value. WS represents the overlap width of the two copper busbars.

[0165] Based on formula (2), the formula of Ls can be expressed as:

[0166]

[0167] Where μ0 is the magnetic permeability in vacuum.

[0168] Based on formula (1) and formula (3), it can be seen that the smaller L, the larger W, and the larger t, the smaller Ls and the smaller V; the larger WS:W, the greater the overlap ratio of the two terminals, the larger k, the smaller Ls, and the smaller the surge voltage.

[0169] 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 embodiment, the power assembly includes a stacked power module 1 and a capacitor assembly 2. The power assembly 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.

[0170] 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 .

[0171] The drive control module 101 is a core component that converts direct current into alternating current and is used to connect to 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 to 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 arranged coplanarly on the surface of the capacitor assembly 2, which can reduce the size of the product's footprint. Among them, the capacitor assembly 2 can be used in conjunction with the power module 1 in the power assembly and is a key component for balancing the DC side bus voltage.

[0172] 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 to the positive pole of the vehicle power battery through the positive DC bus, and the negative terminal is used to connect to the negative pole of the vehicle power battery through the negative DC bus.

[0173] If the motor is a three-phase motor, the drive control module 101 and the power generation control module 102 can 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 in the power module 1 and the capacitor component 2 is as follows: Figure 6-Figure 8 shown.

[0174] refer to Figure 6-Figure 8 , Figure 6 This is a top view of the 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 areas, which are the first area D1, the second area D2, the third area D3 and the fourth area D4.

[0175] Combine 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, with a width of 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. Figure 6 In the second region D2, the first terminal T1 and the second terminal T2 are also staggered and arranged in parallel, with widths of W2- and W2+, respectively. In the third region D3, the first terminal T1 and the second terminal T2 are staggered and arranged in parallel, with widths of W3- and W3+, respectively. In the fourth region D4, the first terminal T1 and the second terminal T2 are stacked and overlapped, with a width of W4.

[0176] 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 factors such as the size and number of the chips 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, requiring a total of 6 positive terminals and 6 negative terminals, resulting in larger overall sizes b01 and b02 of the two control modules, which in turn leads to a larger ESL of the power component and high material costs.

[0177] 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 is stacked up and down, and the ESL in this area is small. In the second area D2, in order to meet the requirements of the positive terminals of the power module 1 and the capacitor component 2 being connected to the positive terminals by screws 8 and the negative terminals being connected to the negative terminals 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.

[0178] Since the terminals between the capacitor assembly 2 and the power module 1 need to be fixed by screws 8, the fixing solution using screws includes at least the following shortcomings: the traditional screw solution requires more materials, which increases the process complexity in the storage, loading, and tightening of the screws; during automatic loading, occasional failures such as jamming may occur due to the consistency of the screws or other factors, requiring manual intervention, reducing the degree of automation and affecting 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 equipment 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.

[0179] Therefore, the use of screw fixing scheme leads to complex assembly process and requires a large assembly space, and the screw 8 will occupy a large space after assembly. Moreover, the fixing method of the screw 8 is prone to loosening, increased contact resistance and thermal overshoot after vibration.

[0180] In order to solve the above problems, the technical solution of the present application provides a power component, including:

[0181] A stacked power module and capacitor assembly;

[0182] The capacitor assembly is connected to a first terminal and a second terminal insulated from each other; the first terminal and the second terminal are arranged opposite to each other;

[0183] The power module includes a plurality of sub-power modules; the sub-power modules are connected to a third terminal and a fourth terminal that are insulated from each other, and the third terminal and the fourth terminal are arranged opposite to each other; at least two sub-power modules are connected to the same third terminal and the same fourth terminal;

[0184] The first terminal and the third terminal are connected, and the second terminal and the fourth terminal are connected.

[0185] In the technical solution of the present application, the first terminal and the second terminal are stacked and arranged relative to each other, and the third terminal and the fourth terminal are stacked and arranged relative to each other, which can increase the stacking relative area between the terminals. Arranging multiple sub-power modules to share the third terminal and the fourth terminal can further increase the stacking relative area of ​​the terminals and reduce the series inductance.

[0186] Optionally, the first terminal and the third terminal, and the second terminal and the fourth terminal can be fixedly connected based on welding, respectively, so that the contact resistance between the two interconnected terminals is low, the thermal risk is reduced, 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.

[0187] Furthermore, if the terminals can be fixedly connected based on welding, compared to 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 welding processing by automated welding 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, which can greatly simplify the assembly process, improve assembly efficiency, reduce the volume of power components, and reduce material costs. The welding process has a smaller 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.

[0188] refer to Figure 9 and Figure 10 , Figure 9 A side view of a power component provided in an embodiment of the present application is shown. Figure 10 for Figure 9 A top view of a power module in a power assembly shown. The power assembly shown includes:

[0189] The power module 1 and the capacitor assembly 2 are stacked.

[0190] The capacitor assembly 2 is connected to a first terminal T1 and a second terminal T2 that are insulated from each other; the first terminal T1 and the second terminal T2 are arranged opposite to each other;

[0191] The power module 1 includes a plurality of sub-power modules 7; the sub-power modules 7 are connected to a third terminal T3 and a fourth terminal T4 that are insulated from each other, and the third terminal T3 and the fourth terminal T4 are arranged opposite to each other; at least two sub-power modules 7 are connected to the same third terminal T3 and the same fourth terminal T4;

[0192] The first terminal T1 and the third terminal T3 are connected, and the second terminal T2 and the fourth terminal T4 are connected.

[0193] Optionally, the first terminal T1 and the third terminal T3 can be fixedly connected by welding, and the second terminal T2 and the fourth terminal T4 can be fixedly connected by welding. Welding can be laser welding or other welding methods, which are not limited in the embodiments of the present application. In subsequent embodiments of the present application, the connection between the terminals is achieved by fixing the terminals by welding. In the embodiments of the present application, other fixed connection methods can also be used, not limited to laser welding, and screw fixation or snap-on connection can also be used.

[0194] in, Figure 10 The power module 1 includes three sub-power modules 7 as an example for illustration. The three sub-power modules 7 are connected to the same third terminal T3 and the same fourth terminal T4. In the embodiment of the present application, the number of sub-power modules 7 in the power module 1 can be set as needed, and the number of sub-power modules 7 that share the third terminal T3 and the fourth terminal T4 can be set as needed, and is not limited to Figure 10 The method shown.

[0195] In the embodiment of the present application, the first terminal T1 and the second terminal T2 are stacked and arranged relative to each other, which can increase the stacking relative area of ​​the first terminal T1 and the second terminal T2; the third terminal T3 and the fourth terminal T4 are stacked and arranged relative to each other, which can increase the stacking relative area of ​​the third terminal T3 and the fourth terminal T4; and multiple sub-power modules are arranged to share the third terminal and the fourth terminal, which can further increase the stacking relative area of ​​the third terminal T3 and the fourth terminal T4. Based on the above formula (3), it can be seen that increasing the stacking relative area between the terminals can increase the coupling coefficient k, thereby reducing the series inductance.

[0196] Optionally, the capacitor assembly 2 is connected to a surface 3 facing the power module 1 with a first terminal T1 and a second terminal T2 that are insulated from each other; the first terminal T1 and the second terminal T2 are arranged opposite each other in a first direction X; the first terminal T1 and the second terminal T2 can both be vertically extended from the surface 3. The first end 4 of the power module 1 is connected to a third terminal T3 and a fourth terminal T4 that are insulated from each other; the third terminal T3 and the fourth terminal T4 can both be vertically extended from the first end 4; the first 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 first end 4; the third terminal T3 includes a first segment terminal T01 connected to the first end 4, and the first segment terminal T01 can be perpendicular to the first end 4; the fourth terminal T4 includes a second segment terminal T02 connected to the first end 4, and the second segment terminal T02 can be perpendicular to the first end 4; the first segment terminal T01 and the second segment terminal T02 are parallel to the first direction X and are arranged opposite each other in the second direction Y;

[0197] 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. Optionally, the connection between the terminals can be laser welding or other connection methods, which are not limited in this embodiment of the present application.

[0198] Optionally, in the power assembly, the sub-power modules 7 may be arranged in sequence along the third direction Z.

[0199] Because the first terminal T1 and the second terminal T2 are arranged relative to each other in the first direction X, they can be stacked in the first direction X, effectively increasing the width WS of the overlapping region between them and reducing the series inductance of the current loop. Because the first segment terminal T01 and the second segment terminal T02 are arranged relative to each other in the second direction Y, they can be stacked in the second direction Y, effectively increasing the width WS of the overlapping region between them and reducing the series inductance of the current loop. Therefore, this application can reduce the series inductance in a power module, avoiding the adverse effects of excessive series inductance on power module performance.

[0200] Moreover, the first terminal T1 and the third terminal T3, and the second terminal T2 and the fourth terminal T4 can be connected and fixed respectively by welding, so that the contact resistance between the two interconnected terminals 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 problems such as increased contact resistance and thermal tolerance caused by poor contact between the terminals, and reducing the risk of abnormal temperature of the power component.

[0201] Compared with the connection scheme in which the terminals are fixed by screws 8, the terminals in the technical solution of the present application can be fixed by welding, without the need to set up the space required for the screws 8 separately, which can greatly simplify the assembly process, improve assembly efficiency, reduce the volume of the power components, and reduce material costs.

[0202] 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 70 used to connect to the PCB.

[0203] In the embodiment of the present application, the fourth terminal T4 is located between the third terminal T3 and the capacitor component 2. 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 first end 4. In the first direction X, the first terminal T1 faces away from the first end 4, and the second terminal T2 faces the first end 4. In this way, Figure 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 component 2 and the positive terminal and the negative terminal of the power module 1.

[0204] In the embodiment of the present application, each sub-power module 7 may have an AC terminal 9 and two DC terminals, where the two DC terminals are a third terminal T3 and a fourth terminal T4 .

[0205] refer to Figure 11 and Figure 12 , Figure 11 A three-dimensional view of a power component provided in an embodiment of the present application, Figure 12 for Figure 11 A three-dimensional view of the power module in the power assembly shown. Based on other embodiments, Figure 11 and Figure 12 In the illustrated embodiment, multiple sub-power modules 7 in the same power module 1 are all connected to the same third terminal T3 and the same fourth terminal T4. This embodiment is illustrated using the first terminal T1 and the third terminal T3 connected via the adapter terminal T5 as an example. As described below, interconnected terminals can be connected via the adapter terminal T5, or the two terminals to be connected can be directly connected.

[0206] Figure 11 and Figure 12 In the shown method, in the same power module 1, each sub-power module 7 uses a separate liner 6, which can achieve accurate and fine control of the power chip in the sub-power module 7. When this method is used for the drive control module, the amplitude, phase and frequency of the current of the drive motor can be more accurately controlled, 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.

[0207] When a plurality of sub-power modules 7 share the third terminal T3 and the fourth terminal T4, the stacking relative area of ​​the positive and negative terminals of these terminals can be maximized to minimize the series inductance.

[0208] refer to Figure 13 , Figure 13 A three-dimensional view of a power module in a power assembly. Based on other methods, Figure 13 In the illustrated embodiment, at least one sub-power module 7 of the power module 1 is connected to a separate third terminal T3 and a separate fourth terminal T4. Figure 13 In the figure, the power module 1 including three sub-power modules 7 with independent third terminals T3 and independent fourth terminals T4 is taken as an example for illustration.

[0209] refer to Figure 14 and Figure 15 , Figure 14 A three-dimensional view of another power component provided in an embodiment of the present application, Figure 15 for Figure 14 A three-dimensional view of the power module in the power assembly shown. Based on other embodiments, Figure 14 and Figure 15 In the illustrated embodiment, multiple sub-power modules 7 within the same power module 1 utilize the same backing plate 6 and are connected to the same third terminal T3 and the same fourth terminal T4. This embodiment is illustrated using the example of a first terminal T1 and a third terminal T3 connected via a transfer terminal T5. As described below, interconnected terminals can be connected via the transfer terminal T5, or the two terminals to be connected can be directly connected.

[0210] Figure 14 and Figure 15 In the illustrated approach, each sub-power module 7 within the same power module 1 utilizes the same liner 6. This reduces costs and improves integration while maintaining certain performance, without significantly impacting energy conversion efficiency. This approach can be used in power generation control modules. Compared to drive motors, the operating current characteristics of generator motors are relatively simple. During the power generation process, AC power is converted to DC power by the power generation control module, and the frequency and amplitude of the current are relatively stable, eliminating the need for complex current control and regulation required by drive motors. Therefore, even if each sub-power module 7 within the power generation control module shares the same liner 6, basic control requirements for the generator motor can be met.

[0211] refer to Figure 16 , Figure 16 This is a 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 to the drive motor; the power generation control module 102 is used to connect to the power generation motor; wherein, the drive control module 101 and the power generation control module 102 each include a stacked power module 1 and a capacitor component 2. The third terminal T3 and the first terminal T1 can be as follows Figure 16 As shown, the two are connected through the transfer terminal T5, or as described below, the two can be directly connected.

[0212] If the power assembly includes both the drive 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 can be as follows: Figure 16 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.

[0213] In other embodiments, if the power component includes both a drive control module 101 and a power generation control module 102, 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 T5 respectively. At this time, one adapter terminal T5 is used to connect the first terminal T1 and the third terminal T3 in the drive control module 101, and another adapter terminal T5 is used to connect the first terminal T1 and the third terminal T3 in the power generation control module 102.

[0214] In the drive control module 101, by stacking the first terminal T1 and the second terminal T2 in the first direction X, the width WS of the overlapping region between them is increased. By stacking the first segment terminal T01 and the second segment terminal T02 in the second direction Y, the width WS of the overlapping region between them is increased. Therefore, based on the above formula (3), the embodiment of the present application can increase WS and reduce the series inductance in the current loop. Similarly, in the power generation control module 102, by increasing the width WS of the overlapping region between the first terminal T1 and the second terminal T2, and by increasing the width WS of the overlapping region between the first segment terminal T01 and the second segment terminal T02, the series inductance in the current loop can be reduced.

[0215] like Figure 16 As shown, the power assembly can adopt a dual-electric control structure, that is, the power assembly includes both a drive control module 101 and a power generation control module 102; wherein, the drive control module 101 and the power generation control module 102 share the same capacitor assembly 2. This approach integrates the drive control module 101 and the power generation control module 102 into one, allowing them to share the same capacitor assembly 2. Compared with a solution where the two control modules are separately packaged, this can improve the integration of the power assembly, reduce the overall volume, and facilitate the miniaturization of the dual-electric control structure.

[0216] The drive control module 101 includes multiple sub-power modules 7, of which the sub-power module 7 is a first sub-power module 701. To achieve more precise and accurate current control of the drive control module 101, each of the first sub-power modules 701 can be configured to use a separate liner 6. Each first sub-power module 701 can be connected to the same third terminal T3 and the same fourth terminal T4.

[0217] The power generation control module 102 includes multiple sub-power modules 7, of which the sub-power module 7 is a second sub-power module 702. Because the generator motor has a relatively low current control requirement, all second sub-power modules 702 can be configured to share a common liner 6 to reduce the size of the power generation control module 102 in the third direction Z, thereby reducing the volume of the power assembly.

[0218] In the embodiment of the present application, each first sub-power module 701 in the drive control module 101 is connected to the same third terminal T3 and the same fourth terminal T4, or at least some of the first sub-power modules 701 are connected to separate third terminals and separate fourth terminals. Each second sub-power module 702 in the power generation control module 102 is connected to the same third terminal T3 and the same fourth terminal T4.

[0219] If the power component includes both a driving control module 101 and a power generation control module 102, the first sub-power module 701 and the second sub-power module 702 are respectively connected to different third terminals T3 and different fourth terminals T4, so that the two control modules can be prepared separately. The third terminals T3 of the two control modules can be prepared separately, and the fourth terminals T4 can be prepared separately to avoid the two control modules being connected to a larger third terminal T3 and a larger fourth terminal T4.

[0220] 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. Optionally, the drive 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 single-phase AC terminals of the drive motor. The three first sub-power modules 701 each have an independent lining plate 6. 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 single-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 in which the three second sub-power modules 702 in the power generation control module 102 each use a separate lining plate 6, the present application can improve the integration of the power generation control module 102 and reduce the product size.

[0221] The first sub-power module 701 and the second sub-power module 702 each include a half-bridge circuit located on the liner 6. The half-bridge circuit is a control circuit formed by interconnecting multiple power chips. Multiple 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 half-bridge circuit, including but not limited to Figure 30 The circuit form shown.

[0222] In the present application, the number of sub-power modules 7 in the drive control module 101 and the power generation control module 102 can be determined according to the type and number of connected motors, and is not limited to the three described in the embodiment of the present application. The embodiment of the present application does not limit the number of sub-power modules 7 in the power module 1.

[0223] As described above, Figure 3-Figure 8 As shown, in a typical dual-electric control structure, the screw connection results in high contact resistance, posing a high risk of thermal failure. Furthermore, the misaligned and parallel arrangement of the positive and negative terminals in a local area results in high ESL in that area, which in turn leads to large bus surge voltages and large bus voltage fluctuations, seriously affecting the performance of the power module. 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 region of the positive and negative terminals can be increased, the ESL in the current loop can be reduced, and the adverse effects of high ESL on the performance of the power module can be avoided, thereby improving the performance of the power module.

[0224] 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 configured to use the same backing plate 6. Compared to a solution in which each second sub-power module 702 in the power generation control module 102 uses an independent backing plate 6, the solution of the present application can achieve miniaturization of the backing plate of the power generation control module 102. Furthermore, each second sub-power module 702 can be integrated from multiple separate half-bridge circuits into a full-bridge circuit located on the same DBC (Direct Bonded Copper). This allows the three second sub-power modules 702 in the power generation control module 102 to share the same third terminal T3 and the same fourth terminal T4, that is, the three second sub-power modules 702 share the same positive terminal and the same negative terminal, thereby reducing the number of DC terminals, making the power generation control module 102 smaller, and making the power components smaller. This improves product performance while reducing material costs, and at the same time maximizes the stacking area of ​​the positive and negative terminals to further reduce ESL.

[0225] In the embodiment of the present application, the two DC terminals of the power module 1 can also be designed to be stacked over a large area in the area facing each other in the first section terminal T01 and the second section 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.

[0226] In the capacitor assembly 2, the first terminal T1 and the second terminal T2 are directly connected perpendicular to the surface 3, which has a simple structure. 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.

[0227] Moreover, the connection areas corresponding to the third terminal T3 and the fourth terminal T4 can be designed to be parallel, or the connection areas corresponding to the third terminal T3 and the fourth terminal T4 can be designed to be vertical, with the connection area corresponding to one being located in the overlapping area of ​​the terminals in the second direction Y, and the connection area corresponding to the other being located in the overlapping area of ​​the terminals in the first direction X.

[0228] In one way, Figure 16 As shown, the first terminal T1 and the second terminal T2 of the capacitor assembly 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 that a connection window for the second terminal T2 and the fourth terminal T4 is reserved between the first terminal T1 and the third terminal T3, which facilitates the connection and assembly of the terminals between the capacitor assembly 2 and the power module 1.

[0229] 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 connected via a transfer terminal T5, which can be welded and fixedly connected to the first terminal T1 and the third terminal T3, respectively. In other embodiments, the second terminal T2 and the fourth terminal T4 can both be negative terminals, and the first terminal T1 and the third terminal T3 can both be positive terminals.

[0230] 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 embodiment of the present application does not limit the size of the liner 6 used by the drive control module 101 and the power generation control module 102.

[0231] In an 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.

[0232] 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 can be 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 can be a three-phase full-bridge circuit structure with an integrated liner 6.

[0233] It should be noted that the embodiments of the present application are not limited to Figure 16 The dual electric control structure shown, Figure 16 The power assembly includes both the drive control module 101 and the power generation control module 102 as an example for illustration. Alternatively, the power assembly may include only the drive control module 101 or only the power generation control module 102. These embodiments can all reduce the ESL of the current loop. When the power assembly includes either the drive control module 101 or the power generation control module 102, it may be a three-phase full-bridge circuit structure sharing the same liner 6, or three single-phase half-bridge circuit structures using independent liner 6, or other circuit structures. The present embodiment does not limit the circuit structure of the power module 1.

[0234] In the embodiment of the present application, the power module 1 and the capacitor assembly 2 are stacked in the second direction Y. Compared with a layout in which the capacitor assembly 2 and the power module 1 are coplanar, the area occupied by the power assembly can be reduced. 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.

[0235] refer to Figures 17-20 , Figure 17 This is 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. Figure 18 for Figure 17 A top view of the power components shown, Figure 19 for Figure 17 The right side view of the power component before connecting the transfer terminal. Figure 20 for Figure 17 The right side view of the power assembly after connecting the adapter terminal is shown. In this method, the terminal connection path between the capacitor assembly 2 and the power module 1 also includes the first area D1 to the fourth area D4. 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 of the capacitor assembly 2 can both be H0.

[0236] The first section terminal T01 includes an integrated first part and a second part, the first part is connected to the first end 4, and the second part is located on the side of the first part away from the first end 4; the first section terminal T01 located in the first area D1 is the first part, and the part located in the second area D2 is the second part.

[0237] like Figure 18 As shown, the width W1 of the first portion is smaller than the width W2 of the second portion, where W1 and W2 represent the lengths of the terminal in the third direction Z, which is perpendicular to the first direction X and the second direction Y and parallel to surface 3. If W1 is smaller than W2, installation space can be reserved to facilitate securing the external housing, facilitating the use of the housing to encapsulate and protect the internal components of the power assembly. Alternatively, the width W1 of the first portion can be set equal to the width W2 of the second portion.

[0238] The lengths of the first region D1 and the second region D2 in the first direction X can be adjusted based on product layout requirements, and this application does not impose any restrictions on the lengths of these two regions. The values ​​of W1 and W2 can be designed based on performance and molding requirements. In theory, the larger the values ​​of W1 and W2, the lower the ESL.

[0239] like Figure 19 and Figure 20As shown, both the first terminal T1 and the second terminal T2 include an integral third portion and a fourth portion. Within the same terminal, the fourth portion is connected to surface 3, and the third portion is located on the side of the fourth portion facing away from surface 3. The width W3 of the third portion is smaller than the width W4 of the fourth portion. W3 and W4 are the nominal widths of the third and fourth portions, respectively. The first and second terminals T1 and T2 partially form the fourth portion in the fourth region D4, and both have a fourth portion with a width of W4. The first and second terminals T1 and T2 partially form the third portion in the third region D3, with the actual width of the third portion of the first terminal T1 being W3- and the actual width of the third portion of the second terminal T2 being W3+. W3+ and W3- are equal to or approximately equal to W3. In this embodiment, W3 is smaller than W4, which allows for installation space to facilitate securing the external housing and facilitating 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 can be equal to the width W4 of the fourth portion.

[0240] 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.

[0241] 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 values. 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 impact of excessive thickness on the volume of the product and the mechanical strength caused by excessive terminal thickness, so as to facilitate stacking connections between terminals and bending and shaping of the terminals.

[0242] 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 .

[0243] In one embodiment, the distance between the first terminal T1 and the second terminal T2 is 1.5 mm to 2 mm, and may be 1.4 mm, 1.7 mm, or 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 may be 1.4 mm, 1.7 mm, or 1.9 mm, etc. When the distance between the terminals is within this range, the distance between the terminals can be moderate. On the one hand, a smaller spacing between the terminals can be achieved, which can reduce ESL. On the other hand, it can avoid short circuit problems caused by too small a spacing.

[0244] Optionally, to facilitate process preparation, 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 .

[0245] 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; the first surface is perpendicular to the first direction X. Figure 13 As shown, the first surface is Figure 19 The vertical projections of the first terminal T1 and the second terminal T2 are arranged to at least partially overlap, so that the two form a stacked relative area, thereby reducing the series inductance.

[0246] 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. Figure 18 As shown, the second surface is Figure 18 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, thereby reducing the series inductance.

[0247] The edges of the first terminal T1 and the second terminal T2 located on either side of the second direction Y meet the flush condition, such that their vertical projections overlap to a large extent, and / or the edges of the third terminal T3 and the fourth terminal T4 located on either side of the first direction X meet the alignment condition, such that their vertical projections overlap to a large extent. The flush condition means that the edges of the two terminals are flush or approximately flush.

[0248] 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 Figure 19 and Figure 20 As 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 achieve 100% or approximately 100% overlap. The graphic structures of the two within this height overlap range can be completely consistent or approximately consistent, thereby allowing the two to have a large overlapping area along the second direction Y, thereby significantly reducing ESL. Optionally, the offset distance between the opposing edges of the first terminal T1 and the second terminal T2 does not exceed 0.2 mm, 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.

[0249] When the edges of the third terminal T3 and the fourth terminal T4 on both sides of the first direction X meet the alignment condition, such as Figure 18 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 segment terminal T01 and the second segment terminal T02, the fourth terminal T4 and the third terminal T3 can achieve 100% or approximately 100% overlap. The graphic structures of the two terminals within this length overlap range can be completely or approximately identical, thereby providing a large overlap area along the first direction X, thereby significantly reducing ESL. Optionally, the offset distance between the opposing edges of the third terminal T3 and the fourth terminal T4 does not exceed 0.2 mm, and the edges of the third terminal T3 and the fourth terminal T4 on both sides of the first direction X meet the alignment condition.

[0250] 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.

[0251] like Figures 17-20 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 transfer terminal T5.

[0252] 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 connect directly 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, with its connection surface facing Figure 17 The third terminal T3 can be connected to the first section terminal T01 and the transfer terminal T5. The first section terminal T01 is the outlet end 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 connection surface faces Figure 17 In this manner, the connection surfaces of the third terminal T3 and the fourth terminal T4 are oriented vertically, which can form two more sufficient different connection positions within a limited space, facilitating the connection of the terminals between the capacitor assembly 2 and the power module 1 .

[0253] exist Figures 17-20In the illustrated embodiment, the second section terminal T02 and the third section terminal T03 of the fourth terminal T4 are vertically bent. The fourth terminal T4 can form a first overlapping region A1 in the first direction X based on the third section terminal T03 extending toward the capacitor assembly 2 and the second terminal T2, facilitating connection between the fourth terminal T4 and the second terminal T2 in the first overlapping region A1. Furthermore, a connection window for connection in the first overlapping region A1 can be formed between the first terminal T1 and the third terminal T3, facilitating connection between the fourth terminal T4 and the second terminal T2.

[0254] Optionally, in the first direction X, the third terminal T3 exposes at least a portion of the third section terminal T03 to form a connection window between the third section terminal T03 and the counterpart (second terminal T2), so as 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. Figure 17 In the illustrated embodiment, in the first direction X, the third terminal T3 exposes the entire third segment terminal T03.

[0255] like Figure 19 As shown, the width of the third segment terminal T03 may be W3+, and the width W3+ of the third segment 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.

[0256] Relative to Figure 6-Figure 8 As shown, Figures 17-20 In the illustrated method, 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 maintained, 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 8 In the manner shown, the positive and negative terminals are at least twice as large as W1. In addition, in the first region D1 to the fourth region D4, the stacked positive and negative terminals have an overlap of approximately 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.

[0257] In the first direction X, a gap is formed between the third terminal T3 and the first terminal T1, exposing the first overlapping area A1. 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, facilitating the connection between the fourth terminal T4 and the second terminal T2.

[0258] like Figure 17 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 based on the second overlapping area A2 and the third overlapping area A3, respectively. By adjusting the position of the second overlapping area A2 and the third overlapping area A3 relative to the first overlapping area A1, 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, thereby facilitating the connection between the capacitor assembly 2 and the power module 1.

[0259] 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 staggered 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.

[0260] In one way, Figure 17 As shown, in the second direction Y, the distance between the first overlapping area A1 and the capacitor assembly 2 is greater than the distance between the second overlapping area A2 and the capacitor assembly 2. In other words, with respect to surface 3, the minimum height of the first overlapping area A1 is greater than the maximum height of the second overlapping area A2. In this approach, if the length of the third-segment terminal T03 is constant, the space between it and surface 3 can be used to arrange the second overlapping area A2, thus preventing the product from having a large thickness in the second direction Y.

[0261] In one way, Figure 17 As 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 approach can achieve 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 with the fourth terminal T4 based on the third overlapping area A3, thereby reducing ESL.

[0262] Alternatively, as Figure 17As shown, the adapter terminal T5 can have a third overlapping area A3 with the first segment terminal T01 in the second direction Y. In this case, the adapter terminal T5 can be directly connected to the first segment terminal T01, eliminating the need for the third terminal T3 to be connected to the first segment terminal T01, simplifying the design of the third terminal T3. In this approach, the adapter terminal T5 overlaps with the third terminal T3 in the second direction Y, forming the third overlapping area A3. It also overlaps with the first terminal T1 in the first direction X, forming the 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. The connection directions of the third terminal T3 and the fourth terminal T4 of the power module 1 are perpendicular to each other.

[0263] refer to Figure 21 , Figure 21 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 embodiment, Figure 21 In the illustrated embodiment, the third terminal T3 further includes a fourth-segment terminal T04 connected to the first-segment terminal T01; the fourth-segment terminal T04 is parallel to the second direction Y and extends away from the capacitor assembly 2; the adapter terminal T5 and the fourth-segment 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-segment terminal T04, and the fourth-segment terminal T04 is perpendicular to the surface 3. With the surface 3 as a reference, the third terminal T3 has a vertical outlet structure, and its connection surface faces Figure 21 on the right side of the . Figure 21 In the manner shown, the design of the positive and negative terminals in the capacitor assembly 2 can be Figure 17 This method is the same as the one shown in the figure. It can also increase the terminal width and the overlapping area of ​​the positive and negative terminals, thereby reducing ESL.

[0264] The fourth section terminal T04 serves 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 adjusted as required. Optionally, the fourth section terminal T04 may be set to have the same or approximately the same width as the first section terminal T01.

[0265] Figure 21 In the illustrated embodiment, the connection areas within each overlapping region are indicated by shaded ovals. Both the third and fourth terminals T3 and T4 feature vertically extending leads. The symmetric patterns of the third and fourth terminals T3 and T4 facilitate the structural design of the terminals within the power module 1. Furthermore, the adapter terminal T5 can be connected to the fourth segment terminal T04 and the first terminal T1 in the same orientation, facilitating connection and assembly of the adapter terminal T5.

[0266] In the embodiment of the present application, Figure 21As 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. The insulating member 5 allows for insulation isolation between the positive and negative terminals of the capacitor assembly 2 when the terminal spacing is small, and also allows for insulation isolation between the positive and negative terminals of the power module 1 when the terminal spacing is small. While ensuring insulation isolation between the positive and negative terminals, the positive and negative terminals have a small terminal spacing in parallel, opposing portions, thereby reducing ESL.

[0267] 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.

[0268] refer to Figure 22 , Figure 22 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, Figure 21 The difference between the two methods is that Figure 22 In the illustrated embodiment, the fourth-segment terminal T04 is parallel to the second direction Y and extends toward the capacitor assembly 2 ; the transition terminal T5 and the fourth-segment terminal T04 have a third overlapping area A3 in the first direction X. Figure 22 In this manner, the fourth segment terminal T04 is bent toward the capacitor assembly 2 , which can reduce the height of the third overlapping area A3 relative to the surface 3 , thereby reducing the thickness of the power assembly in the second direction Y. Figure 22 In the manner shown, the design of the positive and negative terminals in the capacitor assembly 2 can be Figure 17 This method is the same as the one shown in the figure. It can also increase the terminal width and the overlapping area of ​​the positive and negative terminals, thereby reducing ESL.

[0269] exist Figure 22 In the manner shown, 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 perpendicular to the surface 3, and both are vertical outlet structures, and the connection windows of the two are both facing Figure 22 on the right side of the .

[0270] The third terminal T3 consists of a first vertical terminal segment T01 and a fourth vertical terminal segment T04. The length and width of the first and fourth vertical terminals T01 and T04 can be customized. The fourth vertical terminal segment T04 serves as a connection window for connecting to the adapter terminal T5. The length of the fourth vertical terminal segment T04 can be no longer than 10 mm. A through-hole structure can be designed within the third terminal T3 based on product assembly requirements.

[0271] The fourth terminal T4 consists of a second segment T02 and a third segment T03, each perpendicular to the other. The length and width of the second and third segments T02 and T03 can be customized. The third segment T03 serves as a connection window for direct connection to the second terminal T2. The length of the third segment T03 can be no longer than 10 mm. The fourth terminal T4 can be designed with a through-hole structure based on product assembly requirements.

[0272] like Figure 22 As shown, in the second direction Y, the distance between the third overlapping region A3 and the capacitor assembly 2 is greater than the distance between the first overlapping region A1 and the capacitor assembly 2; and the distance between the second overlapping region A2 and the capacitor assembly 2 is less than the distance between the first overlapping region A1 and the capacitor assembly 2. In other words, the height of the third overlapping region A3 is greater than the height of the first overlapping region A1, and the height of the first overlapping region A1 is greater than the height of the second overlapping region A2. In this way, a connection window is formed between the third overlapping region A3 and the second overlapping region A2, exposing the first overlapping region A1. This connection window facilitates the connection of the third segment terminal T03 and the second terminal T2 in the first overlapping region A1.

[0273] Alternatively, as Figure 22 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.

[0274] 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.

[0275] refer to Figure 23 , Figure 23This is a side view of a terminal connection structure for 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 approach can also increase the terminal width and the overlapping area of ​​the positive and negative terminals, thereby reducing ESL.

[0276] exist Figure 23 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 need for the adapter terminal T5.

[0277] like Figure 23 As shown, the fourth-segment terminal T04 and the first terminal T1 have an opposing portion C in the first direction X; the third-segment terminal T03 and the second terminal T2 have a first overlapping area A1 in the first direction X; the first overlapping area A1, including one end of the second connection area B2, is located in the accommodation space formed by the opposing portion C. This approach allows the accommodation space formed by the opposing portion C to be reused to accommodate at least a portion of the first overlapping area A1, reducing the space occupied by the first overlapping area A1 in the second direction Y and thus reducing the size of the product.

[0278] Alternatively, as Figure 23 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 outward protruding design, the fourth terminal T04 and the first terminal T1 can form a receiving space of sufficient size so that at least the end of the first overlapping area A1 can be placed within the receiving space. In other embodiments, a square or triangular receiving space can be formed above the first overlapping area A1 by using the first terminal T1 and the third terminal T3 with a folded line structure, which is not limited to Figure 23 The method shown.

[0279] It can be seen from the above description that when used for a three-phase motor, 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. Compared with the solution in which the three-phase sub-power modules in the same power generation control module 102 each have a set of positive and negative terminals, two positive terminals and two negative terminals can be reduced. 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. 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. 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, material costs can be reduced. The drive control module 101 can also adopt other multi-phase full-bridge circuits.

[0280] The embodiment of the present application does not limit the circuit structure in the power module 1. 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 by the embodiment of the present application, the structure of the first terminal T1 and the second terminal T2 led out by the capacitor component 2 can be made relatively simple, thereby reducing the material cost of the capacitor component 2.

[0281] 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. 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.

[0282] In this application, the terminals can be connected by laser welding, which reduces the contact resistance between the terminals and reduces the risk of thermal failure. Welding also increases the connection strength at the connection point, its vibration durability reliability is higher than that of screw connections, and it is more efficient to assemble.

[0283] 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 of the above embodiments. The preparation method can be as follows: Figure 24 shown.

[0284] refer to Figure 24 , Figure 24 A schematic diagram of a process for preparing a power module according to an embodiment of the present application, combined with Figure 24 As shown in the structural diagram of the power component in the above embodiment, the preparation method includes:

[0285] Step S11: The power module 1 and the capacitor assembly 2 are stacked; the capacitor assembly 2 is connected to a first terminal T1 and a second terminal T2; the power module 1 includes multiple sub-power modules 7; the power module 1 includes at least one third terminal T3 and at least one fourth terminal T4; at least two sub-power modules 7 are connected to a third terminal T3 and a fourth terminal T4.

[0286] Optionally, the sub-power module 7 is connected to a third terminal T3 and a fourth terminal T4 that are insulated from each other, the first terminal T1 and the second terminal T2 are arranged opposite to each other; and the third terminal T3 and the fourth terminal T4 are arranged opposite to each other.

[0287] At least two sub-power modules 7 are connected to the same third terminal T3 and the same fourth terminal T4, which can reduce the number of terminals and reduce the series inductance.

[0288] Step S12: connecting the first terminal T1 and the third terminal T3, and connecting the second terminal T2 and the fourth terminal T4.

[0289] The preparation method provided in the embodiments of the present application can be used to prepare the power components of the above-mentioned embodiments, thereby forming a large stacking area 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 and negative terminals can achieve 100% or nearly 100% overlap, that is, the vertical projections of the positive and negative terminals on the surface 3 can coincide with or nearly 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 can be fixedly connected by welding, making the assembly process simpler and more convenient.

[0290] In one embodiment, the method for connecting the first terminal T1 and the third terminal T3, and the second terminal T2 and the fourth terminal T4 includes: connecting 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, and then connecting the end of the first terminal T1 away from the capacitor assembly 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 via a transfer terminal T5, or the two can be directly connected.

[0291] If the first terminal T1 and the third terminal T3 are directly connected to prepare Figure 23 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: Figure 25 and Figure 26 shown.

[0292] refer to Figure 25 and Figure 26 , Figure 25 and Figure 26 This is a schematic diagram of the principle of a terminal connection method according to an embodiment of the present application, the method comprising:

[0293] First, if Figure 25 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. Figure 25 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° to 80°. Before the terminals of the capacitor component 2 and the power module 1 are connected, as shown Figure 25 As shown, the fourth section terminal T04 is bent inwards and forms an angle b with the first section terminal T01, where b is less than 90°. Optionally, the value of b can be 70° to 80°.

[0294] Then, if Figure 26 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 included angles a and b, an outward-flaring bell-mouth structure is formed between the fourth-segment terminal T04 and the sixth-segment terminal T06. This outward-flaring bell-mouth structure serves as a welding window between the third-segment terminal T03 and the second terminal T2, facilitating welding. Based on the welding window formed by angles a and b, the second terminal T2 and the fourth terminal T4 are welded and secured.

[0295] 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 the following: Figure 23 The power assembly of the structure shown in FIG. In this step, the fourth and sixth terminal segments T04 and T06 can be fixed relative to each other at their ends using a fixture, and then their ends can be connected. Optionally, the fixture can be adapted to increase a and b, so that the end of the fourth terminal segment T04 away from the first terminal segment T01 and the end of the sixth terminal segment T06 away from the fifth terminal segment T05 are brought into contact with each other for welding and fixation.

[0296] For ease of illustration, Figure 25 and Figure 26The 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.

[0297] for Figure 25 and Figure 26 In actual application, 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 Figure 27 or Figure 28 The capacitor assembly 2 of the structure shown is connected to the power module 1 between terminals.

[0298] refer to Figure 27 , Figure 27 This is a schematic diagram of the terminal structure of a capacitor assembly before it is 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 processes, Figure 27 As shown, the fifth section terminal T05 and the sixth section terminal T06 are connected and fixed on the surface 3, and then Figure 25 and Figure 26 As shown, corresponding connections are made with the terminals of the power module 1 to form a Figure 23 Power components of the structure shown.

[0299] refer to Figure 28 , Figure 28 This is a schematic diagram of the terminal structure of another capacitor assembly before being connected and assembled with the power module. In this method, the first terminal T1 is still an integrated structure. Before being connected with the power module 1, Figure 28 As shown by the vertical dotted line in FIG, the first terminal T1 is an integral structure perpendicular to the surface 3. After the main body of the capacitor component 2 completes the necessary assembly / potting and other processes, Figure 28 As shown, the first terminal T1 is bent into two parts, namely the fifth terminal T05 and the sixth 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 needs, and this embodiment of the application does not limit this.

[0300] If the first terminal T1 and the third terminal T3 are connected via the adapter terminal T5, in the foregoing, 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.

[0301] If the first terminal T1 and the third terminal T3 can be connected through the transfer terminal T5, Figure 21Taking the power component of the structure shown 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 transfer terminal T5 is transferred and 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. Figure 21 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. Figure 22 The preparation process of the power component with the structure shown is the same as Figure 21 The corresponding method is the same and will not be described in detail in the embodiments of the present application.

[0302] Based on the power components provided in the above embodiments, another embodiment of the present application further provides a power module. The structure of the power module can be as follows: Figure 12 As shown, it includes: multiple sub-power modules 7, each of which is connected to a third terminal T3 and a fourth terminal T4; at least two sub-power modules 7 are connected to a third terminal T3 and a fourth terminal T4, so that at least two sub-power modules 7 share a third terminal T3 and a fourth terminal T4, reducing the number of terminals and increasing the overlapping area of ​​the third terminal T3 and the fourth terminal T4 to reduce the series inductance.

[0303] Optionally, the third terminal T3 and the fourth terminal T4 are arranged opposite to each other so that they at least partially overlap, thereby reducing the series inductance.

[0304] In the power module, the third terminal T3 and the fourth terminal T4 are stacked and arranged relative to each other, which can increase the stacking relative area between the third terminal T3 and the fourth terminal T4. Arranging multiple sub-power modules 7 to share the third terminal T3 and the fourth terminal T4 can further increase the stacking relative area of ​​the terminals and reduce the series inductance.

[0305] Based on the above embodiment, the first end 4 of the power module is connected to a third terminal T3 and a fourth terminal T4. The third terminal T3 includes a first terminal segment T01 connected to the first end 4, and the fourth terminal T4 includes a second terminal segment T02 connected to the first end 4. The first and second terminal segments T01 and T02 are parallel to a first direction X and arranged opposite each other in a second direction Y. The second direction Y is perpendicular to the plane of the power module, and the first direction is perpendicular to the second direction X. In this embodiment, the power module can at least ensure that the third terminal T3 and the fourth terminal T4 form a larger stacked relative area between the first and second terminal segments T01 and T02, thereby reducing the series inductance between them.

[0306] Based on the above embodiment, the fourth terminal T4 further includes a third section terminal T03 connected to the second section terminal T02; the third terminal T3 further includes a fourth section terminal T04 connected to the first section terminal T01; the third section terminal T03 and the fourth section terminal T04 both extend along the second direction Y; Figure 17 、 Figure 22 and Figure 23 In either embodiment, the third section terminal T03 and the fourth section terminal T04 are bent toward the same side and arranged opposite to each other in the first direction X; or Figure 21 As shown, the third section terminal T03 and the fourth section terminal T04 are bent in opposite directions.

[0307] Based on the above implementation method, Figure 15 As shown, at least two sub-power modules 7 share the same liner 6. This method can be used for the power generation control module 102. While meeting basic current control requirements, the size of the product in the third direction Z can be reduced by using multiple sub-power modules 7 to share the liner 6, thereby reducing the product volume.

[0308] Based on the above embodiment, at least two sub-power modules 7 each have a separate liner 6 so that each sub-power module can achieve precise current control. This method can be used for the drive control module 101 to achieve precise control of the drive motor.

[0309] Based on the above embodiment, at least two sub-power modules 7 share the same liner 6; at least two sub-power modules 7 each have a separate liner 6. In this approach, some of the sub-power modules 7 in the power module are used for the drive control module 101, while others are used for the power generation control module 102. This can form a dual-electric control structure in which the drive control module 101 and the power generation control module 102 are integrated, thereby improving the integration of the power module and reducing the product volume.

[0310] Based on the power components provided in the above embodiments, another embodiment of the present application further provides a motor controller, including the power components provided in the above embodiments.

[0311] Based on the motor controller provided in the above embodiment, another embodiment of the present application further provides an electronic control assembly, including the above motor controller.

[0312] Based on the electronic control assembly provided in the above embodiments, another embodiment of the present application further provides a vehicle, which includes the electronic control assembly provided by any one of the above embodiments.

[0313] In the embodiment of the present application, the vehicle includes an extended-range vehicle, which has independent motor drive requirements and independent power generation requirements. In order to achieve these two requirements, the industry often integrates motor drive (DC to AC) and 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 conventional full-bridge modules and the constraints of excessive single-body size, the size benefit of the simple mechanical integration 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 having to be packaged separately. The technical solution of the present application can achieve integrated packaging of the two control modules, solving the above problems.

[0314] 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.

[0315] 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. 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 topology is as follows: Figure 29 shown.

[0316] refer to Figure 29 , Figure 29 A topological structure diagram of an extended-range new energy vehicle provided in an embodiment of the present application. Figure 29 In the figure, solid lines represent mechanical connections and dashed lines represent electrical connections.

[0317] like Figure 29 As shown, one of the core components of a range-extended new energy vehicle is the range extender 18, which includes a generator motor 16 and a connected generator power assembly 15; 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. The inverter 13 is connected to the drive motor 12, which is connected to the electric drive unit 11. The electric drive unit 11 includes a speed reducer and a differential.

[0318] For example, a range-extended new energy vehicle (REV) has a core component: the range extender 18. Its primary function is to activate the range extender 18 when the power battery 14's charge drops below a certain level, allowing the engine 17 to drive the generator motor 16 to generate electricity. Part of this generated electricity is used to power the drive motor 12, while the remainder is used to charge the power battery 14.

[0319] Extended-range new energy vehicles have many advantages, including:

[0320] For daily commuting in cities, extended-range electric vehicles can run purely on electricity, achieving zero emissions and reducing tail gas pollution, thus meeting environmental requirements. Furthermore, electric drive is more energy-efficient than fuel-powered vehicles, reducing energy consumption and operating costs.

[0321] 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.

[0322] In addition, extended-range new energy vehicles also have the following advantages in driving experience:

[0323] Pure Electric Drive: The extended-range topology is essentially a pure electric drive system. The vehicle's driving power is entirely provided by the drive motor 12. The engine 17 does not directly drive the vehicle, but rather acts as a generator. When the battery is low, it starts to convert fuel into electricity to power the drive motor 12 or charge the battery. This pure electric drive method ensures a single, pure power source for the vehicle, consistent with the drive method of pure electric vehicles, fundamentally ensuring a comfortable driving experience.

[0324] Rapid Power Response: The characteristics of the drive motor 12 dictate its ability to deliver maximum torque instantaneously. In a vehicle with an extended-range topology, when the driver depresses the accelerator, the drive motor 12 responds instantly, rapidly delivering powerful power for rapid starts and acceleration. This immediate power response far surpasses that of traditional fuel vehicles, providing the driver with a more direct and powerful sense of push, ensuring a smooth driving experience, whether in frequent starts and stops in urban areas or overtaking on highways.

[0325] No power interruptions: Since the extended-range vehicle is constantly driven by the electric motor, there's no power interruption during gear shifts, as with traditional fuel-powered vehicles. Power delivery remains continuous and smooth, whether at low or high speeds. Even when the battery is low and the engine starts generating power, the system's sophisticated control strategy ensures unimpeded power delivery from the electric motor, preventing jerks or power interruptions. This provides the driver with a consistent, stable driving experience, enhancing both comfort and safety.

[0326] The electric control assembly of an extended-range new energy vehicle includes components such as the generator motor 16, the drive motor 12, the drive control module, and the power generation control module. In conventional extended-range new energy vehicles, the drive control module and the power generation control module are two separate components, each with its own independent power module (e.g., using diode semiconductors, IGBT semiconductors, SiC semiconductors, etc. to convert AC to DC), current sensors, temperature sensors, and motor rotor position sensors. These components are relatively heavy, bulky, and costly, and require urgent optimization.

[0327] 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 power component.

[0328] refer to Figure 30 , Figure 30 This is an equivalent circuit diagram of a power assembly provided in an embodiment of the present application. The power assembly includes a drive control module 101 for connecting to the drive motor 12 and a power generation control module 102 for connecting to the generator motor 16. The drive control module 101 includes multiple first sub-power modules 701, and the power generation control module 102 includes multiple second sub-power modules 702.

[0329] Each of the first sub-power module 701 and the second sub-power module 702 includes a half-bridge circuit, which 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 both include multiple power chips, which include at least a first power chip 905 and a second power chip 906. The upper bridge arm circuit 901 and the lower bridge arm circuit 902 both include a first power chip 905 and a second power chip 906 connected in parallel. The first power chip 905 can be an IGBT (insulated gate bipolar transistor), and optionally can be a SiC chip. The second power chip 906 can 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.

[0330] 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.

[0331] For the second sub-power module 702, the two ends of the upper bridge arm circuit 901 are respectively connected to the positive busbar 903 and one AC terminal of the generator motor 16, while the two ends of the lower bridge arm circuit 902 are respectively connected to the negative busbar 904 and one AC terminal 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 terminal of the generator motor 16. Different first sub-power modules 701 are connected to different AC terminals of the generator motor 16.

[0332] It should be noted that in the embodiments of the present application, the vehicle type is not limited to extended-range new energy vehicles, and can also be used for other types of vehicles. The embodiments of the present application do not limit this.

[0333] The various embodiments in the specification of this application are described in a progressive, parallel, or progressive and parallel manner. Each embodiment focuses on the differences from other embodiments, and the same or similar parts between the various embodiments can be referenced to each other. The embodiments provided in the embodiments of this application can be combined with each other if there is no contradiction.

[0334] It should be noted that in the description of this application, it should be understood that the description of the drawings and embodiments is illustrative rather than restrictive. The same figure numbers throughout the embodiments of the specification identify the same structure. In addition, for the purpose 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 mean positioning on the upper side of another element according to the direction of gravity.

[0335] The terms "upper," "lower," "top," "bottom," "inner," "outer," and the like, indicating positions or locations, are based on the positions or locations shown in the accompanying drawings and are intended solely to facilitate and simplify the description of this application. They are not intended to indicate or imply that the devices or elements referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on this 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 located component.

[0336] It should also be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion, such that an article or device comprising a series of elements includes not only those elements, but also other elements not explicitly listed, or elements inherent to such article or device. In the absence of further limitations, an element defined by the phrase "comprising a ..." does not exclude the presence of additional identical elements in the article or device comprising the aforementioned elements.

[0337] The above description of the disclosed embodiments is intended to enable one skilled in the art to implement or use the present application. Various modifications to these embodiments will be readily apparent to one 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 is not limited to the embodiments shown herein, but is intended to 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 capacitor assembly is connected to a first terminal and a second terminal; The power module includes a plurality of sub-power modules; The power module includes at least one third terminal and at least one fourth terminal; At least two of the sub-power modules are connected to one of the third terminals and one of the fourth terminals; 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 first terminal and the second terminal are connected to a surface of the capacitor assembly facing the power module.

3. The power component according to claim 2, characterized in that: The first end of the power module is connected to the third terminal and the fourth terminal.

4. The power component according to claim 3, characterized in that: The first end faces the first terminal and the second terminal.

5. The power component according to any one of claims 1 to 4, characterized in that: The first terminal and the second terminal are arranged opposite to each other in a first direction.

6. The power component according to claim 5, characterized in that: The third terminal and the fourth terminal are arranged opposite to each other in the second direction.

7. The power component according to claim 6, characterized in that: The third terminal includes a first-section terminal connected to the first end portion, and the fourth terminal includes a second-section terminal connected to the first end portion.

8. The power component according to claim 7, characterized in that: The first section of terminals and the second section of terminals are parallel to the first direction and are arranged opposite to each other in the second direction.

9. The power component according to any one of claims 5 to 8, characterized in that: The first direction is parallel to a stacking direction of the power module and the capacitor assembly.

10. The power component according to any one of claims 6 to 9, characterized in that: The second direction is parallel to the stacking direction.

11. The power component according to claim 6, 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.

12. The power component according to claim 11, 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.

13. The power component according to claim 12, characterized in that: The offset distance between the opposite edges of the first terminal and the second terminal 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.

14. The power component according to claim 7, 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 first end.

15. The power component according to claim 14, 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 segment terminal and the second terminal have a first overlapping area in the first direction, and the third segment terminal and the second terminal are connected in the first overlapping area.

16. The power component according to claim 15, characterized in that The third terminal and the first terminal are connected via a transfer terminal.

17. The power component according to claim 16, characterized in that: In the first direction, a gap is provided between the third terminal and the first terminal, exposing the first overlapping area, and the transition terminal covers the gap.

18. The power component according to claim 16, characterized in that The transfer terminal and the first terminal have a second overlapping area in the first direction, and the transfer terminal and the first terminal are connected 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.

19. The power component according to claim 18, characterized in that The first overlapping region and the second overlapping region do not overlap in the first direction.

20. The power component according to claim 19, 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.

21. The power component according to claim 18, characterized in that The transfer terminal and the first segment terminal have the third overlapping area in the second direction.

22. The power assembly according to claim 18, wherein: 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.

23. The power assembly according to claim 18, wherein: 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.

24. The power component according to claim 23, 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.

25. The power assembly according to claim 14, 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.

26. The power component according to claim 25, characterized in that The fourth section terminal and the first terminal have opposite portions 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 including one end of the second connection area is located in the accommodation space formed by the opposing parts.

27. The power component according to claim 26, characterized in that In the opposing portion, the fourth segment terminal and the first terminal both protrude toward a side away from the first overlapping region to form the accommodating space.

28. The power component according to any one of claims 15 to 27, characterized in that: In the first direction, the third terminal exposes at least a portion of the third section terminal.

29. The power component according to any one of claims 1 to 28, 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.

30. The power component according to any one of claims 1 to 28, 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.

31. The power component according to any one of claims 1 to 28, 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.

32. The power component according to any one of claims 1 to 28, 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.

33. The power component according to any one of claims 7 to 28, characterized in that: The first section terminal includes an integrated first portion and a second portion, the first portion is connected to the first end portion, and the second portion is located on a side of the first portion away from the first 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.

34. The power component according to any one of claims 1 to 28, characterized in that: The first terminal and the second terminal each include an integral third portion and a fourth portion; in the same terminal, the fourth portion is connected to the surface, and the third portion is located on a side of the fourth portion facing 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.

35. The power component according to any one of claims 7 to 28, characterized in that: The first section terminal includes an integrated first portion and a second portion, the first portion is connected to the first end portion, and the second portion is located on a side of the first portion away from the first end portion; The first terminal and the second terminal each include an integral third portion and a fourth portion; in the same terminal, the fourth portion is connected to the surface, and the third portion is located on a side of the fourth portion facing away from the surface; The width of the first portion is smaller than that 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 that of the fourth portion.

36. The power component according to any one of claims 1 to 35, 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 the drive motor; the power generation control module is used to connect to the 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.

37. The power assembly according to claim 36, 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.

38. The power assembly according to claim 37, 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.

39. The power assembly according to claim 36, wherein: The sub-power module in the drive control module is a first sub-power module, and the drive control module includes a plurality of the first sub-power modules, each of which has an independent liner; The sub-power module in the power generation control module is a second sub-power module. The power generation control module includes a plurality of the second sub-power modules, and the second sub-power modules share the same liner.

40. The power component according to any one of claims 36 to 39, characterized in that: The driving control module includes three of the first sub-power modules; the power generation control module includes three of the second sub-power modules.

41. The power component according to any one of claims 36 to 39, characterized in that: The sub-power module in the drive control module is a first sub-power module, and the drive control module includes a plurality of the first sub-power modules, and the first sub-power modules are connected to the same third terminal and the same fourth terminal; The sub-power module in the power generation control module is a second sub-power module, and the power generation control module includes a plurality of the second sub-power modules, and the second sub-power modules are connected to the same third terminal and the same fourth terminal; If the power assembly includes both the drive control module and the power generation control module, the first sub-power module and the second sub-power module are connected to different third terminals and different fourth terminals, respectively.

42. A method for preparing a power component according to any one of claims 1 to 41, characterized in that: include: A power module and a capacitor assembly are stacked; the capacitor assembly is connected to a first terminal and a second terminal; the power module includes a plurality of sub-power modules; the power module includes at least one third terminal and at least one fourth terminal; at least two of the sub-power modules are connected to one of the third terminals and one of the fourth terminals; The first terminal and the third terminal are connected, and the second terminal and the fourth terminal are connected.

43. The preparation method according to claim 42, characterized in that Connecting the first terminal and the third terminal, and connecting the second terminal and the fourth terminal, comprises: 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; 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.

44. The preparation method according to claim 43, characterized in that The first terminal and the second terminal are connected to the 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; the third terminal and the fourth terminal are connected to the first end of the power module; the first end faces the first terminal and the second terminal; the third terminal includes a first segment terminal connected to the first end, and the fourth terminal includes a second segment terminal connected to the first end; the first segment terminal and the second segment terminal are parallel to the first direction and are arranged opposite to each other in a 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; The fourth terminal further includes a third-segment terminal connected to the second-segment terminal; the third terminal further includes a fourth-segment terminal connected to the first-segment terminal; the third-segment terminal and the fourth-segment terminal both extend away from the capacitor assembly; the first terminal includes a fifth-segment terminal and a sixth-segment terminal, the fifth-segment terminal being perpendicularly connected to the surface; the sixth-segment terminal being connected to an end of the fifth-segment terminal facing away from the capacitor assembly; The method of connecting the capacitor assembly and the terminal of the power module includes: The sixth section of terminals is bent outward and forms an angle a with the first direction; the fourth terminal is bent inward and forms an angle b with the first section of terminals; both a and b are less than 90°; the second terminal and the fourth terminal are welded together based on the welding window formed by a and b; 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.

45. The preparation method according to claim 44, characterized in that Before welding the second terminal and the fourth terminal, the angles of a and b are 70° to 80°.

46. ​​A power module, characterized in that include: a plurality of sub-power modules, wherein the sub-power modules are connected to the third terminal and the fourth terminal; At least two of the sub-power modules are connected to one of the third terminals and one of the fourth terminals.

47. The power module according to claim 46, characterized in that The first end of the power module is connected to the third terminal and the fourth terminal.

48. The power module according to claim 46, characterized in that The third terminal includes a first section terminal connected to the first end, and the fourth terminal includes a second section terminal connected to the first 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.

49. The power module according to claim 48, characterized in that The second direction is perpendicular to the plane where the power module is located, and the first direction is perpendicular to the second direction.

50. The power module according to claim 48, wherein: 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 along the second direction; The third section terminal and the fourth section terminal are bent toward the same side and arranged opposite to each other in the first direction; or the third section terminal and the fourth section terminal are bent toward opposite directions.

51. The power module according to any one of claims 46 to 50, characterized in that: At least two of the sub-power modules share the same liner.

52. The power module according to any one of claims 46 to 50, characterized in that: At least two of the sub-power modules each have a separate liner.

53. The power module according to any one of claims 46 to 50, characterized in that: At least two of the sub-power modules share a same liner; At least two of the sub-power modules each have a separate liner.

54. A motor controller, characterized by comprising: a power component as described in any one of claims 1-41.

55. An electronic control assembly, characterized in that: Comprising a motor controller as claimed in claim 54.

56. A vehicle, characterized in that include: The electronic control assembly as claimed in claim 55.

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