Automobile bus capacitor directly encapsulated in control box

Abstract

The invention relates to the field of bus capacitors, in particular to an automobile bus capacitor directly encapsulated in a control box, which comprises a control box, a retaining wall is arranged on the control box, an encapsulation area is formed by an area surrounded by the retaining wall and the side wall of the control box, the encapsulation area is used for injecting an encapsulation adhesive, and a cooling water channel is arranged at the bottom of the encapsulation area; a first copper bar is arranged at the top of the cooling water channel, one end of the first copper bar extends out of the control box, a plurality of containing cores are arranged at the top of the first copper bar and fixedly connected with the first copper bar, a second copper bar is fixedly connected to the top of each containing core, one end of each second copper bar extends out of the control box, and the other end of each second copper bar is bent and extends into the action range of the cooling water channel. By adopting the technical scheme of the invention, through direct encapsulation, extension of the second copper bar and efficient utilization of the cooling water channel, the bus capacitor is lighter in weight, smaller in size, integrated, low in cost and high in performance.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of bus capacitors, in particular to an automobile bus capacitor directly poured into a control box. BACKGROUND

[0002] In a motor controller, the direct current of a battery pack needs to be connected with the motor controller through a direct current bus as an input power supply, which is called DC-LINK or direct current support, and the capacitor in the direct current support is called a bus capacitor or support capacitor or DC-Link capacitor. Since the motor controller obtains a pulse current with a high effective value or peak value from the battery pack at the same time, a high pulse voltage is generated on the direct current support, which makes the motor controller difficult to withstand, so the bus capacitor needs to be selected for connection. With the rapid rise and growth of new energy vehicle racing tracks, higher requirements for product lightweighting, miniaturization, integration, low cost and high performance are put forward for automobile bus direct current support capacitors.

[0003] In the prior art, the automobile bus capacitors currently mass-produced on the market are poured into a plastic shell or an aluminum shell, and the capacitors are assembled into a motor control box after pouring is completed. Since the capacitor core needs to be poured into the shell first and then installed into the motor control box, an additional shell is provided, and a mounting hole needs to be reserved on the motor control box, and the mounting hole needs to increase the mounting matching material and space. In addition, since the capacitor core itself has a shell, the heat dissipation of the capacitor core needs to be transmitted through the shell, and due to the space limitation, the capacitor can only be indirectly installed with a heat dissipation structure or even cannot be installed with a heat dissipation structure, and can only rely on natural heat dissipation of the capacitor, so that the highest temperature that the product can withstand is severely limited. Therefore, a kind of automobile bus capacitor directly poured into a control box with stronger heat dissipation capacity and lighter weight is needed. SUMMARY

[0004] The application provides an automobile bus capacitor directly poured into a control box to solve the above problems, which is used for directly pouring and extending the second copper bar and the efficient utilization of the cooling water channel to make the bus capacitor more lightweight, miniaturized, integrated, low-cost and high-performance.

[0005] The application realizes the following technical scheme: an automobile bus capacitor directly poured into a control box, comprising a control box, a baffle wall is arranged on the control box, the baffle wall and the side wall of the control box surround a pouring area, the pouring area is used for injecting pouring glue, and a cooling water channel is arranged at the bottom of the pouring area. A first copper bar is arranged at the top of the cooling water channel, one end of the first copper bar extends to the outside of the control box, a plurality of capacitor cores are arranged at the top of the first copper bar, the capacitor cores are fixedly connected with the first copper bar, a second copper bar is fixedly connected with the top of the capacitor core, one end of the second copper bar extends to the outside of the control box, and the other end of the second copper bar is bent and extends to the action range of the cooling water channel.

[0006] Further, the cooling water channel is provided with a plurality of bending and winding sections.

[0007] Further, the control box is provided with a controller cabinet area, the control box is provided with an interface area, the first copper bar and the second copper bar are extended to outside of the control box in the interface area, the core and the retaining wall are arranged in T shape, the controller cabinet area and the interface area are located on two sides of the retaining wall and share the side wall in two directions with the retaining wall.

[0008] Further, the joint module is further included, the joint module is used for providing a wiring port, the joint module is provided with a clamping groove at the bottom, and the joint module is clamped on the side wall shared by the controller cabinet area and the retaining wall through the clamping groove.

[0009] Further, the first copper bar and the second copper bar are provided with extension branches, and the extension branches are extended to the controller cabinet area through the retaining wall.

[0010] Further, the extension branches are extended to the controller cabinet area through the joint module.

[0011] Further, the first copper bar, the second copper bar and the control box are provided with a first insulation layer.

[0012] Further, one end of the second copper bar extending to the cooling water channel is bent and extends along the bottom of the core, and the second copper bar is provided with a second insulation layer between the bottom of the core and the first copper bar.

[0013] Further, the bottom of the pouring area is provided with a clamping protrusion, and the clamping protrusion is located on one side of the second copper bar of the bottom of the core.

[0014] Further, the bottom of the cooling water channel is provided with a heat conduction sheet, and the extension area of the heat conduction sheet corresponds to the area of the first copper bar and the second copper bar located at the bottom of the core.

[0015] The technical scheme of the present application has at least the following beneficial effects: In the present scheme, the bus capacitor is directly poured into the control box, thereby omitting the shell used for pouring the bus capacitor in the conventional means and the corresponding connecting structure, and the weight of the control box and the bus capacitor as a whole is reduced. The retaining wall can form a pouring area with the side wall of the control box, and the bus capacitor can be directly poured into the pouring area and injected with pouring glue.

[0016] In addition to weight reduction, because the bus capacitor is removed from the shell, heat dissipation does not need to pass through the medium of the shell, and can be directly dissipated, so that the control box can be well shared with the heat dissipation structure, the cooling water channel is directly integrated in the pouring area to provide a cooling source for the bus capacitor, thereby reducing the temperature of the bus capacitor, and the heat dissipation structure can also be further extended to dissipate heat for other electrical elements in the control box, such as the controller, thereby realizing high utilization rate and structural reuse of the heat dissipation structure.

[0017] The first copper bar and the second copper bar are connected with both ends of the container core, which functions to extend the positive and negative electrodes of the container core and provide a joint and a circuit wiring port. In addition to being capable of conducting electricity, the copper material itself has good heat conductivity, so that the heat dissipation capacity of the bus capacitor can be enhanced by extending the copper structure. The second copper bar originally only needed to be connected to the top of the container core is bent and extended from the top to the bottom of the container core, so that it can also be cooled by the cooling water channel and conduct the heat dissipation effect to the top of the bus capacitor, achieving the uniform effect of heat dissipation.

[0018] Compared with the prior art, by directly pouring, extending the second copper bar and efficiently utilizing the cooling water channel, the automobile bus capacitor obtained by the scheme has smaller size and stronger heat dissipation effect, so as to adapt to the market demand for light weight, small size, integration and low cost of products. BRIEF DESCRIPTION OF DRAWINGS

[0019] Figure 1 The axonometric view of the automobile bus capacitor directly poured into the control box according to the embodiment of the present application is shown in the figure. Figure 2 The axonometric view of the automobile bus capacitor directly poured into the control box according to the embodiment of the present application is shown in the figure. Figure 3 The axonometric view of the automobile bus capacitor directly poured into the control box according to the embodiment of the present application is shown in the figure. Figure 4 The axonometric view of the automobile bus capacitor directly poured into the control box according to the embodiment of the present application is shown in the figure. Figure 5 The axonometric view of the automobile bus capacitor directly poured into the control box according to the embodiment of the present application is shown in the figure. Figure 6 The axonometric view of the automobile bus capacitor directly poured into the control box according to the embodiment of the present application is shown in the figure. Figure 7 The axonometric view of the automobile bus capacitor directly poured into the control box according to the embodiment of the present application is shown in the figure. Figure 6 The axonometric view of the automobile bus capacitor directly poured into the control box according to the embodiment of the present application is shown in the figure. Figure 8 The temperature thermal map of the bus capacitor before improvement of the automobile bus capacitor directly poured into the control box according to the embodiment of the present application is shown in the figure. Figure 9 The temperature thermal map of the bus capacitor after improvement of the automobile bus capacitor directly poured into the control box according to the embodiment of the present application is shown in the figure.

[0020] 1, control box; 2, retaining wall; 3, potting area; 4, cooling water channel; 5, first copper bar; 6, core container; 7, second copper bar; 8, controller machine case area; 9, interface area; 10, joint module; 11, card slot; 12, extension branch; 13, second insulation layer; 14, clamping protrusion; 15, heat conduction sheet; 401, bending detour section. DETAILED DESCRIPTION

[0021] The technical solutions of the present application will be described in detail below with reference to the drawings. Obviously, the described embodiments are part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0022] In the description of the present application, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" and the like indicate the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application. In addition, the terms "first", "second", "third" are only for descriptive purposes and cannot be understood as indicating or implying relative importance.

[0023] In the description of the present application, it should be noted that unless otherwise explicitly specified and limited, the terms "mounting", "connecting", "connecting" should be understood broadly, for example, it can be fixedly connected, or it can be detachably connected, or integrally connected; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium; it can be the communication inside two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0024] The specific embodiments will be described in detail below: Embodiment 1 As shown in the accompanying drawings Figures 1-9As shown, a bus capacitor directly poured into the control box, comprising a control box 1, the control box 1 is made of aluminum material to reduce the weight, the control box 1 is provided with a retaining wall 2, the retaining wall 2 and the side wall of the control box 1 form a pouring area 3, the pouring area 3 is slightly larger than the volume of the required core 6 to reduce the invalid area, the pouring area 3 is used to inject pouring glue, the bottom of the pouring area 3 is provided with a cooling water channel 4, the cooling water channel 4 is provided with a plurality of bending and winding sections 401, the control box 1 is communicated with a pump body for driving the liquid in the cooling water channel 4 to form a circulation, the pump body can be used from the pump body in the application scene of the bus capacitor, therefore the control box 1 itself only needs to integrate an interface communicated with the pump body, the cooling water temperature in the cooling water channel 4 is ≤65℃, and the cooling water flow rate is 8L / min.

[0025] The top of the cooling water channel 4 is provided with a first copper bar 5, one end of the first copper bar 5 extends to the outside of the control box 1, the top of the first copper bar 5 is provided with a plurality of cores 6, the core 6 is fixedly connected with the first copper bar 5 through welding, the top of the core 6 is welded and fixedly connected with a second copper bar 7, one end of the second copper bar 7 extends to the outside of the control box 1, the other end of the second copper bar 7 is bent and extends to the action range of the cooling water channel 4.

[0026] The control box 1 is provided with a controller case area 8, the control box 1 is provided with an interface area 9, the first copper bar 5 and the second copper bar 7 extend to the outside of the control box 1 at the interface area 9, the core 6 and the retaining wall 2 are in T-shaped layout, the controller case area 8 and the interface area 9 are respectively located on both sides of the retaining wall 2 and share the side wall in two directions with the retaining wall 2.

[0027] In the embodiment, the bus capacitor is directly poured into the control box 1, thereby omitting the shell used for pouring the bus capacitor in the conventional means and the corresponding connecting structure, and the weight of the control box 1 and the bus capacitor as a whole is reduced. The retaining wall 2 can form a groove-shaped pouring area 3 with the side wall of the control box 1, the bus capacitor is placed in the pouring area 3 and pouring glue is injected to directly pour. The core 6 is directly poured into the control box 1, saving a core 6 shell, only a retaining wall 2 needs to be cast on the case, without reserving the core 6 shell space and mounting hole, the volume of the whole control box 1 becomes smaller. At the same time, the size chain assembly tolerance design between the capacitor and the case does not need to be considered, the core 6 is directly poured into the control box 1, eliminating the scrapping caused by the manufacturing error; and the shell does not need to be fixed by bolts, saving the cost of bolts, adopting integral pouring, eliminating the failure risk caused by bolt locking, the overall structural strength is enhanced, more in line with the design specification, and the mechanical performance of the product is better.

[0028] The core 6 and the retaining wall 2 are in T-shaped layout, the controller case area 8 and the interface area 9 are respectively located on both sides of the retaining wall 2 and share the side wall in two directions with the retaining wall 2, further improving the structure utilization rate, making the overall structure more compact, reducing space waste and further reducing the weight.

[0029] The automobile bus capacitor is mostly used in an environment reaching 95℃, while the polypropylene film used in winding of the electric core has a melting point of about 125℃, and the design requires that the highest temperature of the capacitor during use should not exceed 105℃, and the risk of product failure will increase exponentially when used in excess. Since the product has a large current flowing therethrough, the product itself generates a lot of heat, and thus it is necessary to further reduce the temperature of the bus capacitor during operation.

[0030] In addition to weight reduction, since the bus capacitor is free of the shell, heat dissipation does not need to pass through the medium of the shell, and can be directly dissipated, and the natural heat dissipation effect is better, and can be well shared with the control box 1, and the cooling water channel 4 is directly integrated in the pouring area 3 to provide a cooling source for the bus capacitor, reduce the temperature of the bus capacitor, and at the same time, can further extend to dissipate heat for other electrical elements in the control box 1, such as the controller, to realize high utilization and structural reuse of the heat dissipation structure. The cooling water channel 4 can increase the flow area through the bending and winding section 401 to enhance the heat dissipation effect.

[0031] The first copper bar 5 and the second copper bar 7 are connected to both ends of the electric core 6, which serves to extend the positive and negative electrodes of the electric core 6 and provide a joint to provide a circuit wiring port. In addition to being able to conduct electricity, the copper material itself has good thermal conductivity, so the heat dissipation capacity of the bus capacitor can be enhanced by extending the copper structure. Therefore, the second copper bar 7 originally only needed to be connected to the top of the electric core 6 is bent and extended, and is extended from the top to the bottom of the electric core 6, so that it can also be cooled by the cooling water channel 4, and the heat dissipation effect is conducted to the top of the bus capacitor, realizing the uniform effect of heat dissipation. The first copper bar 5 is located at the top of the cooling water channel 4, so it can get good heat dissipation and conduction effect without expansion.

[0032] The temperature of the electric core 6 after improving the heat dissipation of the cooling water channel 4 is compared before and after, as shown in Figure 8 , Figure 9 The temperature is further reduced by about 4℃ compared with before improvement, and the internal temperature of the product is greatly reduced, and the product can normally operate under more extreme conditions, and the electrical performance of the bus capacitor is enhanced.

[0033] Compared with the prior art, by directly pouring and extending the second copper bar 7 and efficiently utilizing the cooling water channel 4, the automobile bus capacitor obtained by the scheme has smaller size and stronger heat dissipation effect, so as to adapt to the market demand for light weight, small size, integration, low cost and high performance of products.

[0034] Example 2 The difference from the above embodiment is that a joint module 10 is further included, the joint module 10 is used to provide a wiring port, the joint module 10 is provided with a clamping groove 11 at the bottom, and the joint module 10 is clamped on the side wall shared by the controller cabinet area 8 and the retaining wall 2 through the clamping groove 11. The first copper bar 5 and the second copper bar 7 are each provided with an extension branch 12, and the extension branch 12 extends to the controller cabinet area 8 through the retaining wall 2. The extension branch 12 extends to the controller cabinet area 8 through the joint module 10.

[0035] The joint module 10 can provide a wiring port, which can be connected with a controller signal in the controller cabinet area 8 to provide a controller signal connection interface, or be electrically connected with the first copper bar 5 and the second copper bar 7 to facilitate the expansion of the circuit connection relationship. The joint module 10 is directly clamped on the retaining wall 2 through the clamping groove 11, and when subsequent pouring is performed, due to the clamping relationship, part of the joint module 10 located in the pouring area 3 can be directly fixed with the retaining wall 2 by using pouring glue, and there is no need to set a fixing structure.

[0036] When pouring is performed, the container core 6 needs to be fixed to prevent the position from deviating during pouring, and therefore the first copper bar 5 and the second copper bar 7 are further provided with the extension branch 12. The extension branch 12 extends to the controller cabinet area 8 through the joint module 10, and the extension branch 12 can be electrically connected with a wire in the controller cabinet area 8 to facilitate control. The extension branch 12 and the joint module 10 form a clamping and fixing relationship, so that the first copper bar 5 and the second copper bar 7 can be effectively constrained during pouring, and the container core 6 is constrained by the first copper bar 5 and the second copper bar 7, thereby maintaining the stability of the container core 6 during pouring. In addition, the first copper bar 5 and the second copper bar 7 extend to the controller cabinet area 8, and can also utilize the heat conduction performance to conduct heat, conduct the heat of the controller cabinet area 8, and utilize the cooling characteristics of the cooling water channel 4 to cool the controller cabinet area 8.

[0037] Embodiment 3 The difference from the above embodiment is that a first insulating layer is arranged between the first copper bar 5, the second copper bar 7 and the control cabinet 1. The second copper bar 7 is bent at one end extending to the cooling water channel 4 and extends along the bottom of the container core 6, and a second insulating layer 13 is arranged between the second copper bar 7 and the bottom of the container core 6, and the first copper bar 5. The pouring area 3 is provided with a clamping protrusion 14 at the bottom, and the clamping protrusion 14 is located on one side of the second copper bar 7 at the bottom of the container core 6. The cooling water channel 4 is provided with a heat conduction sheet 15 at the bottom, and the extension area of the heat conduction sheet 15 corresponds to the area of the first copper bar 5 and the second copper bar 7 at the bottom of the container core 6.

[0038] The first copper bar 5, the second copper bar 7 and the control box 1 are provided with a first insulation layer to avoid the first copper bar 5, the second copper bar 7 and the control box 1 made of aluminum from conducting electricity and causing short circuit. The second copper bar 7 extends to the range of the cooling water channel 4 and then extends along the bottom of the container core 6 to increase the heat exchange area of the second copper bar 7 and the cooling water channel 4. However, since the second copper bar 7 is connected to the top of the container core 6, a second insulation layer 13 is needed to avoid the second copper bar 7 from conducting electricity with the bottom of the container core 6 and causing the positive and negative poles of the container core 6 to be connected. One part of the first insulation layer and the second insulation layer 13 can be filled with the reserved space when the potting glue is filled into the reserved space.

[0039] Since the first copper bar 5 and the second copper bar 7 are both partially located at the bottom of the container core 6, the first copper bar 5 and the second copper bar 7 are separated by the clamping protrusion 14 to avoid contact. When the container core 6 is placed in the potting area 3, the clamping protrusion 14 can be used for positioning to facilitate the quick determination and stable positioning of the container core 6.

[0040] The heat conduction sheet 15 can further extend the cooling effect of the cooling water channel 4 so that the bottom of the cooling water channel 4 can exchange heat through the heat conduction sheet 15. The heat conduction sheet 15 is arranged according to the area of the first copper bar 5 and the second copper bar 7 located at the bottom of the container core 6 to enhance the heat exchange effect with the first copper bar 5 and the second copper bar 7 and improve the cooling performance.

[0041] Obviously, the above embodiments are only examples for clear illustration and do not limit the embodiments. Based on the above description, other different forms of changes or variations can be made by those skilled in the art. Here, all the embodiments do not need to be exhausted and cannot be exhausted. The changes or variations derived therefrom are still within the protection scope of the present application.

Claims

1. An automotive bus capacitor directly potted into a control box, characterized in that, Includes a control box (1), a baffle (2) is provided on the control box (1), the baffle (2) and the side wall of the control box (1) form a potting area (3), the potting area (3) is used to inject potting glue, and a cooling water channel (4) is provided at the bottom of the potting area (3). The top of the cooling water channel (4) is provided with a first copper busbar (5), one end of which extends to the outside of the control box (1). The top of the first copper busbar (5) is provided with several cores (6), which are fixedly connected to the first copper busbar (5). The top of the cores (6) is fixedly connected with a second copper busbar (7), one end of which extends to the outside of the control box (1), and the other end of which is bent and extends into the working range of the cooling water channel (4).

2. The automotive bus capacitor directly potted into the control box according to claim 1, characterized in that, The cooling water channel (4) is provided with several bends and detours (401).

3. The automotive bus capacitor directly potted into the control box according to claim 1, characterized in that, The control box (1) is provided with a controller chassis area (8) and an interface area (9). The first copper busbar (5) and the second copper busbar (7) both extend from the interface area (9) to the outside of the control box (1). The core (6) and the retaining wall (2) are arranged in a T-shape. The controller chassis area (8) and the interface area (9) are located on both sides of the retaining wall (2) and both have two side walls that are shared with the retaining wall (2).

4. The automotive bus capacitor directly potted into the control box according to claim 3, characterized in that, It also includes a connector module (10), which is used to provide a wiring port. The connector module (10) has a slot (11) at the bottom. The connector module (10) is snapped into the side wall shared by the controller chassis area (8) and the retaining wall (2) through the slot (11).

5. The automotive bus capacitor directly potted into the control box according to claim 4, characterized in that, Both the first copper busbar (5) and the second copper busbar (7) are provided with extension branches (12), which extend through the retaining wall (2) to the controller chassis area (8).

6. The automotive bus capacitor directly potted into the control box according to claim 5, characterized in that, The extension branches (12) all pass through the connector module (10) and extend to the controller chassis area (8).

7. The automotive bus capacitor directly potted into the control box according to claim 1, characterized in that, A first insulating layer is provided between the first copper busbar (5), the second copper busbar (7), and the control box (1).

8. The automotive bus capacitor directly potted into the control box according to claim 7, characterized in that, The second copper busbar (7) extends to one end within the range of the cooling water channel (4), bends, and extends along the bottom of the core (6). A second insulating layer (13) is provided between the second copper busbar (7), the bottom of the core (6), and the first copper busbar (5).

9. The automotive bus capacitor directly potted into the control box according to claim 8, characterized in that, The bottom of the potting area (3) is provided with a locking protrusion (14), which is located on one side of the second copper busbar (7) at the bottom of the core (6).

10. The automotive bus capacitor directly potted into the control box according to claim 8, characterized in that, The bottom of the cooling water channel (4) is provided with a heat-conducting plate (15), and the extended area of ​​the heat-conducting plate (15) corresponds to the area of ​​the first copper busbar (5) and the second copper busbar (7) located at the bottom of the core (6).

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