Electrical assembly, motor controller, vehicle and method of assembling electrical assembly

Abstract

The present disclosure relates to an electrical assembly for a motor controller configured to be electrically connected on one hand to a motor and on the other hand to a high voltage supply battery, the electrical assembly comprising: a bracket forming a box on a wall of the bracket, the box being integrally formed with the bracket, a portion of the wall forming a bottom of the box, the side wall extends from the bottom of the box body to form the box body; the capacitor module is accommodated in the box body, the capacitor module comprises a capacitor element and insulation paper, and the insulation paper is used for electric insulation between the capacitor element and the box body; the space between the box body and the capacitor module is filled with the filling substance, so that the capacitor module is fixed, and the sealing performance of the capacitor module is ensured; the support comprises a first area and a second area, the box body is located in the first area, the second area is used for placing the power module, and the first area and the second area do not coincide. The present disclosure also relates to a motor controller comprising such an electrical assembly, a vehicle and a method for assembling such an electrical assembly.

Description

Technical Field

[0001] This disclosure relates to an electrical component for a motor controller. This disclosure also relates to a motor controller including such an electrical component, a vehicle, and a method for assembling such an electrical component. Background Technology

[0002] Typically, during operation, capacitors are subjected to temperature changes. When a capacitor is surrounded by air, these temperature changes can cause moisture from the surrounding air to condense. This condensed water can hinder the proper operation of the capacitor. Therefore, a sealed arrangement is necessary. Generally, the capacitor is immersed in a polymerizable resin. This resin is poured around the capacitor in a fluid state and then polymerizes into a solid state. This polymerization can be carried out by heating in an oven. Thus, the resin completely surrounds the capacitor in a sealed manner. This resin is also an electrical insulator.

[0003] Furthermore, capacitors are components used in automotive inverters, voltage converters, or power chargers. Specifically, in electric or hybrid vehicle applications, the current can be very high. The heat generated by the Joule effect can then become significant, posing a risk of damaging the capacitor. To prevent any reduction in heat, a system for cooling the capacitor is necessary. Disadvantageously, in the case of electric or hybrid vehicles, the resin does not have sufficient thermal conductivity, so heat cannot be dissipated quickly and efficiently.

[0004] Typically, capacitors are housed in a separate plastic casing, which is then attached to the outer shell of the electrical device. This requires a significant amount of material and results in a larger, less compact device. Furthermore, to dissipate heat from the capacitor, it is usually necessary to place it against a thermal pad or cooling circuit, which also increases the size of the electrical device. Summary of the Invention

[0005] Therefore, this disclosure aims to solve the above-mentioned problems, and its object is to provide a novel electrical component, motor controller, vehicle, and method for assembling the electrical component. The electrical component according to this disclosure can:

[0006] (1) Saves materials for manufacturing electrical components and reduces manufacturing costs;

[0007] (2) Improve the mechanical strength of electrical components through integrated structural design;

[0008] (3) Provide more metal contact surfaces for the capacitor module to improve the heat dissipation efficiency of the capacitor module;

[0009] (4) Eliminating the need for a separate capacitor casing eliminates the need for additional structures to secure the capacitor, resulting in smaller and more compact electrical equipment.

[0010] The objective is achieved by an electrical component for a motor controller according to an embodiment of the present disclosure, the motor controller being configured to be electrically connected to a motor on one side and to a high-voltage supply battery on the other side. The electrical component includes: a bracket, a housing formed on the wall of the bracket, the housing being integrally formed with the bracket, a portion of the wall forming the bottom of the housing, and side walls extending from the bottom of the housing; a capacitor module housed within the housing, the capacitor module including a capacitor element and insulating paper for electrical insulation between the capacitor element and the housing; a filler material filling the space between the housing and the capacitor element to accommodate the capacitor element and ensure its sealing; the bracket including a first region and a second region, the housing located in the first region, the second region for housing a power module, the first region and the second region not overlapping.

[0011] According to one embodiment of this disclosure, the filling material extends to the height of the housing.

[0012] According to one embodiment of this disclosure, the electrical component further includes a power module and a cooling device, the power module and the cooling device being fixed to a second region (B) of the bracket, the cooling device being disposed below the power module for cooling the power module.

[0013] According to one embodiment of this disclosure, the support is made of aluminum metal.

[0014] According to one embodiment of this disclosure, the capacitor module further includes a first copper busbar and a second copper busbar, the first copper busbar and the second copper busbar being used to realize the electrical connection between the externally supplied battery and the power module, and the insulating paper being used for electrical insulation between the first copper busbar and the second copper busbar and the housing.

[0015] According to one embodiment of this disclosure, the electrical component further includes a connecting copper busbar with insulating paper, one end of which is connected to the power module and the other end of which is connected to the first copper busbar.

[0016] According to one embodiment of this disclosure, a notch is provided on the side wall of the housing near the second region for the first copper busbar and the second copper busbar to pass through. The notch is sealed by a plastic component, which has an opening for the first copper busbar and the second copper busbar to extend out of the housing.

[0017] According to one embodiment of this disclosure, the power module includes a silicon carbide field-effect transistor.

[0018] According to one embodiment of this disclosure, the filler material includes resin.

[0019] This disclosure also relates to a motor controller that includes the aforementioned electrical components.

[0020] According to one embodiment of this disclosure, the motor controller includes a housing, and the bracket forms the bottom of the housing.

[0021] This disclosure also relates to a vehicle that includes the aforementioned electrical components and / or motor controller.

[0022] This disclosure also relates to a method for assembling the aforementioned electrical components, the method comprising: placing the capacitor module in the housing via an opening in the housing; filling the space between the capacitor module and the housing; depositing a filling material to ensure the sealing of the capacitor module; the filling material extending to the height of the housing. Attached Figure Description

[0023] The above and other features and advantages of this disclosure will become more apparent from the following detailed description of exemplary embodiments taken in conjunction with the accompanying drawings, which are for illustrative purposes only and are not intended to limit the scope of this disclosure in any way. The following drawings are not intentionally drawn to scale with actual dimensions; their focus is on illustrating the gist of this disclosure.

[0024] Figure 1 This is a schematic diagram of an electrical component provided in at least one embodiment of the present disclosure, showing an exploded view of a capacitor module;

[0025] Figure 2 This is a schematic diagram of the assembly of an electrical component provided in at least one embodiment of the present disclosure.

[0026] Explanation of reference numerals in the attached figures

[0027] 10: Electrical components;

[0028] 11: Bracket;

[0029] 12: Capacitor module;

[0030] 121: Capacitor element;

[0031] 122: Insulating paper;

[0032] 123: First Bronze Bar;

[0033] 124: Second Bronze Bar;

[0034] 125: Connecting copper busbar;

[0035] 13: Filler material;

[0036] 14: Box;

[0037] 15: Power module;

[0038] 16: Cooling device. Detailed Implementation

[0039] To make the objectives, technical solutions, and advantages of the embodiments of this disclosure clearer, the technical solutions of the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings.

[0040] For ease of description, the accompanying drawings of this disclosure have correspondingly simplified or omitted components commonly used in the art, such as external connecting lines and other components unrelated to the description of this disclosure. These omitted or simplified components do not affect a person skilled in the art's understanding of the content of this disclosure.

[0041] Figure 1 A schematic diagram of an electrical component 10 provided in at least one embodiment of the present disclosure is shown, wherein an exploded view of a capacitor module is shown.

[0042] like Figure 1 As shown, the electrical component 10 includes a bracket 11, a capacitor module 12, and a filler material 13. A housing 14 is formed on the wall of the bracket 11, and the housing 14 is integrally formed with the wall of the bracket 11. A portion of the wall forms the bottom of the housing 14, and side walls of the housing 14 extend from the bottom of the housing 14. The bracket 11 includes a first region A and a second region B, with the housing 14 located in the first region A and the second region B used to house the power module (…). Figure 1 (Not shown in the image), the first region A and the second region B do not overlap.

[0043] The capacitor module 12 includes a capacitor element 121, and the capacitor module 12 is housed within the housing 14. Figure 1 As shown, the capacitor module 12 also includes insulating paper 122, a first copper busbar 123, and a second copper busbar 124. The insulating paper 122, the first copper busbar 123, the capacitor element 121, and the second copper busbar 124 are stacked sequentially from the bottom of the housing 14 and housed within the housing 14. The first copper busbar 123 and the second copper busbar 124 are used to establish the electrical connection between the external battery and the power module. The insulating paper 122 provides electrical insulation between the capacitor element 121, the first copper busbar 123, and the second copper busbar 124 and the housing 14.

[0044] For example, in some embodiments of this disclosure, a notch is provided on the side wall of the housing 14 near the second region B for the first copper busbar 123 and the second copper busbar 124 to pass through, thereby connecting to the power module of the second region B. This notch on the side wall is closed by a plastic piece 141, which is fixedly sealed to the side wall with adhesive to prevent leakage of filler material. The first copper busbar 123 and the second copper busbar 124 can exit through the opening in the plastic piece 141. The purpose of the first copper busbar 123 and the second copper busbar 124 exiting the housing 14 from the side wall rather than from the top of the housing 14 is to reduce the height of the electrical components, making the electrical components smaller.

[0045] A portion of the wall of the support 11 of the electrical component 10 forms the bottom of the housing 14, and extends from the bottom of the housing 14 to form the sidewalls of the housing 14. The bottom and sidewalls define the space for housing the capacitor module 12. The housing 14 thus acts as a housing for the capacitor module 12, thereby forming a component that is easy to concentrate in the electrical component 10.

[0046] The illustrated example shows a cube-shaped housing 14, the shape of which allows the capacitor module 12 to be completely housed across its entire height. It should be noted that the housing 14 can also have other shapes, and this disclosure does not limit its application.

[0047] In the electrical assembly provided according to this disclosure, the housing of the capacitor module is part of the support frame and is integrally formed with the support frame. Compared with the prior art where the capacitor module has a separate housing, the solution of this disclosure saves manufacturing materials and reduces manufacturing costs. At the same time, it eliminates the need for additional fixing structures to secure the capacitor module, making the electrical assembly smaller and more compact. Furthermore, for the housing of a separate capacitor module, screws or bolts are typically used to fix the housing of the capacitor module to the support frame of the electrical assembly. The integrated design of this disclosure has higher mechanical strength and a more compact spatial structure compared to screw or bolt fixing methods, making the electrical assembly more stable.

[0048] For example, in one embodiment of this disclosure, the bracket is made of aluminum. It should be noted that aluminum is merely an example; the bracket can also be made of other metal materials, and this disclosure is not limiting in this regard. Due to the good thermal conductivity of metal materials, the capacitor module can dissipate heat through the enclosure made of metal material. Therefore, the electrical components provided in this disclosure can improve the heat dissipation efficiency of the capacitor module.

[0049] Therefore, compared to the prior art that uses a plastic casing to house the capacitor module, in the electrical assembly according to the present invention, there is no need to provide a heat dissipation pad or cooling water channel for cooling the capacitor module; instead, heat dissipation is achieved through the enclosure of the electrical assembly. The capacitor module thus has more efficient heat dissipation than in the prior art, and the overall structure of the electrical assembly is therefore more compact.

[0050] The filler material 13 is used to fill the space between the housing 14 and the capacitor module 12 to secure the capacitor module 12 within the housing 14, prevent the capacitor module 12 from shifting within the housing 14, and ensure the sealing of the capacitor module 12. Specifically, the filler material 13 completely surrounds the capacitor module 12, particularly between the capacitor module 12 and the bottom and side walls of the housing 14. The filler material 13 is fluid during the filling of the housing 14 and subsequently becomes solid after the polymerization step. For example, the filler material 13 is a polymerizable material, such as a polymerizable resin.

[0051] For example, in one embodiment of this disclosure, the filler extends to the height of the box.

[0052] Specifically, "height" means the distance measured from the bottom of the housing 14 in the stacking direction of the components of the capacitor module 12.

[0053] This height of the filler material makes it possible to ensure the capacitor's airtightness, thus preventing moisture surrounding the enclosure from penetrating into the capacitor. Specifically, the capacitor is encapsulated within the enclosure by the solidified filler material, thus forming a single, controllable object.

[0054] Figure 2 This is a schematic diagram of the assembly of an electrical component provided in at least one embodiment of the present disclosure.

[0055] like Figure 2 As shown, the electrical component 10 may also include a power module 15 and a cooling device 16, for example, the cooling device 16 is disposed below the power module 15 for cooling the power module 15.

[0056] from Figure 2 As can be seen, the enclosure 14 is located in the first region A of the support 11. The enclosure 14 houses the potted capacitor module 12, while the power module 15 and cooling device 16 are fixed in the second region B of the support 11. The enclosure 14, power module 15, and cooling device 16 are arranged side by side. Compared to the existing "sandwich" structure, in which the capacitor module, cooling device, and power module are stacked sequentially, the side-by-side structure provided in this disclosure can meet the needs of electrical equipment requiring a smaller thickness.

[0057] like Figure 2As shown, the electrical component 10 may further include a connecting copper busbar 125 with insulating paper, one end of which is connected to the power module 15, and the other end of which is connected to the first copper busbar 123. The purpose of using the connecting copper busbar 125 to achieve an electrical connection between the power module 15 and the first copper busbar 123, rather than directly connecting the first copper busbar 123 and the power module 15, is to reduce the equivalent series inductance (ESL) between the positive and negative terminals of the power module 15.

[0058] For example, in one embodiment of this disclosure, power module 15 includes silicon carbide field-effect transistors (SiC-MOSFETs).

[0059] According to another aspect of this disclosure, a method for assembling the aforementioned electrical components is provided, the method comprising: placing a capacitor module 12 in a housing 14 through an opening in the housing 14; filling the space between the capacitor module 12 and the housing 14; depositing a filling material 13 to ensure the sealing of the capacitor module 12; the filling material 13 extending to the height of the housing 14.

[0060] According to another aspect of this disclosure, a motor controller is proposed, which includes the electrical components described above. The motor controller is configured to be electrically connected to a motor on one side and to a high-voltage supply battery on the other. It should be understood that the motor controller of this disclosure also possesses the advantages described above regarding the electrical components.

[0061] According to another aspect of this disclosure, a vehicle is proposed that includes the electrical components and / or motor controller as described above. The vehicle may be an electrified vehicle, such as a battery electric vehicle (BEV), a hybrid electric vehicle (HEV), a plug-in hybrid electric vehicle (PHEV), a range-extended electric vehicle (REEV), or a fuel cell electric vehicle (FCEV). The vehicle may also be a hydrogen fuel cell vehicle. It should be understood that the vehicle of this disclosure also possesses the advantages described above regarding the electrical components.

[0062] Certain features, structures, or characteristics in one or more embodiments of this disclosure may be appropriately combined.

[0063] The foregoing description is illustrative of the present disclosure and should not be construed as limiting it. While several exemplary embodiments of the present disclosure have been described, those skilled in the art will readily understand that many modifications may be made to the exemplary embodiments without departing from the novel teachings and advantages of the present disclosure. Therefore, all such modifications are intended to be included within the scope of the present disclosure as defined in the claims. It should be understood that the foregoing description is illustrative of the present disclosure and should not be construed as limiting it to the specific embodiments disclosed, and modifications to the disclosed embodiments and other embodiments are intended to be included within the scope of this disclosure.

Claims

1. An electrical component (10) for a motor controller, characterized in that, The motor controller is configured to be electrically connected to the motor on one side and to the high-voltage supply battery on the other side. The electrical components (10) include: A support (11), wherein a box (14) is formed on the wall of the support (11), the box (14) is integrally formed with the support (11), a portion of the wall forms the bottom of the box (14), and the side wall of the box (14) extends from the bottom of the box (14); A capacitor module (12), wherein the capacitor module (12) is housed in the housing (14), the capacitor module (12) includes a capacitor element (121) and insulating paper (122), the insulating paper (122) being used for electrical insulation between the capacitor element (121) and the housing (14); A filling material (13) fills the space between the housing (14) and the capacitor module (12) to fix the capacitor module (12) and ensure the sealing of the capacitor module (12); The bracket (11) includes a first region (A) and a second region (B). The housing (14) is located in the first region (A) and the second region (B) is used to place the power module. The first region (A) and the second region (B) do not overlap.

2. The electrical component (10) according to claim 1, characterized in that, The filling material (13) extends to the height of the box (14).

3. The electrical component (10) according to claim 1, characterized in that, The electrical component (10) also includes a power module (15) and a cooling device (16), which are fixed in a second region (B) of the bracket (11). The cooling device (16) is disposed below the power module (15) for cooling the power module (15).

4. The electrical component (10) according to claim 1, characterized in that, The support (11) is made of aluminum metal.

5. The electrical component (10) according to claim 3, characterized in that, The capacitor module (12) further includes a first copper busbar (123) and a second copper busbar (124), wherein the first copper busbar (123) and the second copper busbar (124) are used to realize the electrical connection between the external power supply battery and the power module (15), and the insulating paper (122) is used for electrical insulation between the first copper busbar (123) and the second copper busbar (124) and the housing (14).

6. The electrical component (10) according to claim 5, characterized in that, The electrical component (10) also includes a connecting copper busbar (125) with insulating paper, one end of which is connected to the power module (15), and the other end of which is connected to the first copper busbar (123).

7. The electrical component (10) according to claim 5, characterized in that, The side wall of the housing (14) near the second region (B) is provided with a notch for the first copper busbar (123) and the second copper busbar (124) to pass through. The notch is sealed by a plastic part (141) with an opening for the first copper busbar (123) and the second copper busbar (124) to extend out of the housing (14).

8. The electrical component (10) according to claim 3, characterized in that, The power module (15) includes a silicon carbide field-effect transistor.

9. The electrical component (10) according to claim 1, characterized in that, The filler material (13) includes resin.

10. A motor controller comprising an electrical component (10) according to any one of claims 1 to 9.

11. The motor controller according to claim 10, characterized in that, The motor controller includes a housing, and the bracket (11) forms the bottom of the housing.

12. A vehicle comprising an electrical component (10) according to any one of claims 1 to 9 and / or a motor controller according to claim 10 or 11.

13. A method for assembling an electrical component (10) according to any one of claims 1 to 9, comprising: The capacitor module (12) is placed inside the housing (14) through an opening in the housing (14). The space between the capacitor module (12) and the housing (14) is filled to deposit a filling material (13) that ensures the sealing of the capacitor module (12), wherein the filling material (13) extends to the height of the housing (14).

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