Voltage-stable high-voltage automobile filtering device with discharge resistor

Abstract

The invention discloses a voltage-stable high-voltage automobile filtering device with a discharge resistor, which relates to the technical field of automobile filtering devices and comprises an outer shell, an inner shell, an anode copper bar, a cathode copper bar, an anti-interference component and a ferrite magnetic core, the shell has the effects of electromagnetic shielding, mechanical protection and auxiliary heat dissipation on the interior; the inner shell is fixed inside the outer shell through screws and plays roles in insulation isolation, buffering vibration reduction and positioning fixation, and the inner shell comprises a flat plate and a blocky plate. Compact design is adopted for the automobile filtering device, the anti-interference assembly and the ferrite magnetic core are integrated into a whole, the automobile filtering device is made to be matched with narrow installation spaces such as an automobile chassis and a battery pack, and the anti-interference effect of the automobile filtering device is improved. A plurality of auxiliary parts do not need to be additionally arranged, the installation space and the assembly cost are saved, meanwhile, relative displacement generated by vibration of the filtering device and the power supply equipment is compensated through the arranged connector assembly, and the situation that an interface is damaged due to forced stretching and extrusion is avoided.

Description

Technical Field

[0001] This invention relates to the field of automotive filter equipment technology, specifically a voltage-stabilized high-voltage automotive filter with a discharge resistor. Background Technology

[0002] The core working principle of a high-voltage automotive filter is to utilize the frequency selectivity of passive components such as inductors and capacitors to "separate" useful signals (such as stable DC, specific frequency operating signals) and interference noise (such as high-frequency pulses and harmonics) in high-voltage circuits. This allows useful signals to pass smoothly while attenuating or bypassing interference noise, ultimately purifying the circuit signal / power supply. Essentially, a high-voltage automotive filter is a "shunt-blocking system based on the frequency selectivity of LC components": through differential-mode + common-mode topology, it uses inductors to block high-frequency interference and capacitors to discharge high-frequency interference. Combined with high-voltage insulation and shielding grounding designs, it suppresses interference noise while withstanding the high-voltage, high-current environment of a vehicle, ensuring that high-voltage equipment (motors, BMS, OBC) receives clean power / signals and preventing malfunctions or damage.

[0003] Differential-mode capacitors and common-mode capacitors (especially large-capacity safety capacitors in high-voltage scenarios) in automotive electronic filters store a large amount of charge when powered on. If this charge cannot be released quickly after power is off, it will remain on the capacitor terminals for a long time, forming a "hidden high-voltage source." Therefore, in high-voltage / high-power filtering scenarios, discharge resistors need to be added to the electronic filter. Additionally, to reduce electromagnetic radiation and conducted interference from high-voltage systems (such as switching power supplies and motor drives), ferrite cores are often added to the automotive electronic filter. The addition of these components increases the size of the automotive electronic filter. Without a proper structural design, the automotive electronic filter may be difficult to fit into the confined installation space of the car chassis and battery pack. Furthermore, the input of the automotive electronic filter is usually directly plugged into the output of the car's power supply. When the car is moving or the equipment is operating, the different mounting base rigidities of the filter and the power supply (e.g., the filter is mounted on a flexible bracket, while the power supply is mounted on a rigid engine compartment wall) can cause significant differences in their vibration frequency, amplitude, and phase. This can lead to forced stretching and compression of the interface, resulting in damage. Summary of the Invention

[0004] The purpose of this invention is to provide a voltage-stabilized high-voltage automotive filter device with a discharge resistor to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] A voltage-stabilized high-voltage automotive filter device with a discharge resistor includes: a housing, an inner housing, a positive copper strip, a negative copper strip, an anti-interference component, a ferrite core, and a connector assembly.

[0007] The outer shell serves to provide electromagnetic shielding, mechanical protection, and auxiliary heat dissipation for the interior.

[0008] The inner shell is fixed inside the outer shell by screws, serving as insulation, buffering, vibration reduction, and positioning. The inner shell includes a flat plate and a block plate, which are integrally formed. The end of the inner shell has two through-holes for storing copper strips. The upper end of the flat plate has a groove, and the end of the block plate has a magnetic core storage compartment.

[0009] The positive and negative copper bars are respectively disposed in two copper bar receiving holes;

[0010] The anti-interference component is fixedly installed in the groove, which plays the role of suppressing clutter and regulating energy.

[0011] The number of ferrite cores is two, and both ferrite cores are located in the core storage compartment, which can play the role of suppressing electromagnetic interference and stabilizing magnetic field coupling.

[0012] As a further preferred embodiment of this technical solution, the magnetic core storage compartment is located at the outer periphery of the end of the copper strip storage hole, and the magnetic core storage compartment and the copper strip storage hole form an isolation layer;

[0013] The connector assembly is located on one side of the housing and is used to compensate for the relative displacement between the filter device and the power supply equipment caused by vibration.

[0014] As a further preferred embodiment of this technical solution, the connector assembly includes a first connector and a second connector. The first connector is fixedly connected to the side wall of the outer casing. The two holes of the first connector are electrically connected to the positive copper strip and the negative copper strip, respectively. The second connector is electrically connected to the first connector via a corrugated cable. A first side post is fixedly installed on both sides of the first connector, and a second side post is fixedly installed on both sides of the second connector. A damping spring shock absorber is provided between the first side post and the second side post. The two ends of the damping spring shock absorber are ball-jointed at the ends of the first connector and the second connector that are close to each other.

[0015] As a further preferred embodiment of this technical solution, the anti-interference component includes a circuit board, which is fixed in a groove by screws, and eight discharge resistor bodies, two No. 1 capacitors and one No. 2 capacitor are fixedly disposed on the circuit board.

[0016] As a further preferred embodiment of this technical solution, all eight discharge resistor bodies are fixedly mounted on the circuit board using silicone. The eight discharge resistor bodies are connected in series in pairs to form four groups, and the four groups of discharge resistor bodies are connected in parallel between the positive and negative copper bars.

[0017] As a further preferred embodiment of this technical solution, both capacitors are fixedly mounted on the circuit board using silicone. One end of each capacitor is connected to a positive copper strip and a negative copper strip, respectively, and the other end of each capacitor is grounded. The two capacitors will form a common-mode capacitor.

[0018] As a further preferred embodiment of this technical solution, the second capacitor is fixedly mounted on the circuit board using silicone, and the second capacitor is connected in parallel between the positive copper strip and the negative copper strip.

[0019] As a further preferred embodiment of this technical solution, the ferrite core is fixedly connected to the block plate by silicone, and two core holes are opened in the middle of the ferrite core, with the inner walls of the two core holes matching the outer wall of the isolation layer.

[0020] This invention provides a voltage-stabilized high-voltage automotive filter device with a discharge resistor, which has the following advantages:

[0021] This invention employs a compact design for automotive filtering devices, integrating anti-interference components and ferrite cores into a single unit. This allows it to fit within the limited installation space of automotive chassis and battery packs, eliminating the need for additional auxiliary components and saving installation space and assembly costs. Through the synergistic cooperation of the anti-interference components and ferrite cores, it filters out high-frequency noise, harmonics, spike pulses, and other interference from high-voltage circuits. This ensures that core devices such as motor controllers, battery management systems (BMS), and on-board chargers (OBC) receive clean power or signals, reducing control logic errors, performance fluctuations (such as unstable motor power output), or momentary shutdowns caused by interference. Simultaneously, it reduces electromagnetic radiation and conducted interference generated by high-voltage systems (such as switching power supplies and motor drives), preventing interference with low-voltage electronic devices such as radios, navigation systems, and sensors. This prevents problems such as radio noise, navigation signal failure, and sensor mis-triggering. Furthermore, the designed connector assembly compensates for the relative displacement between the filtering device and the power supply equipment caused by vibration, preventing damage to the interface due to forced stretching or compression. Attached Figure Description

[0022] Figure 1 This is an overall schematic diagram of a voltage-stabilized high-voltage automotive filter device with a discharge resistor according to the present invention.

[0023] Figure 2 This is a split schematic diagram of a voltage-stabilized high-voltage automotive filter device with a discharge resistor according to the present invention;

[0024] Figure 3 This is a schematic diagram of the assembly structure of the inner shell in a voltage-stabilized high-voltage automotive filter device with a discharge resistor according to the present invention.

[0025] Figure 4 This is a schematic diagram showing the disassembled inner shell of a voltage-stabilized high-voltage automotive filter device with a discharge resistor according to the present invention.

[0026] Figure 5 This is a further disassembled schematic diagram of the inner shell in a voltage-stabilized high-voltage automotive filter device with a discharge resistor according to the present invention.

[0027] Figure 6 This is a schematic diagram of the inner shell of a voltage-stabilized high-voltage automotive filter device with a discharge resistor according to the present invention.

[0028] Figure 7 This is a schematic diagram of the bottom of the inner shell of a voltage-stabilized high-voltage automotive filter device with a discharge resistor according to the present invention.

[0029] Figure 8 This is a circuit diagram of a voltage-stabilized high-voltage automotive filter device with a discharge resistor according to the present invention.

[0030] Figure 9 This is a schematic diagram of the connector assembly in a voltage-stabilized high-voltage automotive filter device with a discharge resistor according to the present invention.

[0031] In the picture:

[0032] 100. Outer shell; 101. Positioning sleeve;

[0033] 200. Inner shell; 201. Flat plate; 202. Block plate; 203. Copper strip storage hole; 204. Magnetic core storage compartment; 205. Isolation layer; 206. Groove;

[0034] 300. Positive electrode copper strip;

[0035] 400. Negative electrode copper strip;

[0036] 500. Anti-interference component; 501. Circuit board; 502. Discharge resistor body; 503. Capacitor No. 1; 504. Capacitor No. 2;

[0037] 600, Ferrite core; 601, Core hole.

[0038] 700. Connector assembly; 701. Connector No. 1; 702. Connector No. 2; 703. Corrugated cable; 704. Side post No. 1; 705. Side post No. 2; 706. Damping spring shock absorber. Detailed Implementation

[0039] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0040] This invention provides a technical solution: such as Figure 1 As shown in this embodiment, a voltage-stabilized high-voltage automotive filter device with a discharge resistor includes a housing 100, an inner housing 200, a positive copper strip 300, a negative copper strip 400, an anti-interference component 500, a ferrite core 600, and a connector assembly 700.

[0041] like Figure 1 As shown, the outer shell 100 is made of aluminum alloy, which serves to provide electromagnetic shielding (prevent internal interference from leaking out and external interference from intruding), mechanical protection (vibration resistance and collision protection), and auxiliary heat dissipation.

[0042] like Figure 6 As shown, the inner shell 200 is made of epoxy fiberglass board and is fixed inside the outer shell 100 by screws. It serves to provide insulation (isolate high voltage from the outer shell), buffer and damping (protect internal components), and positioning and fixing (prevent component displacement). The inner shell 200 includes a flat plate 201 and a block plate 202, which are integrally formed. The inner shell 200 has two through-hole copper strip storage holes 203 at its end. The upper end of the flat plate 201 has a groove 206, and the end of the block plate 202 has a magnetic core storage compartment 204. The magnetic core storage compartment 204 is located outside the end of the copper strip storage hole 203. The magnetic core storage compartment 204 and the copper strip storage hole 203 form an isolation layer 205. Through the isolation layer 205, the copper strip and the ferrite core 600 can maintain a fixed distance, which can not only avoid direct contact between the two, but also prevent the magnetic ring and copper strip from shifting due to vibration by means of the structural stability of the plate.

[0043] like Figure 3As shown, the positive copper strip 300 and the negative copper strip 400 are respectively disposed in two copper strip receiving holes 203. The positive copper strip 300 and the negative copper strip 400 are respectively adapted to the two copper strip receiving holes 203. The inner shell 200 is produced by injection molding. When producing the inner shell 200, the positive copper strip 300 and the negative copper strip 400 need to be placed in the injection mold. After the inner shell 200 is formed, the copper strip receiving holes 203 will naturally form to cover the positive copper strip 300 and the negative copper strip 400. The function of the positive copper strip 300 and the negative copper strip 400 is that one end of the positive copper strip 300 is connected to the positive terminal of the vehicle power battery (or charging interface), and the other end is connected to the downstream electrical equipment (such as motor controller, DC / DC converter). The positive terminal of the converter is connected to the negative terminal of the power supply, and the negative terminal of the copper strip 400 is connected to the negative terminal of the equipment, forming a complete high-voltage power supply circuit. At the same time, the current is forced to flow through the filter elements inside the filter (anti-interference component 500, ferrite core 600) to ensure that the interference is filtered out before it is supplied to the load.

[0044] like Figure 4 As shown, the anti-interference component 500 is fixedly installed in the groove 206, as... Figure 5 As shown, the anti-interference component 500 includes a circuit board 501, which is fixed in the groove 206 by screws. Eight discharge resistor bodies 502, two capacitors 503, and one capacitor 504 are fixedly disposed on the circuit board 501.

[0045] like Figure 8 As shown, eight discharge resistor bodies 502 are fixedly mounted on the circuit board 501 using silicone. The eight discharge resistor bodies 502 are connected in series in pairs to form four groups. Each of the four groups of discharge resistor bodies 502 is connected in parallel between the positive copper strip 300 and the negative copper strip 400. Differential-mode capacitors and common-mode capacitors (especially large-capacity safety capacitors in high-voltage scenarios) in automotive electronic filters store a large amount of charge when powered on. If this charge cannot be released quickly after the device is powered off, it will remain on both ends of the capacitor for a long time, forming a "hidden high-voltage source." The discharge resistor body 502 can provide a low-impedance discharge path for the capacitor after the device is powered off, quickly dissipating the residual charge (converting it into heat energy), allowing the voltage across the capacitor to drop to a safe value in a short time, eliminating the risk caused by the "hidden high-voltage source" at its source. At the same time, during vehicle operation, the load of the high-voltage system changes frequently (e.g., the motor load increases during acceleration and decreases during deceleration), which can easily cause fluctuations in the filter's output voltage. The discharge resistors connected in parallel in the circuit can serve as a fixed "base load." When the load impedance increases and the load current decreases, the discharge current will increase accordingly; conversely, the discharge current will decrease. This complementary relationship can reduce the variation of the total current at the filter output, thereby suppressing large voltage fluctuations, making the output voltage more stable, and ensuring the stable operation of downstream equipment such as motors and BMS.

[0046] like Figure 8 As shown, both capacitors 503 are fixed on the circuit board 501 with silicone. One end of each capacitor 503 is connected to the positive copper strip 300 and the negative copper strip 400, respectively, and the other end is grounded. The two capacitors 503 form a common-mode capacitor, the core function of which is to suppress the common-mode interference of the positive / negative copper strips to ground at the same time. By constructing a ground discharge circuit, the symmetrical interference current is safely conducted to the vehicle ground / engine housing ground, preventing interference from entering sensitive electronic systems such as the ECU, CAN bus, and vehicle radar, while not affecting the normal power supply.

[0047] like Figure 8 As shown, capacitor 504 is fixed on circuit board 501 with silicone. It is connected in parallel between positive copper bar 300 and negative copper bar 400. It forms a differential mode capacitor, which suppresses differential mode interference between positive and negative copper bars. It filters high-frequency crosstalk signals between positive and negative buses by bypassing and absorbing spikes, ensuring stable transmission of low-frequency / DC operating current and preventing back-end equipment from malfunctioning due to power supply fluctuations.

[0048] like Figure 5 As shown, there are two ferrite cores 600, both located within the core storage compartment 204. The ferrite cores 600 are fixedly connected to the block plate 202 via silicone. Two core holes 601 are formed in the middle of each ferrite core 600. The inner walls of the two core holes 601 are compatible with the outer wall of the isolation layer 205. The ferrite cores 600 can suppress electromagnetic interference (EMI) and stabilize magnetic field coupling. Through their special magnetic properties, they can "hinder" or "dissipate" high-frequency interference signals, while not affecting the transmission of low-frequency / DC operating current. Together with copper strips and capacitors, they form a complete filter network.

[0049] like Figure 9 As shown, the connector assembly 700 is disposed on one side of the housing 100, including a first connector 701 and a second connector 702. The first connector 701 is fixedly connected to the side wall of the housing 100. The two holes of the first connector 701 are electrically connected to the positive copper strip 300 and the negative copper strip 400, respectively. The second connector 702 is electrically connected to the first connector 701 through a corrugated cable 703. The first side post 704 is fixedly installed on both sides of the first connector 701, and the second side post 705 is fixedly installed on both sides of the second connector 702. A damping spring shock absorber 706 is disposed between the first side post 704 and the second side post 705. The two ends of the damping spring shock absorber 706 are ball joints at the ends of the first connector 701 and the second connector 702 that are close to each other.

[0050] During installation, connector assembly 700 is the input terminal, connected to the power output terminal. During use, connector 702 is connected to the power output terminal. Through the arrangement of connector 701, connector 702, and corrugated cable 703, when the filter device and power supply equipment vibrate relative to each other, the corrugated cable 703 can flexibly deform by bending and stretching to compensate for the displacement difference between the two. The damping spring shock absorber 706 compensates for the relative displacement between the filter device and the power supply equipment while absorbing vibration energy, avoiding the concentration of vibration energy at the root of the corrugated cable 703 and the connection of the connector, which could cause damage to the root of the corrugated cable 703 and the connection of the connector. Since the interface type of the output terminal of the automotive filter device will vary depending on the diverse in-vehicle terminal equipment it is adapted to, only the exposed copper strip is shown.

[0051] The top cover of the outer shell is not shown. It can be fixed with screws by selecting a top cover with a suitable shape, which will not be described in detail here.

[0052] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A voltage-stabilized high-voltage automotive filter device with a discharge resistor, characterized in that, include: Outer shell (100), inner shell (200), positive copper strip (300), negative copper strip (400), anti-interference component (500), ferrite core (600) and connector assembly (700). The outer shell (100) serves to provide electromagnetic shielding, mechanical protection, and auxiliary heat dissipation for the interior. The inner shell (200) is fixed inside the outer shell (100) by screws, which serves to provide insulation, buffering, vibration reduction and positioning. The inner shell (200) includes a flat plate (201) and a block plate (202). The flat plate (201) and the block plate (202) are integrally formed. The end of the inner shell (200) has two through-hole copper strip storage holes (203). The upper end of the flat plate (201) has a groove (206). The end of the block plate (202) has a magnetic core storage compartment (204). The positive electrode copper strip (300) and the negative electrode copper strip (400) are respectively disposed in two copper strip receiving holes (203); The anti-interference component (500) is fixedly installed in the groove (206) and plays the role of suppressing clutter and regulating energy. The number of ferrite cores (600) is two, and both ferrite cores (600) are located in the core storage compartment (204), which can play a role in suppressing electromagnetic interference and stabilizing magnetic field coupling. The connector assembly (700) is disposed on one side of the housing (100) and is used to compensate for the relative displacement between the filter device and the power supply device caused by vibration.

2. The voltage-stabilized high-voltage automotive filter with discharge resistor according to claim 1, characterized in that: The magnetic core storage compartment (204) is located at the outer periphery of the end of the copper strip storage hole (203), and the magnetic core storage compartment (204) and the copper strip storage hole (203) form an isolation layer (205).

3. The voltage-stabilized high-voltage automotive filter with discharge resistor according to claim 1, characterized in that: The connector assembly (700) includes a first connector (701) and a second connector (702). The first connector (701) is fixedly connected to the side wall of the outer shell (100). The two holes of the first connector (701) are electrically connected to the positive copper strip (300) and the negative copper strip (400) respectively. The second connector (702) is electrically connected to the first connector (701) through a corrugated cable (703). The first side post (704) is fixedly installed on both sides of the first connector (701). The second side post (705) is fixedly installed on both sides of the second connector (702). A damping spring shock absorber (706) is provided between the first side post (704) and the second side post (705). The two ends of the damping spring shock absorber (706) are ball joints at the ends of the first connector (701) and the second connector (702) that are close to each other.

4. A voltage-stabilized high-voltage automotive filter with a discharge resistor according to claim 1, characterized in that: The anti-interference component (500) includes a circuit board (501), which is fixed in a groove (206) by screws. Eight discharge resistor bodies (502), two capacitors (503) and one capacitor (504) are fixedly arranged on the circuit board (501).

5. A voltage-stabilized high-voltage automotive filter with a discharge resistor according to claim 4, characterized in that: The eight discharge resistor bodies (502) are fixed on the circuit board (501) by silicone. The eight discharge resistor bodies (502) are connected in series in pairs to form four groups. The four groups of discharge resistor bodies (502) are connected in parallel between the positive copper strip (300) and the negative copper strip (400).

6. A voltage-stabilized high-voltage automotive filter with a discharge resistor according to claim 4, characterized in that: Both capacitors (503) are fixed on the circuit board (501) with silicone. One end of each capacitor (503) is connected to the positive copper strip (300) and the negative copper strip (400) respectively. The other end of each capacitor (503) is grounded. The two capacitors (503) will form a common-mode capacitor.

7. A voltage-stabilized high-voltage automotive filter with a discharge resistor according to claim 4, characterized in that: The second capacitor (504) is fixed on the circuit board (501) by silicone, and the second capacitor (504) is connected in parallel between the positive copper strip (300) and the negative copper strip (400).

8. A voltage-stabilized high-voltage automotive filter with a discharge resistor according to claim 1, characterized in that: The ferrite core (600) is fixedly connected to the block plate (202) by silicone. Two core holes (601) are opened in the middle of the ferrite core (600), and the inner walls of the two core holes (601) are adapted to the outer wall of the isolation layer (205).

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