Filter and contactor integrated structure of new energy electric vehicle

Abstract

The invention discloses a new energy electric vehicle filter and contactor integrated structure which comprises a filter shell and a copper bar assembly, an inner cavity is formed in the shell, a contactor is fixed in the inner cavity, and the copper bar assembly and the filter shell are integrally formed in an injection molding mode and connected with the contactor; wherein a plurality of limiting ribs are formed between the inner wall of the periphery of the inner cavity and the cavity bottom, and each limiting rib abuts against the outer side of the contactor in a limiting mode. According to the invention, the filter and the contactor are integrated in one structure, the integration of filtering and circuit on-off functions is realized, the space is saved, the integration level of the system is improved, the copper bar assembly and the filter shell are subjected to integral injection molding, the consistency of products is ensured, the production efficiency and the product quality are improved, and the production cost is reduced. And the limiting ribs arranged in the inner cavity can effectively limit the contactor, so that the contactor is prevented from shaking in the installation and use processes, and the working stability and reliability of the contactor are improved.

Description

Technical Field

[0001] This invention relates to the technical field of new energy electric vehicles, and in particular to an integrated structure of a filter and contactor for new energy electric vehicles. Background Technology

[0002] With the rapid development of the new energy electric vehicle industry, the motor controller system, as a key core component of electric vehicles, has a direct and crucial impact on the overall vehicle operation and safety due to its performance and reliability. During the operation of the motor controller system, two critical issues urgently need to be addressed: first, electromagnetic interference (EMI). The motor controller generates significant EMI interference under different operating conditions, which can severely affect the vehicle's radio communication signals, leading to communication failures and ultimately interfering with the vehicle's normal operation; second, the safe switching and isolation of high-voltage circuits. This requires the rapid, safe, and reliable switching of high-current circuits to achieve power management for the main circuit of the power battery and high-voltage branches such as fast charging, pre-charging, and PTC heating.

[0003] Currently, the industry generally adopts a split-installation approach to address the aforementioned issues, using independent filters to solve EMI interference problems and separate contactors to achieve safe switching and isolation of high-voltage circuits. However, this split-installation method has many drawbacks. Its structure is relatively complex, with a large number of components, making installation and maintenance difficult. Furthermore, because the filters and contactors each occupy their own space, the overall space usage is large, making it difficult to achieve efficient space utilization in the limited space of new energy electric vehicles. This hinders the miniaturization and lightweight design of the vehicle and increases the overall cost. Summary of the Invention

[0004] In view of the aforementioned problems with existing filter and contactor installations, this paper aims to provide an integrated structure for filters and contactors in new energy electric vehicles.

[0005] The specific technical solution is as follows: An integrated structure of filter and contactor for a new energy electric vehicle includes a filter housing and a copper busbar assembly. An inner cavity is formed on the housing, and the contactor is fixed in the inner cavity. The copper busbar assembly is integrally injection molded with the filter housing and connected to the contactor. Among them, a number of limiting ribs are formed between the inner wall of the cavity and the bottom of the cavity, and each of the limiting ribs abuts against the outer side of the contactor.

[0006] As a further improvement and optimization of this solution, a guide slope is formed at the top of each of the limiting ribs.

[0007] As a further improvement and optimization of this solution, the contactor is fixed to the inner cavity by adhesive.

[0008] As a further improvement and optimization of this solution, the fixing adhesive is applied to the bottom of the inner cavity and bonded to the bottom of the contactor.

[0009] As a further improvement and optimization of this solution, the contactor is disposed in the inner cavity in a side-lying manner.

[0010] As a further improvement and optimization of this solution, the stationary contact of the contactor is connected to the copper busbar assembly by bolts, and the low-voltage terminal of the contactor is led out from the top opening of the inner cavity.

[0011] As a further improvement and optimization of this solution, a nanocrystalline magnetic ring is embedded in one side of the filter housing.

[0012] As a further improvement and optimization of this solution, the nanocrystalline magnetic ring has a waist-shaped structure.

[0013] As a further improvement and optimization of this solution, two contactors are provided, which are symmetrically distributed on both sides of the filter housing, and two contactors are correspondingly provided in the inner cavity, with the two contactors respectively located in the two inner cavities.

[0014] As a further improvement and optimization of this solution, both sides of the filter housing are provided with connection terminals, which are connected to the copper busbar assembly via capacitors.

[0015] The positive effects of the above technical solution compared with the existing technology are: (1) By integrating the filter and the contactor into one structure, the present invention realizes the integration of filtering and circuit switching functions, saves space, improves the system integration, and the copper busbar assembly and the filter housing are integrally injection molded, ensuring product consistency, improving production efficiency and product quality. The limiting ribs set in the inner cavity can effectively limit the contactor, prevent the contactor from shaking during installation and use, and improve the stability and reliability of the contactor operation.

[0016] (2) The design of the guide slope of the present invention enables the contactor to enter the inner cavity more smoothly and cooperate with the limiting rib during the installation process, which reduces the installation difficulty, improves the installation efficiency, and avoids damage to the contactor or the limiting rib due to collision during the installation process. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the integrated structure of a filter and contactor for a new energy electric vehicle according to the present invention; Figure 2This is an exploded view of an integrated structure of a filter and contactor for a new energy electric vehicle according to the present invention; Figure 3 This is a schematic diagram showing the connection between the copper busbar assembly and the contactor in the integrated structure of a filter and contactor for a new energy electric vehicle according to the present invention. In the attached diagram: 1. Filter housing; 2. Contactor; 3. Nanocrystalline magnetic ring; 4. Copper busbar assembly; 5. Capacitor; 6. Connecting terminal; 11. Inner cavity; 12. Limiting rib; 121. Guide slope. Detailed Implementation

[0018] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. 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.

[0019] In the description of this invention, it should be noted that terms such as "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and for 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. Furthermore, terms such as "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0020] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0021] Figure 1 This is a schematic diagram of the integrated structure of a filter and contactor for a new energy electric vehicle according to the present invention; Figure 2 This is an exploded view of an integrated structure of a filter and contactor for a new energy electric vehicle according to the present invention; Figure 3This is a schematic diagram illustrating the connection between the copper busbar assembly and the contactor in an integrated structure of a filter and contactor for a new energy electric vehicle according to the present invention. It shows a preferred embodiment of the integrated structure of a filter and contactor 2 for a new energy electric vehicle, including a filter housing 1 and a copper busbar assembly 4. An inner cavity 11 is formed on the housing, and the contactor 2 is fixed within the inner cavity 11. The copper busbar assembly 4 is integrally injection molded with the filter housing 1 and connected to the contactor 2. Several limiting ribs 12 are formed between the inner walls and the bottom of the inner cavity 11, and each limiting rib 12 abuts against the outer side of the contactor 2. In this application, by integrating the filter and contactor 2 into one structure, the filtering and circuit switching functions are integrated, saving space and improving the system integration. The integral injection molding of the copper busbar assembly 4 and the filter housing 1 ensures product consistency, improves production efficiency and product quality, and the limiting ribs 12 within the inner cavity 11 effectively limit the contactor 2, preventing it from shaking during installation and use, thus improving the stability and reliability of the contactor 2.

[0022] Furthermore, as a preferred embodiment, a guide slope 121 is formed on the top of each limiting rib 12. The design of the guide slope 121 allows the contactor 2 to enter the inner cavity 11 more smoothly and cooperate with the limiting rib 12 during installation, reducing the installation difficulty, improving the installation efficiency, and avoiding damage to the contactor 2 or the limiting rib 12 due to collision during installation.

[0023] Furthermore, as a preferred embodiment, the contactor 2 is fixed to the inner cavity 11 using adhesive. Using adhesive to fix the contactor 2 further enhances its fixation within the inner cavity 11, effectively preventing it from loosening due to vibration or other reasons, improving its operational stability under complex operating conditions, and ensuring safe switching and isolation of the high-voltage circuit.

[0024] Furthermore, as a preferred embodiment, the adhesive is applied to the bottom of the inner cavity 11 and bonded to the bottom of the contactor 2. Applying the adhesive to the bottom of the inner cavity 11 and bonding it to the bottom of the contactor 2 ensures that the contactor 2 is subjected to uniform force, resulting in a more secure fixation. It also facilitates operation and control of the amount of adhesive used, improving the reliability and consistency of the fixation.

[0025] Furthermore, as a preferred embodiment, the contactor 2 is disposed in a side-lying manner within the inner cavity 11. This side-lying installation of the contactor 2 makes full use of the space within the inner cavity 11, further reducing the overall size of the product and making the integrated structure more compact. This is beneficial for installation and use within the limited space of new energy electric vehicles.

[0026] Furthermore, as a preferred embodiment, the stationary contact of contactor 2 is bolted to the copper busbar assembly 4, and the low-voltage terminal of contactor 2 is led out from the top opening of the inner cavity 11. The bolted connection between the stationary contact and the copper busbar assembly 4 ensures a robust connection and conductivity, enabling it to withstand large current flows and improving circuit reliability. The low-voltage terminal's lead-out from the top opening of the inner cavity 11 facilitates the connection and layout of low-voltage lines, making the electrical connections of the entire integrated structure more rational and concise.

[0027] Furthermore, as a preferred embodiment, a nanocrystalline magnetic ring 3 is embedded in one side of the filter housing. The nanocrystalline magnetic ring 3 has excellent magnetic properties, and its embedding in one side of the filter housing can effectively enhance the filtering effect of the filter, more effectively suppress EMI interference generated by the motor controller, and better meet the relevant standard requirements for EMI interference during normal vehicle operation, thus protecting radio communications.

[0028] Furthermore, as a preferred embodiment, the nanocrystalline magnetic ring 3 has a waist-shaped structure. The waist-shaped nanocrystalline magnetic ring 3 can better adapt to the internal space of the filter housing, achieving a larger magnetic area within a limited space, thereby improving the filtering performance of the magnetic ring and further enhancing its ability to suppress EMI interference.

[0029] Furthermore, as a preferred embodiment, two contactors 2 are provided, symmetrically distributed on both sides of the filter housing 1, with two corresponding contactors 2 disposed within the two inner cavities 11. The symmetrical distribution of two contactors 2 can meet the power management requirements of different high-voltage branches in new energy electric vehicles, enabling independent control of multiple circuits and improving the system's flexibility and reliability. Simultaneously, the symmetrical distribution design makes the product structure more balanced, which is beneficial for improving overall stability and reducing vibration.

[0030] As a further improvement and optimization of this solution, both sides of the filter housing 1 are also equipped with connection terminals 6, which are connected to the copper busbar assembly 4 via capacitors 5. The addition of connection terminals 6 on both sides of the filter housing 1, connected to the copper busbar assembly 4 via capacitors 5, further optimizes the filter's circuit structure, enhances its ability to suppress interference at different frequencies, improves the filtering effect, and better ensures the normal operation of the new energy electric vehicle motor controller system.

[0031] The above description is merely a preferred embodiment of the present invention and does not limit the implementation and protection scope of the present invention. Those skilled in the art should realize that any equivalent substitutions and obvious changes made based on the description and illustrations of the present invention should be included within the protection scope of the present invention.

Claims

1. An integrated structure of filter and contactor for a new energy electric vehicle, characterized in that, The filter includes a filter housing and a copper busbar assembly. An inner cavity is formed on the filter housing, and a contactor is fixed inside the inner cavity. The copper busbar assembly is integrally injection molded with the filter housing and connected to the contactor. Among them, a number of limiting ribs are formed between the inner wall of the cavity and the bottom of the cavity, and each of the limiting ribs abuts against the outer side of the contactor.

2. The integrated structure of filter and contactor for new energy electric vehicles according to claim 1, characterized in that, Each of the aforementioned limiting ribs has a guide slope formed at its top.

3. The integrated structure of filter and contactor for new energy electric vehicles according to claim 1, characterized in that, The contactor is fixed to the inner cavity by adhesive.

4. The integrated structure of filter and contactor for new energy electric vehicles according to claim 3, characterized in that, The adhesive is applied to the bottom of the inner cavity and bonded to the bottom of the contactor.

5. The integrated structure of filter and contactor for new energy electric vehicles according to any one of claims 1-4, characterized in that, The contactor is disposed in the inner cavity in a side-lying manner.

6. The integrated structure of filter and contactor for new energy electric vehicles according to claim 1, characterized in that, The stationary contact of the contactor is bolted to the copper busbar assembly, and the low-voltage terminal of the contactor is led out from the top opening of the inner cavity.

7. The integrated structure of filter and contactor for new energy electric vehicles according to claim 1, characterized in that, A nanocrystalline magnetic ring is embedded in one side of the filter housing.

8. The integrated structure of filter and contactor for new energy electric vehicles according to claim 7, characterized in that, The nanocrystalline magnetic ring has a waist-shaped structure.

9. The integrated structure of filter and contactor for new energy electric vehicles according to claim 1, characterized in that, Two contactors are provided, which are symmetrically distributed on both sides of the filter housing, and two contactors are correspondingly provided in the inner cavity, with the two contactors respectively located in the two inner cavities.

10. The integrated structure of filter and contactor for new energy electric vehicles according to claim 9, characterized in that, Both sides of the filter housing have connection terminals, which are connected to the copper busbar assembly via capacitors.

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