A film capacitor with dual electronic control including power relay, EMC filtering, and heat dissipation device.

Abstract

This invention discloses a film capacitor with dual electronic control including a power relay, EMC filtering, and heat dissipation device, belonging to the field of capacitor technology. The film capacitor includes a casing, an EMC filtering component, and a copper busbar assembly. The copper busbar assembly includes a first positive copper busbar and a second positive copper busbar, which connect two separate circuits into a dual electronic control circuit. This allows for more reliable logic control with simplified hardware, resulting in high sensitivity and good coordination for controlling subsequent equipment. After assembly, this capacitor reduces the number of electronic components, saving space. Furthermore, the centralized control logic reduces the number of fault points, making subsequent fault diagnosis easier and reducing energy consumption from redundant components.

Description

Technical Field

[0001] This invention belongs to the field of capacitor technology, and particularly relates to a thin-film capacitor with dual electronic control of power relay EMC filtering and heat dissipation device. Background Technology

[0002] Electric vehicles represent a significant development direction for new energy vehicles, and four-wheel drive is gradually becoming more common in them. Currently, most four-wheel drive electric vehicles use drive motors equipped with multiple circuit systems. These multiple circuit systems typically employ a design with independent capacitors: each circuit system is equipped with a corresponding independent capacitor to regulate the motor. This control method with multiple independent capacitors has several drawbacks: complex wiring, numerous electrical components, and large space requirements. Furthermore, the interconnected independent circuits within these systems are difficult to control, leading to delayed transmission or situations where other circuit systems cannot respond promptly when one system malfunctions. Additionally, the high heat generation of multiple independent capacitor circuit systems can cause some electrical components to overheat and malfunction, resulting in poor overall system stability. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide a film capacitor with dual electronic control of power relay EMC filtering and heat dissipation device that can overcome or at least partially solve the above problems.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] A film capacitor with dual electronic control via power relay, EMC filtering, and heat dissipation device includes a film capacitor housing, an EMC filtering component, and a copper busbar assembly. The EMC filtering component is installed inside the film capacitor housing and has a capacitor core. The copper busbar assembly has terminals, a negative copper busbar, and a ground copper busbar. The copper busbar assembly also has a first positive copper busbar and a second positive copper busbar. The first positive copper busbar is located in the upper half of the housing, and the second positive copper busbar is located in the lower half of the film capacitor housing. The first and second positive copper busbars are mounted on the capacitor core. Dual electronic control of the capacitor is achieved by connecting the first and second positive copper busbars to different circuits.

[0006] Furthermore, circular through holes are evenly distributed on the first and second positive electrode copper busbars.

[0007] Furthermore, the terminals of the second positive copper busbar extend into the upper part of the casing of the film capacitor and are arranged correspondingly to the terminals of the first positive copper busbar.

[0008] Furthermore, a power relay is provided in the bottom area inside the casing of the film capacitor, and the power relay can control the on or off of the connected circuit.

[0009] Furthermore, the power relay is provided with a connector that enables the power relay to receive transmitted signals.

[0010] Preferably, the power relay is provided with a mounting bracket on its outer side, and the power relay is mounted inside the housing of the film capacitor by the mounting bracket, so that the power relay will not shake or shift inside the housing of the film capacitor.

[0011] Furthermore, a heat-conducting plate is provided on the bottom outer side of the outer casing of the thin-film capacitor.

[0012] Preferably, the heat-conducting plate is provided with snap-fit ​​components on both sides, which extend to the edges of the film capacitor housing and leave gaps between the snap-fit ​​components and the edges of the film capacitor housing.

[0013] Furthermore, the EMC filter assembly also includes a Y2 capacitor bank, which is located in the side area inside the housing of the film capacitor.

[0014] By adopting the above technical solution, the present invention has the following beneficial effects compared with the prior art:

[0015] 1. By setting up a first positive copper busbar and a second positive copper busbar, this invention connects two separate circuits into a dual-control circuit, achieving more reliable logic control with more streamlined hardware, avoiding the use of more electronic components in the two circuits, saving space; it also reduces related components, resulting in fewer fault points, centralized control logic, easier fault location during later troubleshooting, and improved maintenance efficiency; at the same time, it also reduces the energy consumption of redundant components, thus reducing energy consumption.

[0016] The dual electronic control circuit also ensures that there is no conflict or interference between subsequent devices, and performs coordinated control of subsequent devices with high control sensitivity and good coordination; the subsequent devices here refer to related equipment or components connected after the output terminal of the thin film capacitor of the present invention.

[0017] 2. The use of circular through holes on the first and second positive copper busbars enables the copper busbars to be lightweight, reducing weight and cost. At the same time, it increases the surface area and airflow of the copper busbars, which helps heat dissipation and prevents the copper busbars from overheating and causing performance degradation or damage in high-current scenarios. For copper busbars in high-frequency circuits, the through holes can avoid the eddy current loops formed by large areas of copper foil, reduce eddy current losses, and improve circuit efficiency.

[0018] 3. By utilizing the standardized arrangement of the terminals on the first positive copper busbar and the terminals on the second positive copper busbar, the terminals of the thin-film capacitor product of the present invention can be made more regular and orderly, making it easier to distinguish different terminals, ensuring that the wiring is simpler and more convenient for users, and avoiding the product from failing to operate or even being damaged due to wiring errors.

[0019] 4. By combining power relays and connectors, a small current signal can control the on / off state of a high-current, high-power circuit, avoiding direct connection of the control circuit corresponding to the capacitor product of this invention to a high voltage, achieving electrical isolation between the control circuit and the main circuit, and protecting the control components; at the same time, it can also prevent electric shock when personnel operate the control terminal.

[0020] 5. By using a snap-fit ​​design, the power relay can be snapped into the housing of the film capacitor, preventing the power relay from shaking or shifting within the housing. This avoids damage to the product caused by collisions or detachment of the power relay due to vehicle bumps during vehicle operation.

[0021] 6. By utilizing the heat-conducting plate, the heat inside the invention can be transferred to the outside, preventing heat from accumulating inside the casing and causing the internal temperature to become too high, which would affect the normal operation of electronic components.

[0022] In summary, the present invention, through the arrangement of the first positive copper busbar and the second positive copper busbar, can realize a dual-electric control circuit, saving space while achieving coordinated control of the circuit; by utilizing the design of power relays and connectors, it can realize the control of a large current circuit with a small current signal, which is safe and efficient; by using the installation of heat-conducting plates, the heat inside the present invention can be transferred to the outside, ensuring that heat does not accumulate and generate local high temperature. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the structure of a film capacitor with dual electronic control of power relay EMC filtering and heat dissipation device proposed in this invention;

[0024] Figure 2 This is a schematic diagram of the internal structure of a film capacitor with dual electronic control of power relay, EMC filtering, and heat dissipation device proposed in this invention.

[0025] Figure 3 This is a schematic diagram of the structure of the first positive copper busbar in a film capacitor with dual electronic control of power relay, EMC filtering and heat dissipation device proposed in this invention;

[0026] Figure 4 This is a schematic diagram of the structure of the second positive electrode copper busbar in a film capacitor with dual electronic control of power relay EMC filtering and heat dissipation device proposed in this invention;

[0027] Figure 5 This is a top view inside the casing of a film capacitor with dual electronic control of power relay, EMC filtering, and heat dissipation device proposed in this invention.

[0028] Figure 6 For the present invention Figure 5 An enlarged schematic diagram of the local structure at point A in the diagram;

[0029] Figure 7 The circuit diagram of the internal capacitor core and Y2 capacitor bank of a film capacitor with dual electronic control of power relay, EMC filtering and heat dissipation device is presented in this invention.

[0030] Figure 8 This is a top view of a film capacitor with dual electronic control of power relay, EMC filtering, and heat dissipation device proposed in this invention.

[0031] Figure 9 This is a schematic diagram of the heat-conducting plate in a film capacitor with dual electronic control of power relay EMC filtering and heat dissipation device proposed in this invention.

[0032] In the diagram: 1. Casing of the film capacitor; 2. Capacitor core; 3. Terminal block; 4. Negative copper busbar; 5. Grounding copper busbar; 6. First positive copper busbar; 7. Second positive copper busbar; 8. Power relay; 9. Connector; 10. Clip-on component; 11. Heat-conducting plate; 12. Clip-on component; 13. Y2 capacitor bank. Detailed Implementation

[0033] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0034] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0035] Example 1:

[0036] Reference Figure 1 , Figure 2 and Figure 7A film capacitor with dual electronic control of power relay, EMC filtering and heat dissipation device includes a film capacitor shell 1, an EMC filtering component and a copper busbar assembly. The EMC filtering component is installed inside the film capacitor shell 1 and has a capacitor core 2. The copper busbar assembly has terminals 3 and has a negative copper busbar 4 and a grounding copper busbar 5. The copper busbar assembly also has a first positive copper busbar 6 and a second positive copper busbar 7. The first positive copper busbar 6 is located in the upper half of the film capacitor shell 1 and the second positive copper busbar 7 is located in the lower half of the film capacitor shell 1. The first positive copper busbar 6 and the second positive copper busbar 7 are attached to the capacitor core 2. The dual electronic control of the capacitor is achieved by connecting the first positive copper busbar 6 and the second positive copper busbar 7 to different circuits.

[0037] By setting up a first positive copper busbar 6 and a second positive copper busbar 7, this invention connects two separate circuits into a dual-control circuit, achieving more reliable logic control with more streamlined hardware. This avoids the use of more electronic components in the two circuits, saving space. The reduction in hardware components also means fewer potential failure points, and the centralized control logic makes it easier to locate faults during later troubleshooting, improving maintenance efficiency. At the same time, it also reduces the energy consumption of redundant components, thus lowering energy consumption.

[0038] The dual electronic control circuit also ensures that there is no conflict or interference between subsequent devices, and performs coordinated control of subsequent devices with high control sensitivity and good coordination; the subsequent devices here refer to related equipment or components connected after the output terminal of the thin film capacitor of the present invention.

[0039] Example 2:

[0040] Reference Figure 3 and Figure 4 Based on Example 1, the difference is that: circular through holes are evenly distributed on the first positive copper busbar 6 and the second positive copper busbar 7;

[0041] The use of circular through-holes on the first positive copper busbar 6 and the second positive copper busbar 7 enables the copper busbars to be lightweight, reducing weight and manufacturing costs. Simultaneously, it increases the surface area and airflow of the copper busbars, aiding in heat dissipation and preventing performance degradation or damage due to overheating in high-current scenarios. For copper busbars in high-frequency circuits, the through-holes can break the eddy current loops formed by large-area copper foil, reducing eddy current losses and improving circuit efficiency.

[0042] Example 3:

[0043] Reference Figure 4Based on Example 2, the difference is that the terminals 3 of the second positive copper busbar 7 extend into the upper part of the outer shell 1 of the film capacitor and are arranged in a corresponding manner to the terminals 3 of the first positive copper busbar 6. This design is a regular arrangement design of the first positive copper busbar 6 and the second positive copper busbar 7.

[0044] By standardizing the arrangement of terminals 3 on the first positive copper busbar 6 and terminals 3 on the second positive copper busbar 7, the terminals 3 of the thin-film capacitor product of the present invention can be made more regular and orderly, making it easier to distinguish different terminals, ensuring that the wiring is simpler and more convenient for users, and avoiding the product from failing to operate or even being damaged due to wiring errors.

[0045] Example 4:

[0046] Reference Figures 5-7 Based on Example 1, the difference is that a power relay 8 is provided on the inner side of the outer shell 1 of the film capacitor, and the power relay 8 can control the on or off of the connected circuit.

[0047] The power relay 8 is provided with a connector 9, which enables the power relay 8 to stably receive transmitted signals.

[0048] The rated DC voltage of this power relay 8 is 10~1000V, and the rated current is 50~70A;

[0049] By combining the power relay 8 and the connector 9, when the power relay 8 receives a control signal through the connector 9, it can attract the contacts through electromagnetic attraction to connect part of the circuit, thereby enabling the control of the on / off state of a high-current, high-power circuit with a small current signal.

[0050] These designs prevent the control circuit from being directly connected to high voltage, achieve electrical isolation between the control circuit and the main circuit, protect the control components, and also prevent electric shock when personnel operate the control terminal.

[0051] Example 5:

[0052] Reference Figure 6 Based on embodiment 4, the difference is that: a mounting piece 10 is provided on the outside of the power relay 8, and the power relay 8 is mounted in the housing 1 of the film capacitor by the mounting piece 10, so that the power relay 8 will not shake or shift inside the housing 1 of the film capacitor.

[0053] By using the design of the mounting component 10, the power relay 8 can be mounted inside the housing 1 of the film capacitor, so that the power relay 8 will not shake or shift inside the housing 1 of the film capacitor. This avoids damage or detachment of the power relay 8 due to vehicle bumps during vehicle operation, thus preventing damage to the film capacitor product.

[0054] Example 6:

[0055] Reference Figure 8 and Figure 9 Based on Example 1, the difference is that a heat-conducting plate 11 is provided on the bottom of the outer side of the outer casing 1 of the thin film capacitor;

[0056] The heat-conducting plate 11 has snap-fit ​​parts 12 on both sides, which extend to the edges of the outer shell 1 of the film capacitor and leave gaps with the edges of the outer shell 1 of the film capacitor.

[0057] By utilizing the heat-conducting plate 11, the heat inside the present invention can be transferred to the outside through the heat-conducting plate 11, avoiding the accumulation of heat inside the outer shell 1 of the film capacitor, which would cause the internal temperature to be too high and affect the normal operation of the electronic components.

[0058] By combining the heat-conducting plate 11 and the snap-fit ​​connector 12, the heat-conducting plate 11 can be mounted on the bottom of the film capacitor's outer casing 1, thus increasing the heat-conducting area. A certain gap is left at the connection area between the snap-fit ​​connector 12 and the film capacitor's outer casing 1. This design increases the heat dissipation channel of the invention, allowing some of the heat inside the film capacitor's outer casing 1 to dissipate through the gap. Simultaneously, since the operating environment temperature of the invention is relatively high, the gap also provides space for the heat-conducting plate 11 to expand due to heat, preventing deformation of the film capacitor's outer casing 1 after a period of use.

[0059] Example 7:

[0060] Reference Figure 2 Based on Embodiment 1, the difference is that the EMC filter assembly not only includes capacitor cores, but also provides a Y2 capacitor group 13, wherein the number of capacitor cores is an integer greater than one, and the Y2 capacitor group 13 is located in the side area inside the outer shell 1 of the film capacitor.

[0061] like Figure 7 As shown, C1 represents the capacitor core mounted on the first positive copper busbar 6, with a rated DC voltage of 400~900V and a total capacitance of 120~300uF; C2 represents the capacitor core mounted on the second positive copper busbar 7, with a rated DC voltage of 400~900V and a total capacitance of 120~300uF; CY1~CY12 represent the capacitors in the Y2 capacitor bank, with a rated AC voltage of 275~305V and a capacitance of 1~22nF for each capacitor; where, Figure 7 In this invention, KT represents the power relay 8 in the film capacitor with dual electronic control of power relay, EMC filtering, and heat dissipation device.

[0062] The capacitance range of the capacitors in the Y2 capacitor bank 13 is 1~22nF. Through the design of the Y2 capacitor bank 13, this invention utilizes the low impedance characteristics of capacitors to high-frequency signals to guide high-frequency common-mode interference signals in the power supply to the ground through the capacitors, thereby preventing interference signals from entering the equipment or leaking into the interconnected system and ensuring the long-term stable operation of the circuit.

[0063] A typical application of this invention in a four-wheel drive electric vehicle is as follows: When the film capacitor of this invention, with dual electronic control of power relay, EMC filtering, and heat dissipation device, is installed in an electric vehicle, the battery in the electric vehicle can control the drive motors of the front and rear wheels through the first positive copper busbar 6 and the second positive copper busbar 7 of the film capacitor, realizing the logical linkage of dual electronic control of multiple motors. It can adjust the output torque of different motors in real time (e.g., when the front wheel slips, immediately reduce the torque of the front wheel motor and increase the torque of the rear wheel motor), avoiding the "one-size-fits-all" control limitation of a single electronic control circuit and improving the vehicle's grip. At the same time, it also allows the car to directly control the speed difference between the left and right motors through the dual electronic control circuit without relying on a traditional mechanical differential (e.g., when turning, reduce the speed of the inner motor and increase the speed of the outer motor), reducing understeer or oversteer and improving handling precision.

[0064] When the entire invention is installed in a vehicle, the film capacitor is also charged when the electric vehicle is being charged. The power relay 8 is activated and receives the charging signal through the connector 9, which connects the charging circuit to charge the film capacitor. When charging is complete, the power relay 8 receives the charging completion signal and disconnects the charging circuit. This design can prevent the film capacitor from being overcharged, thus affecting its lifespan.

[0065] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A film capacitor with dual electronic control of power relay, EMC filtering, and heat dissipation device, comprising a film capacitor housing (1), an EMC filtering assembly, and a copper busbar assembly, wherein the EMC filtering assembly is installed inside the film capacitor housing (1), the EMC filtering assembly has a capacitor core (2), the copper busbar assembly has terminals (3), and the copper busbar assembly has a negative copper busbar (4) and a grounding copper busbar (5), characterized in that, The copper busbar assembly also includes a first positive copper busbar (6) and a second positive copper busbar (7). The first positive copper busbar (6) is located in the upper half of the outer shell (1) of the film capacitor, and the second positive copper busbar (7) is located in the lower half of the outer shell (1) of the film capacitor. The first positive copper busbar (6) and the second positive copper busbar (7) are attached to the capacitor core (2). The capacitor is dual-controlled by connecting the first positive copper busbar (6) and the second positive copper busbar (7) to different circuits. The EMC filter assembly is also provided with a Y2 capacitor bank (13), which is located in the side area inside the shell (1) of the film capacitor. In the Y2 capacitor bank (13), capacitors CY1 and CY2 are connected in series and grounded, and then connected in parallel with the two ends of C1. In capacitor bank Y2 (13), capacitors CY3 and CY4 are connected in series and grounded, and then connected in parallel with the two ends of C1. In the Y2 capacitor bank (13), capacitors CY5 and CY6 are connected in series and grounded, and then connected in parallel with the two ends of C1; capacitors CY1 and CY2, capacitors CY3 and CY4, and capacitors CY5 and CY6 are connected in parallel with each other at the two ends of C1, and C1 represents the capacitor core that is attached to the first positive copper busbar (6). In capacitor bank Y2 (13), capacitors CY7 and CY8 are connected in series and grounded, and then connected in parallel with the two ends of C2; In capacitor bank (13) Y2, capacitors CY9 and CY10 are connected in series and grounded, and then connected in parallel with the two ends of C2; In the Y2 capacitor bank (13), capacitors CY11 and CY12 are connected in series and grounded, and then connected in parallel with the two ends of C2; capacitors CY7 and CY8, capacitors CY9 and CY10, and capacitors CY11 and CY12 are connected in parallel with each other across the two ends of C2, where C2 represents the capacitor core that is attached to the second positive copper busbar (7).

2. The film capacitor with dual electronic control of power relay EMC filtering and heat dissipation device according to claim 1, characterized in that, The first positive electrode copper busbar (6) and the second positive electrode copper busbar (7) are uniformly distributed with circular through holes.

3. A film capacitor with dual electronic control of power relay, EMC filtering, and heat dissipation device according to claim 2, characterized in that, The terminals (3) of the second positive copper busbar (7) extend into the upper part of the outer shell (1) of the film capacitor and are arranged in a corresponding manner to the terminals (3) of the first positive copper busbar (6).

4. A film capacitor with dual electronic control of power relay, EMC filtering, and heat dissipation device as described in claim 1, characterized in that, The film capacitor has a power relay (8) located at the bottom of its casing (1), which can control the connection or disconnection of the connected circuit.

5. A film capacitor with dual electronic control of power relay, EMC filtering, and heat dissipation device according to claim 4, characterized in that, The power relay (8) is provided with a connector (9), which enables the power relay (8) to receive transmitted signals.

6. A film capacitor with dual electronic control of power relay, EMC filtering, and heat dissipation device according to claim 5, characterized in that, The power relay (8) is provided with a mounting piece (10) on the outside. The power relay (8) is mounted in the shell (1) of the film capacitor by the mounting piece (10), so that the power relay (8) will not shake or shift inside the shell (1) of the film capacitor.

7. A film capacitor with dual electronic control of power relay, EMC filtering, and heat dissipation device according to claim 1, characterized in that, A heat-conducting plate (11) is provided on the bottom outer side of the outer casing (1) of the thin film capacitor.

8. A film capacitor with dual electronic control of power relay, EMC filtering, and heat dissipation device according to claim 7, characterized in that, The heat-conducting plate (11) is provided with snap-fit ​​parts (12) on both sides. The snap-fit ​​parts (12) extend to the edges of the outer shell (1) of the film capacitor on both sides, and there is a gap between the snap-fit ​​parts (12) and the edges of the outer shell (1) of the film capacitor.

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