Flexible circuit assembly and cover for traction inverter system of electric vehicle

Abstract

A flexible circuit assembly and cover for a traction inverter system of an electric vehicle is provided. The flexible circuit assembly includes a flexible printed circuit body, a first connector, and a second connector. The flexible printed circuit body forms an angled shape having an inner side and an outer side. The cover includes an outer surface, an inner surface including ribs, and a perimeter configured to attach to the housing. The outer surface includes a central region, a first lateral region and a second lateral region, and a constraining layer damping material. The central region, the first lateral region, and the second lateral region form a profile, and the restraint layer damping material conforms to the profile.

Description

Background Technology

[0001] This disclosure relates to electric vehicles (EVs). More specifically, this disclosure relates to traction inverter systems for electric vehicles. Summary of the Invention

[0002] The embodiments of this disclosure advantageously provide a flexible circuit assembly and cover for a traction inverter system for electric vehicles.

[0003] In some embodiments, the flexible circuit assembly includes a flexible printed circuit body, a first connector, and a second connector. The flexible printed circuit body is formed into an angled shape with inner and outer sides and includes: a reinforcement region; a copper-clad laminate (CCL) region disposed between a first cover region and a second cover region; and a shielding region including a shielding layer. The CCL region includes one or more trace layers. The first connector is attached to the reinforcement region at a first end of the flexible printed circuit body. The second connector is attached to the reinforcement region at a second end of the flexible printed circuit body.

[0004] In some embodiments, the cover includes an outer surface, an inner surface including ribs, and a periphery configured to attach to a housing. The outer surface includes a central region, a first lateral region, and a second lateral region, and a restraining layer damping material. The restraining layer damping material is attached to at least a portion of the central region, at least a portion of the first lateral region, and at least a portion of the second lateral region. The central region, the first lateral region, and the second lateral region form a contour, and the restraining layer damping material conforms to the contour. Attached Figure Description

[0005] Figure 1 An illustration of an example electric vehicle according to an embodiment of the present disclosure is depicted.

[0006] Figure 2A , Figure 2B , Figure 2C , Figure 2D The top view, bottom view, front view and rear view of an example traction inverter system according to an embodiment of this disclosure are presented respectively.

[0007] Figure 3A , Figure 3B A top cross-sectional view of a traction inverter system according to an embodiment of this disclosure is presented.

[0008] Figure 3C A front cross-sectional view of a traction inverter system according to an embodiment of this disclosure is presented.

[0009] Figure 3D , Figure 3EThe embodiments according to this disclosure are presented. Figure 3C Close-up views of each part.

[0010] Figure 4A A perspective view of an example flexible circuit assembly according to an embodiment of this disclosure is presented.

[0011] Figure 4B A partial cross-sectional view of the flexible circuit assembly according to an embodiment of the present disclosure is presented.

[0012] Figure 5 A plan view of the traces of a flexible circuit assembly according to an embodiment of the present disclosure is presented.

[0013] Figure 6A A perspective view of an example cover of a traction inverter system according to an embodiment of the present disclosure is presented.

[0014] Figure 6B The adoption of the implementation scheme according to this disclosure is presented. Figure 6A The diagram depicts a cross-sectional view of the cover of the traction inverter system. Detailed Implementation

[0015] Typically, a single-motor electric drive unit (EDU) for electric vehicles includes an AC electric motor, a gearbox, and a traction inverter system. The gearbox couples the AC motor to a differential drive shaft for either the front or rear wheels. The traction inverter system converts DC power received from the battery into AC power to drive the AC electric motor. During regeneration, the traction inverter system converts the AC power generated by the AC motor back into DC power to recharge the battery.

[0016] Similarly, a dual-motor EDU for electric vehicles specifically includes two AC electric motors, two gearboxes, and a traction inverter system for each AC electric motor. Each gearbox couples one AC electric motor to a dedicated drive shaft for one wheel. The traction inverter system converts DC power received from the battery into AC power to drive each AC electric motor. During regeneration, the traction inverter system converts the AC power generated by the AC motors back into DC power to recharge the battery.

[0017] The traction inverter system includes a main controller board for the power inverter module (PIM) used for AC motors and a motor controller board. The main controller board is coupled to the motor controller board using a low-voltage (LV) wiring harness with separate copper wires.

[0018] Integrating power electronics for two AC electric motors into a dual traction inverter system offers many advantages, but it can also present certain challenges, such as size and weight limitations, electrical noise issues (e.g., electromagnetic interference or EMI) caused by the PIM and AC electric motors, and mechanical vibration issues caused by the AC electric motors and gearbox.

[0019] For example, reducing the size of a dual-traction inverter system may affect the configuration, diameter, size, and operation of power and signal cables within the dual-power electronics housing. Similarly, reducing the weight of a dual-traction inverter system, such as by using a thinner cast or stamped cover, may increase airborne and structural noise radiated from and propagating into the passenger compartment.

[0020] The embodiments of this disclosure advantageously provide a flexible circuit assembly and cover for a traction inverter system of a dual-motor EDU for electric vehicles.

[0021] The flexible circuit assembly couples the main controller board to each motor controller board. The flexible circuit assembly offers a thinner footprint than LV harnesses with individual copper wires, improving the mechanical packaging of the connection between the main controller board and the motor controller board. The flexible circuit assembly also provides an integrated shielding layer to protect both the main controller board and the motor controller board from EMI. The flexible circuit assembly has the same geometry and construction and can be mounted in any relative orientation. Using the same components advantageously simplifies parts tracking, simplifies assembly, and reduces manufacturing time, among other benefits.

[0022] The cover of the traction inverter system includes a component of confined layer damping (CLD) material that significantly reduces airborne and structurally propagated noise radiated from and propagating into the passenger compartment (e.g., by up to 1 / 10).

[0023] Although the aspects of this disclosure are discussed in relation to traction inverter systems for dual-motor EDUs (also known as dual-traction inverter systems), the principles and advantages also apply to single-traction inverter systems, such as increased EMI protection, reduced airborne and structurally propagated noise radiation, etc.

[0024] Figure 1 A diagram depicts an electric vehicle 100 according to an embodiment of the present disclosure.

[0025] Electric vehicles 100 include, in particular, a frame and body 110, an energy storage and distribution system, a propulsion system, a suspension system, a steering system, auxiliary and accessory systems (such as thermal management, lighting, wireless communication, navigation, etc.), and so on.

[0026] Typically, the body 110 can be directly or indirectly mounted to the frame (i.e., a body structure on the frame), or the body 110 can be integrally formed with the frame (i.e., a unibody structure). The body 110 specifically includes a front end 120, headlight strips 122, front turn signals 123, a wraparound light ring 124, headlights 126, a charging port 130 with a charging port cover 136 containing a concealed charging connector socket, a driver / passenger compartment or cabin 140, a cargo box 150, a rear end 160 with taillights 162, a rear light strip, etc. The electric vehicle 100 can be a pickup truck, a sports utility vehicle (SUV) where the cargo box 150 is replaced by an extension of the cabin 140, or a passenger car where the cargo box 150 is replaced by a luggage compartment. In some embodiments, the electric vehicle can be an electric transport vehicle, an electric van, etc.

[0027] The propulsion system may include, in particular, one or more electronic control units (ECUs), one or more electric drive units (EDUs), front wheels 170, rear wheels 172, etc. The power storage and distribution system may include, in particular, one or more ECUs; a battery housing containing a battery pack including one or more batteries or battery modules (hereinafter referred to as "batteries"); and a vehicle charging subsystem including a charging port 130, a high-voltage (HV) cable connecting the batteries to the EDU, etc.

[0028] A single-motor EDU can be used to drive either the front wheels 170 (front-wheel drive) or the rear wheels 172 (rear-wheel drive). Alternatively, a single-motor EDU can be used to drive both the front wheels 170 and the rear wheels 172 (four-wheel drive). A dual-motor EDU can be used to independently drive either the front wheels 170 (independent front-wheel drive) or the rear wheels 172 (independent rear-wheel drive). Alternatively, a dual-motor EDU can be used to independently drive both front wheels 170 and both rear wheels 172 (independent four-wheel drive).

[0029] Figure 2A , Figure 2B , Figure 2C , Figure 2D Top view, bottom view, front view and rear view of the traction inverter system (TIS) 200 according to an embodiment of the present disclosure are presented respectively.

[0030] In some implementations, a dual-motor EDU for an electric vehicle may include two three-phase AC electric motors, two gearboxes, and a TIS200 containing power electronics. The TIS200 may include capacitor modules (such as DC link capacitors), six PIMs, a cooling subsystem, a main controller board, and two motor controller boards. Each motor controller board includes one or more controllers, processors, support components, circuitry, connectors, etc. Three PIMs are provided for each motor, and one PIM generates one phase of AC power supplied to each three-phase AC motor. Additionally, HV battery cable connectors, electrical signal connectors, and cooling subsystem connectors are also provided.

[0031] Figure 2A and Figure 2B A top view and a bottom view of the TIS200 according to an embodiment of this disclosure are presented.

[0032] The power electronics module 200 includes a cover 210 and a housing 220, which together form a sealed enclosure for mounting power electronics inside.

[0033] Cover 210 can be a metal casting, stamping, or other component formed as a single part. Cover 210 can closely conform to the dimensions of the power electronics contained within TIS 200. In other words, the profile of cover 210 can be set to minimize the volume within TIS 200.

[0034] The cover 210 may define several openings 212 to receive fasteners 214 that cooperate with threaded holes 226 in the housing 220 to secure the cover 210 to the housing 220. Figure 2A , Figure 2B The center indicates two openings 212 and two fasteners 214. The cover 210 may define several bosses 216 for attaching certain components to the TIS200 (in...). Figure 2A , Figure 2C , Figure 2D Four bosses 216 are identified in the housing 220, such as mounting brackets for wiring harnesses. Each boss 216 may define an opening configured to receive mounting fasteners, such as snap-fit ​​connectors. The cover 210 may also define several openings 218 to receive fasteners (not shown) that pass through the bosses 228 in the housing 220 to secure the TIS200 to the drive unit, and more specifically to the housing of the motor and gearbox. Figure 2A , Figure 2B The middle section is marked with two openings 218 and two bosses 228.

[0035] The housing 220 may be a metal casting formed as a single component.

[0036] Housing 220 includes several external connectors, such as electrical signal connectors 221 and 222, cooling subsystem connectors 223, 224, and 225, electric motor 1 bus assembly 230, electric motor 2 bus assembly 234, and HV battery cable connector 240. Typically, electrical signal connectors 221 and 222 are pin-type connectors. Electric motor 1 bus assembly 230 includes A-terminal blade 231, B-terminal blade 232, and C-terminal blade 233. Similarly, electric motor 2 bus assembly 234 includes A-terminal blade 235, B-terminal blade 236, and C-terminal blade 237. HV battery cable connector 240 includes a positive terminal blade 241 and a negative terminal blade 242.

[0037] Electric motor 1 bus assembly 230 is connected to 3-phase AC electric motor 1, electric motor 2 bus assembly 234 is connected to 3-phase AC electric motor 2, and HV battery cable connector 240 is connected to the battery via HV battery cable.

[0038] exist Figure 2A , Figure 2B The longitudinal and transverse axes of TIS200, as well as section lines 3A and 3B, are marked in the image.

[0039] Figure 2C and Figure 2D A front view and a rear view of the TIS200 according to an embodiment of this disclosure are presented.

[0040] exist Figure 2C The document identifies a cover 210, a housing 220, an electric motor 1 busbar assembly 230 with an A-terminal blade 231, an electric motor 2 busbar assembly 234 with an A-terminal blade 235, and an HV battery cable connector 240 with a positive terminal blade 241 and a negative terminal blade 242.

[0041] exist Figure 2D The components identified are cover 210, housing 220, electrical signal connector 221, electrical signal connector 222, cooling subsystem connectors 223, 224, 225, electric motor 1 bus assembly 230 with C-terminal blade 233, electric motor 2 bus assembly 234 with C-terminal blade 237, and HV battery cable connector 240 with positive end blade 241 and negative end blade 242.

[0042] Also there Figure 2C , Figure 2D The longitudinal axis and vertical axis of TIS200, as well as section line 3C, are marked in the middle.

[0043] Figure 3A , Figure 3B A top cross-sectional view through TIS200 is presented according to an embodiment of this disclosure. Figure 3A , Figure 3B The cross section is defined by the longitudinal axis and the transverse axis. Figure 3A The cross section passes through the joint between the cover 210 and the housing 220, while Figure 3B The cross section is in comparison Figure 3A The section passes through the cover at a vertical height slightly higher than the cross section.

[0044] Figure 3C A front cross-sectional view through TIS200 is presented according to an embodiment of this disclosure. Figure 3C The cross section is defined by the longitudinal axis and the vertical axis.

[0045] The power electronics module 200 specifically includes a capacitor module 300, PIMs 410, 420, and 430 for motor 1, PIMs 440, 450, and 460 for motor 2, a main controller board 500, a motor controller board 510 for motor 1, and a motor controller board 520 for motor 2. The capacitor module 300 is coupled to the input side of PIMs 410, 420, and 430 using capacitor bus contacts laser-welded to the corresponding PIM bus contacts. Similarly, the capacitor module 300 is coupled to the input side of PIMs 440, 450, and 460 using capacitor bus contacts laser-welded to the corresponding PIM bus contacts.

[0046] PIMs 410, 420, and 430 each include an inverter to supply one phase of three-phase AC power to the AC motor 1. The output side of PIM 410 is coupled to the A-terminal blade 231 of the bus assembly 230 of the AC motor 1 via power trace 261. The output side of PIM 420 is coupled to the A-terminal blade 232 of the bus assembly 230 of the AC motor 1 via power trace 262. The output side of PIM 430 is coupled to the A-terminal blade 233 of the bus assembly 230 of the AC motor 1 via power trace 263.

[0047] Similarly, PIMs 440, 450, and 460 each include an inverter to supply one phase of the three-phase AC power to the AC motor 2. The output side of PIM 440 is coupled to the A-terminal blade 235 of the bus assembly 234 of the AC motor 2 via power trace 265. The output side of PIM 450 is coupled to the A-terminal blade 236 of the bus assembly 234 of the AC motor 2 via power trace 266. The output side of PIM 460 is coupled to the A-terminal blade 237 of the bus assembly 234 of the AC motor 2 via power trace 267.

[0048] The inverter can also be used as a converter to convert AC power generated by an AC motor into DC power for recharging the battery during regeneration. Alternatively, the PIM 410, 420, 430, 440, 450, and 460 may each include a separate converter for regeneration.

[0049] The capacitor module 300 includes several capacitors (such as 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, etc.), a positive terminal 331, a negative terminal 332, and a DC common-mode choke 340. The positive terminal of each capacitor is connected to the positive capacitor bus, and the negative terminal of each capacitor is connected to the negative capacitor bus. The capacitors are coupled in parallel to the battery and maintain a consistent voltage across the PIM inverter. More specifically, the capacitors stabilize the DC voltage received from the battery to limit fluctuations when the PIM inverter intermittently requires large (or strong) DC current. The positive terminal 331 is connected to the positive capacitor bus and to the positive terminal blade 241 of the HV battery cable connector 240. Figure 2B , Figure 2C The negative terminal 332 is connected to the negative capacitor bus and to the negative terminal blade 242 of the HV battery cable connector 240. Figure 2B , Figure 2C The DC common-mode choke 340 surrounds the positive terminal 331 and the negative terminal 332, and reduces the high-frequency transmission to and from the capacitor module 300.

[0050] The main controller board 500 and motor controller boards 510 and 520 each include one or more controllers, processors, support components, circuits, connectors, etc. The main controller board 500 is connected to electrical signal connectors 221 and 222. Controller board 510 controls the AC power (AC voltage and current) supplied to motor 1, while motor controller board 520 controls the AC power (AC voltage and current) supplied to motor 2. The main controller board 500 controls the operation of motor controller boards 510 and 520 in response to control signals received via wires coupled to electrical signal connectors 221 and 222.

[0051] Motor controller board 510 is connected to main controller board 500 via a flexible circuit assembly 600, and motor controller board 520 is connected to main controller board 500 via another flexible circuit assembly 600. In some embodiments, each flexible circuit assembly 600 has an angled shape (such as a right angle) and can be mounted in any relative orientation (such as 180°). Typically, each flexible circuit assembly 600 may have an angled shape or a straight shape.

[0052] In some embodiments, the flexible circuit assembly 600 has: a flexible printed circuit body having an angled shape (such as 90° or a right angle, 45° angle, 30° angle, etc.); and a connector disposed at each end of the flexible printed circuit body. The main controller board 500 includes two sockets, the motor controller board 510 includes one socket, and the motor controller board 520 includes one socket. One flexible circuit assembly 600 has a connector fixed to one socket of the main controller board 500 and another connector fixed to the socket of the motor controller board 510. Similarly, another flexible circuit assembly 600 has a connector fixed to another socket of the main controller board 500 and another connector fixed to the socket of the motor controller board 520.

[0053] The cover 210 has an outer surface 211, an inner surface 213, and ribs 217 for stiffness, strength, etc.

[0054] Figure 3D , Figure 3E The embodiments according to this disclosure are presented. Figure 3C Close-up views of each part.

[0055] Figure 3D A portion of the flexible circuit assembly 600 connected to the main controller board 500 and the motor controller board 510 is depicted. The flexible circuit assembly 600 includes a connector 610 and a flexible printed circuit body 630, with a portion of the flexible printed circuit body depicted near the connector 610. The main controller board 500 includes a socket 502 configured to receive and secure the connector 610 of the flexible circuit assembly 600. The socket 502 and the connector 610 may include cooperating locking mechanisms such as bayonet locks, latch locks, lever locks, push-pull locks, unit locks, snap-locks, etc.

[0056] Figure 3E A portion of the flexible circuit assembly 600 connected to the main controller board 500 and the motor controller board 520 is depicted. The flexible circuit assembly 600 includes a connector 610 and a flexible printed circuit body 630, with a portion of the flexible printed circuit body depicted near the connector 610. The main controller board 500 includes a socket 504 configured to receive and secure the connector 610 of the flexible circuit assembly 600. The socket 504 and the connector 610 may include cooperating locking mechanisms such as bayonet locks, latch locks, lever locks, push-pull locks, unit locks, snap-locks, etc.

[0057] Figure 4A A perspective view of a flexible circuit assembly 600 according to an embodiment of this disclosure is presented. Section line 4B is identified.

[0058] As described above, the flexible circuit assembly 600 provides a thinner footprint than LV harnesses with individual copper wires, which improves the mechanical packaging of the connection between the main controller board 500 and the motor controller boards 510, 520. The flexible circuit assembly 600 also provides an integrated shielding layer to protect the main controller board 500 and the motor controller boards 510, 520 from EMI. In various embodiments, each flexible circuit assembly 600 has the same geometry and construction and can be mounted in any relative orientation. For example, Figure 2B Each flexible circuit assembly 600 shown in the TIS200 may have the same geometry and construction, but may be mounted at a 180-degree orientation relative to each other. Using the same components advantageously simplifies part tracking, simplifies assembly, and reduces manufacturing time and costs, among other things.

[0059] In some embodiments, the flexible circuit assembly 600 includes connector 610, connector 620, and a flexible printed circuit body 630 having an angled shape (such as a right angle) having an inner side 631 and an outer side 632. Connector 610 is disposed at one end of the flexible printed circuit body 630, while connector 620 is disposed at the other end of the flexible printed circuit body 630. Connectors 610 and 620 can be the same type of connector, such as an Insulated Displacement Contact (IDC) or Insulated Puncture Contact (IPC) connector, a DIN 41612 connector, a DIL connector, etc. In some embodiments, the connector can be a 40-position (40P) flexible printed circuit (FPC) connector. The flexible printed circuit body 630 includes several flexible printed circuit layers, such as... Figure 4B The description.

[0060] Figure 4B A partial cross-sectional view of the flexible circuit assembly 600 according to an embodiment of the present disclosure is presented.

[0061] Connector 610 includes connector housing 612 that holds a plurality of electrical contacts (pins, terminals, etc.) in a predetermined pattern (such as two offset rows). Each electrical contact mates with a corresponding electrical contact in a socket on main controller board 500, motor controller board 510, or motor controller board 520 to form an electrical connection. Pins extend from each electrical contact into flexible printed circuit body 630 to contact different signal traces, power traces, or ground traces within flexible printed circuit body 630. For example, pin 614 extends from connector housing 612 into (and through) flexible printed circuit body 630, contacts one of the traces, and is secured to flexible printed circuit body 630 using solder joint 616.

[0062] Typically, the flexible printed circuit body 630 includes several laminated layers, such as one or more polyimide (or polyester) layers 632, adhesive layers 634, plating layers 636, copper layers 638, FR4 (or other composite materials) layers 639, etc. The flexible printed circuit body 630 can be arranged into several regions, and each region may include one or more layers.

[0063] In some embodiments, the flexible printed circuit body 630 includes a reinforcing region 640, a cover region 650, a copper clad laminate (CCL) region 660, a cover region 670, and an EMI shielding region 680. The cover region 650 forms a first side of the flexible printed circuit body 630, and the cover region 670 forms a second side of the flexible printed circuit body 630. The cover regions 650 and 670 surround and protect the CCL region 660, which includes signal traces, power traces, and ground traces. Typically, the CCL region 660 may also be referred to as a trace layer region.

[0064] The reinforcing region 640 is a very short area disposed between the ends of the connector housing 612 and the cover region 650 to reinforce the mechanical connection between the flexible printed circuit body 630 and the connector housing 612. The reinforcing region 640 may include an FR4 layer 639 and an adhesive layer 634. The FR4 may be formed of epoxy resin and one or more braided glass fiber pads. The reinforcing region 640 defines a through-hole TH 641 through which a pin 614 passes. In some embodiments, surface mount technology (SMT) may be used, which eliminates the need for the through-hole.

[0065] The cover region 650 may include a polyimide layer 632 and an adhesive layer 634. The polyimide layer 632 at the end of the cover region 650 contacts the adhesive layer 634 of the reinforcing region 640. The cover region 650 defines a through-hole 651 through which a pin 614 passes.

[0066] CCL region 660 may include a first plating layer 636, a first copper layer 638, a first adhesive layer 634, a polyimide layer 632, a second adhesive layer 634, a second copper layer 638, and a second plating layer 636. The first copper layer 638 forms a ground and EMI shielding layer, while the second copper layer 638 contains signal traces, power traces, and ground traces. A plated via (PTH) 663 connects the ground trace within the second copper layer 638 to the ground layer within the first copper layer 638. Ground current is discharged from the flexible printed circuit body 630 through a pin of an electrical connector connected to the ground plane in the connector housing 612 of the connector 620, and then through an electrical connector in a socket on the motor controller board 510 or motor controller board 520. CCL layer 660 defines a via 661 through which a pin 614 passes.

[0067] Cover region 670 may include a polyimide layer 632 and an adhesive layer 634. Cover region 650 defines a through-hole 671 through which a pin 614 passes and a solder joint 616 is formed in the through-hole. Solder joint 616 forms a mechanical connection between pin 614 and a second plating layer 636 of CCL layer 660.

[0068] An EMI shielding region 680 extends along a cover region 670 between connectors 610 and 620. The EMI shielding region 680 may be formed of a silver sheet, silver ink, copper layer, shielding film, etc. A contact portion 683 connects the EMI shielding region 680 to a ground trace within the second copper layer 638 of the CCL layer 660. The EMI shielding region 680 exposes the end 681 of the cover region 670.

[0069] Typically, each layer in each region can have a thickness within a certain range.

[0070] For the reinforcing region 640, the FR4 layer 639 may have a thickness between 400 μm and 600 μm (such as 500 μm), and the adhesive layer 634 may have a thickness between 40 μm and 60 μm (such as 50 μm).

[0071] For the cover region 650, the polyimide layer 632 may have a thickness between 20 μm and 30 μm (such as 25 μm), and the adhesive layer 634 may have a thickness between 20 μm and 35 μm (such as 28 μm).

[0072] For CCL region 660, the first plating layer 636 may have a thickness between 10 μm and 20 μm (such as 15 μm), the first copper layer 638 may have a thickness between 15 μm and 20 μm (such as 17.5 μm), the first adhesive layer 634 may have a thickness between 5 μm and 15 μm (such as 10 μm), the polyimide layer 632 may have a thickness between 20 μm and 30 μm (such as 25 μm), the second adhesive layer 634 may have a thickness between 5 μm and 15 μm (such as 10 μm), the second copper layer 638 may have a thickness between 15 μm and 20 μm (such as 17.5 μm), and the second plating layer 636 may have a thickness between 10 μm and 20 μm (such as 15 μm).

[0073] For the cover region 670, the polyimide layer 632 may have a thickness between 20 μm and 30 μm (such as 25 μm), and the adhesive layer 634 may have a thickness between 20 μm and 35 μm (such as 28 μm).

[0074] The EMI shielding area 680 may have a thickness between 10 μm and 20 μm (such as 16 μm).

[0075] Figure 5 A plan view of the trace 690 of the flexible circuit assembly 600 according to an embodiment of the present disclosure is presented.

[0076] Trace 690 is formed within the second copper layer 638 of CCL region 660 and includes a signal trace 691, a power trace 692, an inner ground trace 693, an outer ground trace 694, and an additional ground trace 695. Typically, the signal trace 691 is narrower than the power trace 692, and the power trace 692 is narrower than the inner ground trace 693 and the outer ground trace 694. In one example, the width of the signal trace 691 is approximately one-fifth the width of the power trace 692, and the width of the power trace 692 is approximately one-half the width of the inner ground trace 693 and the outer ground trace 694. The width of the additional ground trace 695 may be the same as or slightly narrower than the widths of the inner ground trace 693 and the outer ground trace 694, and slightly wider than the width of the power trace 692.

[0077] Trace 690 also includes connector pin pads 696 for connector 610 and connector pin pads 697 for connector 620. Each signal trace 691, power trace 692, and ground trace 693 is respectively connected to one connector pin pad in connector pin pad 696 and one connector pin pad in connector pin pad 697. Additional ground trace 694 and external ground trace 695 are not connected to any pin pads.

[0078] exist Figure 5 In the example depicted, signal trace 691 includes 36 signal traces and two power traces 692. Other numbers and distributions of signal traces 691 and power traces 692 (such as one power trace 692, three power traces 692, etc.) are also supported. Power traces 692 are advantageously routed along the inside 631 of the flexible printed circuit body 630 to reduce voltage drop and copper usage for each power trace 692.

[0079] Typically, the first copper layer and the second copper layer 638 of the CCL region 660 can also be referred to as the trace layer.

[0080] Figure 6A A perspective view of the cover 210 of the TIS200 according to an embodiment of this disclosure is presented. It indicates... Figure 6B The area of ​​the cross-sectional view.

[0081] As discussed above, cover 210 can be a metal casting, stamping, etc., formed as a single component to closely conform to the positions of power electronic components contained within housing 220, which also minimizes the volume within TIS 200. Advantageously, cover 210 includes CLD material 700, which reduces airborne and structurally propagated noise radiated from cover 210 and propagated to cabin 140 (e.g., reduced to 1 / 5, reduced to 1 / 10, etc.).

[0082] In some embodiments, the cover 210 specifically includes an outer surface 211, an inner surface 213 (not visible), a periphery 215, and a boss 216. The outer surface 211 includes a central region 701, lateral regions 702, and lateral regions 703. The inner surface 213 may include ribs for stiffness, strength, etc. The periphery 215 is configured to attach to the housing 220 of the TIS 200.

[0083] The central region 701, lateral regions 702, and lateral regions 703 each include one or more flat portions located above certain spaces formed between the inner surface 213 of the cover 210 and components housed within the TIS 200, such as the main controller board 500, motor controller board 510, motor controller board 520, flexible circuit assembly 600, etc. Transition regions may couple adjacent flat portions located at different relative heights, such that the central region 701, lateral regions 702, and lateral regions 703 form a profile conforming to the positions of the components within the housing 220. Advantageously, the CLD material 700 may conform to the profile formed by the central region 701, lateral regions 702, and lateral regions 703.

[0084] The flat portion of cover 210 above these spaces can radiate noise more effectively than other areas of cover 210 that include more complex structural features. Therefore, in some embodiments, CLD material 700 may be attached to less than 100% of cover 210 (e.g., from about 30% to about 70%). For example, CLD material 700 may be attached to about 40% of cover 210.

[0085] In some embodiments, the CLD material 700 may include a central region 710, lateral regions 720, 722, and lateral regions 730, 732. The central region 710 may be attached to a flat portion of the central region 701 disposed above the main controller board 500. The lateral region 720 may be attached to a flat portion of the lateral region 702 disposed above the flexible circuit assembly 600, and the lateral region 722 may be attached to a flat portion of the lateral region 702 disposed above a portion of the motor controller board 510. Similarly, the lateral region 730 may be attached to a flat portion of the lateral region 703 disposed above the flexible circuit assembly 600, and the lateral region 732 may be attached to a flat portion of the lateral region 703 disposed above a portion of the motor controller board 520.

[0086] The CLD material 700 advantageously includes a transition region that allows the CLD material 700 to conform to (or follow) the contour of the outer surface 211 from the central region 710 to the lateral regions 720, 730, and the contour of the outer surface 211 within the lateral regions 720, 730. In other words, the CLD material 700 can be formed as a single continuous component to avoid discontinuities that could compromise the noise reduction effect.

[0087] Therefore, the CLD material 700 may also include transition regions 711, 712, 721, and 731. Transition region 711 joins the central region 710 and the lateral regions 720 and 722, while transition region 712 joins the lateral regions 730 and 732. Similarly, transition region 721 joins the lateral regions 720 and 722, while transition region 731 joins the lateral regions 730 and 732.

[0088] Additionally, the CLD material 700 may include several raised portions or towers, each tower aligned above a corresponding boss 216 to attach certain components to the cover 210, such as mounting pieces for wire harnesses. Each tower may define an opening configured to receive a mounting fastener (such as a snap-fit ​​connector) that attaches a mounting piece to the tower and / or boss 216. In this way, each pair of towers and bosses 216 cooperates to secure a component to the cover 210. Figure 6A In the example depicted, the central region 710 includes two tower portions 716 aligned with the boss 216 formed in the central region 701, the lateral region 720 includes tower portions 726 aligned with the boss 216 formed in the lateral region 702, and the lateral region 730 includes tower portions 736 aligned with the boss 216 formed in the lateral region 703.

[0089] Figure 6B The adoption of the implementation scheme according to this disclosure is presented. Figure 6A Cross-sectional view of cover 210.

[0090] CLD material 700 includes a metal constraint layer 740 and a polymer layer 760 attached together by a first adhesive layer 750. A second adhesive layer 750 attaches the polymer layer 760 to the outer surface 211 of the cover 210. In some embodiments, CLD material 700 may include one or more portions in which neither the metal constraint layer 740 nor the polymer layer 760 is present.

[0091] In some embodiments, the metal constraint layer 740 may be formed of a thin, corrosion-resistant steel sheet and may have a thickness in the range of 1 mm to 2 mm, such as 1.5 mm. In other embodiments, the metal constraint layer 740 may be formed of an aluminum sheet and may have a thickness in the range of 3 mm to 6 mm, such as 4.5 mm. Other types of metals (or sufficiently dense materials) may also be used.

[0092] In some embodiments, the polymer layer 760 may be formed of closed-cell polymer foam and may have a thickness in the range of 1 mm to 3 mm, such as 2 mm.

[0093] In some implementations, the CLD material 700 may have a thickness in the range of 2 mm to 5 mm, such as 3.5 mm.

[0094] From the detailed description, many features and advantages of this disclosure will be apparent, and therefore the appended claims are intended to cover all such features and advantages of this disclosure that fall within the scope of this disclosure. Furthermore, since many modifications and variations will readily occur to those skilled in the art, it is not intended to limit this disclosure to the exact construction and operation shown and described, and therefore all suitable modifications and equivalents may be invoked within the scope of this disclosure.

Claims

1. A flexible circuit assembly for a traction inverter system, the flexible circuit assembly comprising: A flexible printed circuit body, the flexible printed circuit body being formed into an angled shape having an inner side and an outer side, the flexible printed circuit body comprising: Reinforced area, A trace layer region, wherein the trace layer region is disposed between the first cover region and the second cover region, the trace layer region comprising one or more trace layers, and A shielded area, the shielded area including a shielding layer; A first connector, the first connector being attached to the reinforcing region at a first end of the flexible printed circuit body; and The second connector is attached to the reinforcement region at the second end of the flexible printed circuit body.

2. The flexible circuit assembly of claim 1, wherein the second connector is oriented substantially perpendicular to the first connector.

3. The flexible circuit assembly of claim 1, wherein the trace layer region includes a first trace layer and a second trace layer, and wherein the first trace layer includes a first ground trace along the inner wiring and a second ground trace along the outer wiring.

4. The flexible circuit assembly of claim 3, wherein the first trace layer includes at least one power trace routed close to the first ground trace, and a signal trace routed between the at least one power trace and the second ground trace.

5. The flexible circuit assembly of claim 4, wherein the first ground trace and the second ground trace have a first width, the power trace has a second width less than the first width, and each signal trace has a third width less than the second width.

6. The flexible circuit assembly of claim 5, wherein the first width is at least twice the second width, and the second width is at least five times the third width.

7. The flexible circuit assembly of claim 4, wherein the first trace layer includes at least one additional ground trace layer disposed adjacent to the power trace.

8. The flexible circuit assembly of claim 4, wherein the second trace layer is an additional shielding layer.

9. A traction inverter system, the traction inverter system comprising the first flexible circuit assembly according to claim 1, wherein: The first connector of the first flexible circuit assembly is coupled to the main controller board of the traction inverter system; and The second connector of the first flexible circuit assembly is coupled to the first motor controller board of the traction inverter system.

10. The traction inverter system according to claim 9, further comprising the second flexible circuit assembly according to claim 1, wherein: The first connector of the second flexible circuit assembly is coupled to the main controller board of the traction inverter system; The second connector of the second flexible circuit assembly is coupled to the second motor controller board of the traction inverter system; and The angled shape of the first flexible circuit assembly has an orientation opposite to the angled shape of the second flexible circuit assembly.

11. A cover for a traction inverter system, the cover comprising: The outer surface includes: Central area, first lateral area and second lateral area, and A constraint layer damping material, said constraint layer damping material being attached to at least a portion of the central region, at least a portion of the first lateral region, and at least a portion of the second lateral region; Inner surface, the inner surface including ribs; and The periphery is configured to attach to the housing. The central region, the first lateral region, and the second lateral region form a contour that conforms to the position of the component within the housing, and the constraint layer damping material conforms to the contour.

12. The cover according to claim 11, further comprising: One or more bosses, extending from at least one of the central region, the first lateral region, and the second lateral region, each boss defining an opening configured to receive a corresponding fastener; and One or more tower sections extend from the constraint layer damping material, each tower section is aligned above one of the bosses, and each tower section defines an opening configured to receive the corresponding fastener.

13. The cover according to claim 11, wherein the constraint layer damping material comprises: Central area, first lateral area, and second lateral area; A first transition region joins the central region to the first lateral region; and A second transition region joins the central region to the second lateral region.

14. The cover according to claim 13, wherein the first lateral region of the constraint layer damping material includes a third transition region, and the second lateral region of the constraint layer damping material includes a fourth transition region.

15. The cover of claim 13, wherein the constraint layer damping material comprises a metal constraint layer, a polymer layer and at least one adhesive layer to secure the metal constraint layer to the polymer layer.

16. The cover according to claim 15, wherein: The metal constraint layer is a steel sheet with a thickness between 1 mm and 2 mm; The polymer layer is a high-temperature polymer and has a thickness between 1 mm and 3 mm.

17. The cover of claim 13, wherein the transition region conforms to the contour between the central region and the first lateral region and the contour between the central region and the second lateral region.

18. A traction inverter system, the traction inverter system comprising: A first flexible circuit assembly is attached to the main controller board and the first motor controller board; A second flexible circuit assembly is attached to the main controller board and the second motor controller board, wherein each flexible circuit assembly includes: A flexible printed circuit body, the flexible printed circuit body being formed into a shape with an angled inner side and an outer side. A first connector is attached to a first end of the flexible printed circuit body, and A second connector is attached to a second end of the flexible printed circuit body; and The cover, the cover comprising: The outer surface includes: Central area, first lateral area and second lateral area, and A constraint layer damping material, said constraint layer damping material being attached to at least a portion of the central region, at least a portion of the first lateral region, and at least a portion of the second lateral region. Inner surface, the inner surface including ribs, and The periphery is attached to the housing. The central region, the first lateral region, and the second lateral region form a contour that conforms to the positions of the first flexible circuit assembly and the second flexible circuit assembly, the main controller board, and the first motor controller board and the second motor controller board within the housing, and the constraint layer damping material conforms to the contour.

19. The traction inverter system according to claim 18, wherein the flexible printed circuit body comprises: Reinforced area; A copper clad laminate (CCL) area is disposed between a first cover area and a second cover area. The CCL area includes a trace layer, which includes a first ground trace along the inner wiring and a second ground trace along the outer wiring. and A shielded area, the shielded area including a shielding layer.

20. The traction inverter system according to claim 18, wherein: One or more bosses extend from at least one of the central region, the first lateral region, and the second lateral region, and each boss defines an opening configured to receive a corresponding fastener; and One or more towers extend from the constraint layer damping material, each tower being aligned above one of the bosses, and each tower defining an opening configured to receive the corresponding fastener.

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