Motor controller module, motor controller, power assembly and electric vehicle

Abstract

The invention provides a motor controller module, a motor controller, a power assembly and an electric vehicle, the motor controller module comprises a bus capacitor and a heat dissipation plate, the heat dissipation plate is laminated on the outer side of a shell, and one side surface of the heat dissipation plate is used for fixing a three-phase bridge arm. The shell comprises a groove, the groove is used for containing the partition plate, one surface of the partition plate is used for forming a liquid cooling cavity with the groove bottom of the groove and one part of the groove peripheral wall of the groove, and the other surface of the partition plate is used for forming another liquid cooling cavity with the other side face of the heat dissipation plate and the other part of the groove peripheral wall of the groove. And the maximum distance between the other surface and the bottom of one groove is smaller than the depth of one groove. According to the motor controller, the double-layer flow channel is formed by the heat dissipation plate, the partition plate and the groove of the shell, the bus capacitor and the three-phase bridge arm are cooled, the cooling efficiency and the integration degree of the motor controller are improved, and miniaturization of the motor controller is facilitated.

Description

Motor controller module, motor controller, power assembly and electric vehicle

[0001] The present application claims priority to the Chinese patent application No. 202421703635.3, filed on July 17, 2024, and entitled "Motor controller module, motor controller, power assembly and electric vehicle", the content of which is incorporated herein by reference in its entirety. TECHNICAL FIELD

[0002] The present application relates to the technical field of electric vehicles, and in particular to a motor controller module, a motor controller, a power assembly and an electric vehicle. BACKGROUND

[0003] In the field of electric vehicles, the power assembly includes a motor controller and a motor. The motor controller supplies power to the motor to drive the wheels to move. The motor controller includes multiple electronic and electrical components such as bus capacitors, three-phase bridge arms, heat sinks, and circuit boards. The number of components is large, the assembly is complex, and the integration of the motor controller is low, resulting in a large size of the motor controller. SUMMARY

[0004] The present application provides a motor controller module, a motor controller, a power assembly and an electric vehicle.

[0005] In a first aspect, the present application provides a motor controller module. The motor controller module includes a bus capacitor and a heat sink. An inner cavity of a shell of the bus capacitor is used to accommodate a capacitor core package. The heat sink is laminated to the outer side of the shell. Along the laminating direction of the heat sink and the shell, the heat sink includes two side surfaces. One side surface is used to fix a three-phase bridge arm. The three-phase bridge arm is used to receive power supply from a power battery of an electric vehicle through the capacitor core package and output three-phase current to drive a motor of the electric vehicle. The shell includes a groove. Along the laminating direction of the heat sink and the shell, the groove opening faces the heat sink. The groove is used to accommodate a partition plate. The partition plate includes two surfaces. One surface is used to form a liquid cooling cavity with the groove bottom and a part of the groove peripheral wall of the groove. The other surface is used to form another liquid cooling cavity with the other side surface of the heat sink and another part of the groove peripheral wall of the groove. The maximum distance between the other surface and the groove bottom is less than the depth of the groove.

[0006] In the embodiment of the present application, the shell comprises a groove, the groove has a slot opening facing the heat sink in the stacking direction of the heat sink and the shell, and the groove is used to accommodate a partition plate, so that the groove, the heat sink and the partition plate can enclose two liquid cooling cavities, one of the two liquid cooling cavities is used to circulate cooling liquid, and the other of the two liquid cooling cavities is used to circulate cooling liquid, the two liquid cooling cavities are stacked, the cooling liquid in one of the two liquid cooling cavities is used to cool the bus capacitor, and the cooling liquid in the other of the two liquid cooling cavities is used to cool the three-phase bridge arm, the double-layer flow channel formed by the two liquid cooling cavities is used to cool the three-phase bridge arm and the bus capacitor, the heat dissipation efficiency of the motor controller module can be improved, and the operation of the motor controller module can be smoothly performed.

[0007] In the embodiment of the present application, one surface is used to form one liquid cooling cavity together with the groove bottom of one groove and part of the groove wall of one groove, and the other surface is used to form another liquid cooling cavity together with the other side of the heat sink and another part of the groove wall of one groove, the groove bottom and part of the groove wall of one groove formed by the shell are directly used to form one liquid cooling cavity together with one surface of the partition plate, and the other surface of the partition plate is used to form another liquid cooling cavity together with the other side of the heat sink and another part of the groove wall of one groove, so that the bus capacitor and the heat sink in the motor controller module have higher integration. Directly using one groove of the shell to form two liquid cooling cavities can not only improve the integration of the motor controller module, but also enable the motor controller module to have a smaller volume in the stacking direction of the heat sink and the shell, which is beneficial to the miniaturization of the motor controller module and the miniaturization of the motor controller.

[0008] In the embodiment of the present application, the maximum distance between the other surface and the groove bottom of one groove is less than the depth of one groove, so that part of the groove wall of one groove can participate in forming one liquid cooling cavity, and another part of the groove wall of one groove can participate in forming another liquid cooling cavity, and the double-layer flow channel formed thereby does not excessively occupy the space of the motor controller module in the stacking direction of the heat sink and the shell, which is beneficial to improving the heat dissipation efficiency of the motor controller module while having a smaller volume.

[0009] In one embodiment, the distance between one surface and the groove bottom of one groove in the stacking direction of one heat sink and one shell is greater than or equal to the distance between the other surface and the slot opening of one groove.

[0010] In the embodiment of the present application, the distance between one surface and the groove bottom of one groove in the stacking direction of the heat sink and the shell is greater than the distance between the other surface and the groove opening of one groove, so that the liquid cooling cavity formed by one surface and the groove bottom of one groove has a larger space, which is conducive to the circulation of more cooling liquid in the liquid cooling cavity, and is conducive to improving the heat dissipation effect of the liquid cooling cavity on the bus capacitor, thereby improving the cooling efficiency of the motor controller module. The distance between the other surface and the groove opening of one groove is smaller, which is conducive to making the partition plate not occupy too much space of the motor controller module in the stacking direction of the heat sink and the shell, and is conducive to the miniaturization of the motor controller module.

[0011] In the embodiment of the present application, the distance between one surface and the groove bottom of one groove in the stacking direction of the heat sink and the shell is equal to the distance between the other surface and the groove opening of one groove, so that the other part of the groove wall of one groove and the other side of the heat sink can form another liquid cooling cavity with a larger volume, thereby improving the heat dissipation and cooling effect of the three-phase bridge arm.

[0012] In one embodiment, the shell further comprises a plurality of turbulence teeth, each of which extends from the groove bottom to the groove opening of one groove in the stacking direction of the heat sink and the shell, and the height of each turbulence tooth is less than the depth of one groove.

[0013] In the embodiment of the present application, each turbulence tooth extends from the groove bottom to the groove opening of one groove in the stacking direction of the heat sink and the shell, so that the turbulence tooth can stir the cooling liquid in the liquid cooling cavity formed by the groove bottom of one groove, increase the heat dissipation area of the cooling liquid and the shell, and prolong the flow path of the cooling liquid in the liquid cooling cavity, thereby improving the heat dissipation effect of the liquid cooling cavity on the bus capacitor and improving the cooling efficiency of the motor controller module.

[0014] In the embodiment of the present application, the height of each turbulence tooth is less than the depth of one groove, so that there is space above the turbulence tooth for accommodating the partition plate and forming another liquid cooling cavity.

[0015] In one embodiment, the three-phase bridge arm comprises a plurality of power modules, the plurality of power modules are arranged at intervals in the length direction of the three-phase bridge arm, each power module comprises two groups of copper bars, the two groups of copper bars are opposite in the width direction of the three-phase bridge arm, and the length of the three-phase bridge arm in the length direction is greater than the length of the three-phase bridge arm in the width direction. The partition plate comprises a plurality of pairs of through holes, the plurality of pairs of through holes are used to communicate the liquid cooling cavity and the other liquid cooling cavity, the plurality of pairs of through holes penetrate the partition plate in the stacking direction of the heat sink and the shell, each pair of through holes comprises two through holes, the plurality of pairs of through holes are arranged at intervals in the length direction of the three-phase bridge arm, the two through holes of each pair of through holes are arranged at intervals in the width direction of the three-phase bridge arm, and each power module is aligned with a pair of through holes in the stacking direction of the heat sink and the shell.

[0016] In the embodiment of the present application, the plurality of power modules are arranged at intervals along the length direction of the three-phase bridge arm, so that the plurality of power modules can work relatively independently and do not interfere with each other. Each power module includes two groups of copper bars, the two groups of copper bars are opposite along the width direction of the three-phase bridge arm, one group of the two groups of copper bars of the power module receives the direct current supplied by the power battery, converts the direct current into alternating current, and outputs the alternating current to the motor through the other group of the two groups of copper bars. The two groups of copper bars are arranged opposite along the width direction of the three-phase bridge arm, which is convenient for the arrangement of the internal circuit of the motor controller, and is also beneficial to the smoother driving of the motor by the current of the power battery.

[0017] In the embodiment of the present application, the length of the three-phase bridge arm along its length direction is greater than the length along its width direction, so that the three-phase bridge arm does not occupy too much space of the motor controller module along the width direction of the three-phase bridge arm.

[0018] In the embodiment of the present application, a plurality of pairs of through holes are used to communicate one liquid cooling cavity and another liquid cooling cavity, and the plurality of pairs of through holes penetrate the partition plate along the stacking direction of the heat dissipation plate and the shell, so that the two liquid cooling cavities in the motor controller module have higher integration, and the plurality of pairs of through holes communicating one liquid cooling cavity and another liquid cooling cavity enable the cooling liquid flowing into the motor controller module to flow in parallel in one liquid cooling cavity and another liquid cooling cavity, so as to cool and heat the three-phase bridge arm and the bus capacitor, which is beneficial to improve the cooling efficiency of the motor controller module.

[0019] In the embodiment of the present application, each pair of through holes includes two through holes, and the plurality of pairs of through holes are arranged at intervals along the length direction of the three-phase bridge arm, so that more cooling liquid in one liquid cooling cavity and another liquid cooling cavity can flow through the plurality of pairs of through holes, which is beneficial to speed up the exchange speed of the cooling liquid in one liquid cooling cavity and another liquid cooling cavity, and improve the heat dissipation efficiency. The plurality of pairs of through holes are arranged at intervals along the length direction of the three-phase bridge arm, and the two through holes of each pair of through holes are arranged at intervals along the width direction of the three-phase bridge arm, so that the cooling liquid in another liquid cooling cavity can flow through each pair of through holes to realize parallel flow, which is beneficial to the cooling liquid flowing faster from another liquid cooling cavity, quickly taking away the heat of the three-phase bridge arm, and improving the heat dissipation efficiency of the motor controller module.

[0020] In the embodiment of the present application, each power module is aligned with a pair of through holes along the stacking direction of the heat dissipation plate and the shell, and the two through holes of each pair of through holes are arranged at intervals along the width direction of the three-phase bridge arm, so that each pair of through holes has the same arrangement direction as the two groups of copper bars of each power module, and the direction of the cooling liquid flowing between the two through holes of each pair of through holes is the same as the direction of the current flowing through each power module, which is beneficial to improve the heat dissipation efficiency. Each power module is aligned with a pair of through holes along the stacking direction of the heat dissipation plate and the shell, which is also beneficial to each power module having a larger heat dissipation area with the cooling liquid in another liquid cooling cavity, and improving the heat dissipation efficiency.

[0021] In an embodiment, each through hole has a length along a length direction of the three-phase bridge arm that is greater than a width along a width direction of the three-phase bridge arm. The two through holes of each pair of through holes have a spacing along the width direction of the three-phase bridge arm that is greater than half of a width of the one groove along the width direction of the three-phase bridge arm.

[0022] In the embodiments of the present application, each through hole has a length along a length direction of the three-phase bridge arm that is greater than a width along a width direction of the three-phase bridge arm, and the width of each through hole along the width direction of the three-phase bridge arm is small, so that the cooling liquid flows through a longer path along the width direction of the three-phase bridge arm, and thus the cooling liquid contacts more turbulence teeth in the one groove, improving the heat dissipation effect on the bus capacitor. The length of each through hole along the length direction of the three-phase bridge arm is large, which is conducive to the formation of a wider parallel flow of each pair of through holes along the length direction of the three-phase bridge arm in the other liquid cooling cavity, and is conducive to the flow of more cooling liquid from the through hole to the upper layer of the other liquid cooling cavity. The length direction of the through hole is the same as the length direction of the three-phase bridge arm, so that the cooling efficiency of the three-phase bridge arm is more uniform. Therefore, the length of each through hole along the length direction of the three-phase bridge arm is greater than the width of the through hole along the width direction of the three-phase bridge arm, so that the cooling liquid can take away more heat of the capacitor module without affecting the flow efficiency of the through hole, thereby facilitating the cooling liquid to take away the heat of the three-phase bridge arm more quickly, and improving the heat dissipation efficiency of the motor controller module.

[0023] In the embodiments of the present application, the two through holes of each pair of through holes have a spacing along the width direction of the three-phase bridge arm that is greater than half of a width of the one groove along the width direction of the three-phase bridge arm, which is conducive to increasing the flow distance of the cooling liquid between the two through holes of each pair of through holes, and thus effectively taking away the heat of the turbulence teeth, so that the cooling liquid in the one liquid cooling cavity and the other liquid cooling cavity flows uniformly.

[0024] In an embodiment, the one housing further includes a plurality of reinforcing ribs, each of which protrudes from a groove bottom of the one groove to the partition plate in a stacking direction of the one heat dissipation plate and the one housing. In the embodiment, a height of each reinforcing rib in the stacking direction of the one heat dissipation plate and the one housing is less than a depth of the one groove. The part of the through holes and the part of the reinforcing ribs are arranged alternately along the length direction of the three-phase bridge arm.

[0025] In the embodiments of the present application, the housing further includes a plurality of reinforcing ribs, each of which protrudes from a groove bottom of the one groove to the partition plate in a stacking direction of the one heat dissipation plate and the one housing. The protrusion of the reinforcing rib from the groove bottom of the one groove to the partition plate can reinforce the partition plate to compensate for the reduced structural strength of the partition plate due to the formation of the through hole, and thus is conducive to improving the overall structural strength of the motor controller module.

[0026] In the embodiment of the present application, the height of each reinforcing rib is less than the depth of one groove in the stacking direction of the heat dissipation plate and the shell, so as to avoid the reinforcing rib being too high to support the partition plate at a high position, and to form another liquid cooling cavity in the space above the partition plate.

[0027] In the embodiment of the present application, the part of the through holes and the part of the reinforcing ribs are arranged alternately along the length direction of the three-phase bridge arm, so that the reinforcing ribs can reinforce the partition plate with weakened structural strength due to the through hole structure, which is conducive to improving the structural strength of the motor controller module, and the part of the through holes and the part of the reinforcing ribs are arranged alternately, so as to avoid the reinforcing ribs blocking the through holes and affecting the flow of the cooling liquid.

[0028] In one embodiment, one shell further comprises one protrusion and two inlets and outlets, the protrusion protrudes from the groove bottom of one groove to the groove opening of the groove in the stacking direction of one heat dissipation plate and one shell, one partition plate is stacked on the protrusion, the protrusion is used for separating one liquid cooling cavity into two liquid cooling sub-cavities and separating the two inlets and outlets, each liquid cooling sub-cavity is used for connecting another liquid cooling cavity and an inlet and outlet, and the two inlets and outlets are used for connecting external flow channels. Wherein, the height of the protrusion is less than the depth of the groove in the stacking direction of the heat dissipation plate and the shell. The length of the protrusion is greater than or equal to the length of the groove along the length direction of the three-phase bridge arm.

[0029] In the embodiment of the present application, the protrusion protrudes from the groove bottom of one groove to the groove opening of the groove in the stacking direction of the heat dissipation plate and the shell, and the partition plate is stacked on the protrusion, so that the protrusion can separate one liquid cooling cavity into two liquid cooling sub-cavities. The protrusion is used for separating the two inlets and outlets, each liquid cooling sub-cavity is used for connecting another liquid cooling cavity and an inlet and outlet or another liquid cooling cavity and another inlet and outlet, and the two inlets and outlets are used for connecting external flow channels. The protrusion makes the cooling liquid in one liquid cooling cavity not directly flow through the two inlets and outlets, and the protrusion makes the cooling liquid in one liquid cooling cavity and another liquid cooling cavity connected through the through hole.

[0030] In the embodiment of the present application, the height of the protrusion is less than the depth of the groove in the stacking direction of the heat dissipation plate and the shell, so that the partition plate is stacked on the protrusion, and the groove above the partition plate has space for forming another liquid cooling cavity.

[0031] In the embodiment of the present application, the length of the protrusion is greater than or equal to the length of the groove along the length direction of the three-phase bridge arm, so that the protrusion can enhance the structural strength of the groove, and the protrusion can effectively separate the two inlets and outlets.

[0032] In an embodiment, the protrusion comprises a sealing groove recessed away from the partition plate in the stacking direction of the heat dissipation plate and the housing, the sealing groove is used for accommodating a sealing member, the other side of the heat dissipation plate comprises a plurality of heat dissipation teeth protruding towards the partition plate in the stacking direction of the heat dissipation plate and the housing, and the sealing member is used for sealing the gap between the partition plate and the protrusion and abutting the other surface of the partition plate with the plurality of heat dissipation teeth. In this embodiment, the distance between the plurality of heat dissipation teeth and the bottom of the sealing groove in the stacking direction of the heat dissipation plate and the housing is less than the sum of the free length of the sealing member and the length of the part of the partition plate in contact with the sealing member.

[0033] In the embodiment, the sealing groove is recessed away from the partition plate in the stacking direction of the heat dissipation plate and the housing, and is used for accommodating a sealing member. Thus, the sealing member can seal the gap between the partition plate and the protrusion, so that the cooling liquid in the two liquid cooling sub-cavities can be effectively isolated, and the cooling liquid in one liquid cooling sub-cavity needs to flow back into the other liquid cooling sub-cavity after flowing through the other liquid cooling cavity.

[0034] In the embodiment, the other side of the heat dissipation plate comprises a plurality of heat dissipation teeth protruding towards the partition plate in the stacking direction of the heat dissipation plate and the housing, and the plurality of heat dissipation teeth are located in the other liquid cooling cavity and used for increasing the heat dissipation area in the other liquid cooling cavity, improving the heat dissipation effect of the cooling liquid in the other liquid cooling cavity, improving the cooling efficiency of the cooling liquid on the three-phase bridge arm, and further improving the cooling efficiency of the motor controller module.

[0035] In the embodiment, the sealing member is used for sealing the gap between the partition plate and the protrusion and abutting the other surface of the partition plate with the plurality of heat dissipation teeth. Thus, the sealing member can not only relatively seal and isolate the two liquid cooling sub-cavities, but also can prevent the cooling liquid flowing into the other liquid cooling cavity from forming a laminar flow on the tooth surface of the heat dissipation teeth and the other surface of the partition plate. The laminar flow of the cooling liquid has smaller resistance than the flow of the cooling liquid between the heat dissipation teeth. If the laminar flow is formed, the cooling liquid will flow more from the tooth surface of the heat dissipation teeth, has less contact with the heat dissipation teeth, and is not stirred by the heat dissipation teeth, thereby reducing the cooling effect of the cooling liquid on the three-phase bridge arm in the other liquid cooling cavity and being not conducive to the improvement of the cooling efficiency of the motor controller module.

[0036] In the embodiment of the present application, the spacing between the plurality of heat dissipation fins and the groove bottom of the sealing groove is less than the sum of the free length of the sealing member and the length of the portion of the partition plate in contact with the sealing member along the stacking direction of the heat dissipation plate and the shell, so that the sealing member in the sealing groove can exert an elastic force on the partition plate in the upward direction along the stacking direction of the heat dissipation plate and the shell, so that the other surface of the partition plate can abut against the plurality of heat dissipation fins, thereby preventing the cooling liquid flowing from the liquid cooling cavity through the through hole into the other liquid cooling cavity from forming a laminar flow on the tooth surface of the heat dissipation fin, which is beneficial to increasing the contact area of the cooling liquid with the heat dissipation fin, thereby improving the cooling effect of the other liquid cooling cavity on the three-phase bridge arm, and further improving the cooling efficiency of the motor controller module.

[0037] In an embodiment, one surface of one partition plate includes one sealing protrusion, the sealing protrusion protrudes towards one sealing groove along the stacking direction of one heat dissipation plate and one shell, the sealing groove is used for accommodating the sealing protrusion, and the sealing protrusion is used for extruding one sealing member. Wherein, the sum of the length of the sealing protrusion and the free length of the sealing member is greater than the depth of the sealing groove along the stacking direction of the heat dissipation plate and the shell.

[0038] In the embodiment of the present application, the sealing protrusion protrudes towards the sealing groove along the stacking direction of the heat dissipation plate and the shell, the sealing groove is used for accommodating the sealing protrusion, and the sealing protrusion is used for extruding the sealing member. The sealing protrusion, the sealing groove and the sealing member cooperate with each other, so that the sealing connection between the partition plate and the protrusion is more stable. Not only can one liquid cooling cavity be divided into two liquid cooling sub-cavities, but also the sealing member can better exert force on the partition plate, so that the other surface of the partition plate abuts against the plurality of heat dissipation fins, preventing the cooling liquid in the other liquid cooling cavity from flowing between the heat dissipation fins and the partition plate, so that the cooling liquid flows more between the heat dissipation fins, thereby improving the cooling effect of the other liquid cooling cavity on the three-phase bridge arm.

[0039] In the embodiment of the present application, the sum of the length of the sealing protrusion and the free length of the sealing member is greater than the depth of the sealing groove along the stacking direction of the heat dissipation plate and the shell, so that the sealing member can have an upward elastic force on the partition plate, so that the other surface of the partition plate abuts against the plurality of heat dissipation fins, preventing the cooling liquid in the other liquid cooling cavity from flowing between the heat dissipation fins and the partition plate, so that the cooling liquid flows more between the heat dissipation fins, thereby improving the cooling effect of the other liquid cooling cavity on the three-phase bridge arm.

[0040] In an embodiment, the protrusion includes a first segment, a second segment and a third segment connected in sequence. Wherein, the first segment and the second segment are arranged on both sides of the two inlets and outlets along the length direction of the three-phase bridge arm. The two ends of the second segment are arranged on different sides of the two inlets and outlets along the width direction of the three-phase bridge arm.

[0041] In the embodiment of the present application, the first section and the second section along the length direction of the three-phase bridge arm are arranged on both sides of the two inlets and outlets, so that the protrusions can better isolate the two inlets and outlets, and can also improve the problem of strength reduction of the shell due to the opening of the two inlets and outlets.

[0042] In the embodiment of the present application, the two ends of the second section along the length direction are arranged on different sides of the two inlets and outlets along the width direction of the three-phase bridge arm, so that the two inlets and outlets can be isolated in the two liquid cooling sub-cavities respectively, so that the cooling liquid flowing into one liquid cooling cavity will not only flow between the two inlets and outlets without flowing through the other liquid cooling cavity. The double-layer flow channel enables the three-phase bridge arm and the bus capacitor of the motor controller module to be cooled at the same time, thereby improving the cooling efficiency of the motor controller module.

[0043] In one embodiment, the groove wall of one groove includes a plurality of clamping protrusions for limiting the partition plate. Wherein, along the stacking direction of the heat sink and the shell, the distance between each clamping protrusion and the groove bottom is greater than the distance between the other surface of the partition plate and the groove bottom.

[0044] In the embodiment of the present application, the groove wall of one groove includes a plurality of clamping protrusions for limiting the partition plate, and the plurality of clamping protrusions enable the partition plate to be fixedly placed above the shell, which is conducive to forming two relatively stable liquid cooling cavities, improving the structural reliability of the motor controller module, and further improving the structural reliability of the motor controller. The clamping protrusion is located on the groove wall of one groove and is used to clamp the side plate below the clamping protrusion, so that another part of the groove wall where the clamping protrusion is located, the other surface of the partition plate and the heat sink enclose another liquid cooling cavity, improving the fusion and integration between the structures of the motor controller module.

[0045] In the embodiment of the present application, along the stacking direction of the heat sink and the shell, the distance between each clamping protrusion and the groove bottom is greater than the distance between the other surface of the partition plate and the groove bottom, so that the clamping protrusion can be stacked with the partition plate along the stacking direction of the heat sink and the shell. Along the stacking direction of the heat sink and the shell, the clamping protrusion, the partition plate and the groove mouth of one groove are arranged in sequence, so that the clamping protrusion can limit the partition plate, fix the partition plate on one groove, and make the structure of the motor controller module more stable.

[0046] In an embodiment, the other surface of the heat dissipation plate further comprises another recess and a plurality of heat dissipation teeth, the other recess is recessed away from the partition plate in the stacking direction of the heat dissipation plate and the housing, and the plurality of heat dissipation teeth protrude towards the partition plate from the bottom of the other recess, the other surface is used to form another liquid cooling cavity with the other recess of the other side of the heat dissipation plate and the other part of the circumferential wall of the recess. In this embodiment, the depth of the other recess is less than the length of at least part of the heat dissipation teeth in the stacking direction of the heat dissipation plate and the housing, the depth of the other recess is less than the maximum distance between the bottom of the recess and the partition plate, and the length of the plurality of heat dissipation teeth is less than the depth of the recess.

[0047] In the embodiment, the other recess is recessed away from the partition plate in the stacking direction of the heat dissipation plate and the housing, so that the other recess of the heat dissipation plate can form a larger another liquid cooling cavity with the partition plate, and sufficient space is provided for the arrangement of the plurality of heat dissipation teeth, and more cooling liquid can flow in the another liquid cooling cavity, thereby improving the cooling effect of the cooling liquid on the three-phase bridge arm.

[0048] In the embodiment, the other surface is used to form another liquid cooling cavity with the other recess of the other side of the heat dissipation plate and the other part of the circumferential wall of the recess, and the circumferential wall of the recess is used to form not only one liquid cooling cavity but also another liquid cooling cavity, so that the formation of the two liquid cooling cavities does not excessively occupy the space of the motor controller module in the stacking direction of the heat dissipation plate and the housing, which is beneficial to the miniaturization arrangement of the motor controller module and can improve the integration of the motor controller module.

[0049] In the embodiment, the depth of the other recess is less than the length of at least part of the heat dissipation teeth in the stacking direction of the heat dissipation plate and the housing, so that at least part of the heat dissipation teeth can abut against the other surface of the partition plate, avoiding the occurrence of laminar flow of the cooling liquid between the tooth surface of the heat dissipation teeth and the other surface of the partition plate in the another liquid cooling cavity, thereby improving the heat dissipation efficiency. The longer length of the heat dissipation teeth is also beneficial to increasing the contact area of the cooling liquid and the heat dissipation teeth, thereby improving the cooling effect of the cooling liquid and the cooling efficiency of the motor controller module.

[0050] In the embodiment, the depth of the other recess is less than the maximum distance between the bottom of the recess and the partition plate, so that the formation of the one liquid cooling cavity and the another liquid cooling cavity does not excessively occupy the space of the motor controller module in the stacking direction of the heat dissipation plate and the housing, which is beneficial to the miniaturization arrangement of the motor controller module.

[0051] In the embodiment of the present application, the length of the plurality of heat dissipation fins is less than the depth of the groove, so that when the heat dissipation plate borrows a groove to form another liquid cooling cavity, the other liquid cooling cavity does not occupy too much space of the motor controller module along the stacking direction of the heat dissipation plate and the shell, which is beneficial to the miniaturization of the motor controller module.

[0052] In a second aspect, the present application provides a motor controller, which comprises a shell and the motor controller module as in the first aspect, the shell is used to accommodate the motor controller module, and the internal flow channel of the shell is used to connect two inlets and outlets of a shell of a bus capacitor in the motor controller module.

[0053] In the motor controller module in the embodiment of the present application, two liquid cooling cavities are formed by using the heat dissipation plate, the partition plate and a groove of the shell of the bus capacitor, the two liquid cooling cavities are used to circulate cooling liquid to form a double-layer flow channel, the bus capacitor and the three-phase bridge arm are cooled and cooled, and the cooling efficiency of the motor controller module is improved. The groove of the shell of the bus capacitor is used to form a liquid cooling cavity, which can also improve the integration of the motor controller module, which is beneficial to the miniaturization of the motor controller module, and thus is beneficial to the miniaturization of the motor controller.

[0054] In a third aspect, the present application provides a power assembly, which comprises a motor and the motor controller as in the second aspect, the motor is used to receive power supply of the motor controller module of the motor controller.

[0055] In the motor controller in the embodiment of the present application, the motor controller module is formed by using the heat dissipation plate, the partition plate and a groove of the shell of the bus capacitor, the two liquid cooling cavities are used to circulate cooling liquid to form a double-layer flow channel, the bus capacitor and the three-phase bridge arm are cooled and cooled, and the cooling efficiency of the motor controller module is improved. The groove of the shell of the bus capacitor is used to form a liquid cooling cavity, which can also improve the integration of the motor controller module, which is beneficial to the miniaturization of the motor controller module, and thus is beneficial to the miniaturization of the motor controller and the power assembly.

[0056] In a fourth aspect, the present application provides an electric vehicle, which comprises a vehicle frame, a power battery and the power assembly as in the third aspect, the vehicle frame is used to fix the power battery and the power assembly, and the motor of the power assembly is used to receive power supply of the power battery through the motor controller to drive the wheels.

[0057] The power assembly in the embodiment of the present application comprises a motor controller module, two liquid cooling cavities are formed by using a heat dissipation plate, a partition plate and a recess of a shell of a bus capacitor, the two liquid cooling cavities are used for circulating cooling liquid to form double-layer flow channels, the bus capacitor and three-phase bridge arms are cooled and cooled, and the cooling efficiency of the motor controller module is improved. The recess of the shell of the bus capacitor is used for forming the liquid cooling cavity, and the integration of the motor controller module is also improved, which is beneficial to the miniaturization of the motor controller module, thereby being beneficial to the miniaturization of the motor controller and the power assembly, and further optimizing the whole vehicle layout. BRIEF DESCRIPTION OF DRAWINGS

[0058] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required to be used in the embodiments of the present application will be described below.

[0059] FIG. 1 is a structural schematic diagram of an electric vehicle provided by the embodiment of the present application;

[0060] FIG. 2 is a structural schematic diagram of a power assembly provided by the embodiment of the present application;

[0061] FIG. 3 is a structural schematic diagram of a motor controller module provided by the embodiment of the present application;

[0062] FIG. 4 is an exploded view of the motor controller module provided by the embodiment of the present application;

[0063] FIG. 5 is a sectional view of the motor controller module provided by the embodiment of the present application;

[0064] FIG. 6 is a partial enlarged view of M1 part of the motor controller module in FIG. 5;

[0065] FIG. 7 is a structural schematic diagram of a shell provided by the embodiment of the present application;

[0066] FIG. 8 is a sectional view of the shell provided by the embodiment of the present application;

[0067] FIG. 9 is a structural schematic diagram of a partition plate provided by the embodiment of the present application;

[0068] FIG. 10 is a structural schematic diagram of a partition plate provided by another embodiment of the present application;

[0069] FIG. 11 is a partial enlarged view of M2 part of the motor controller module in FIG. 5;

[0070] FIG. 12 is another structural schematic diagram of a partition plate provided by the embodiment of the present application;

[0071] FIG. 13 is a partial enlarged view of M1 part of the motor controller module in FIG. 5;

[0072] FIG. 14 is another exploded view of the motor controller module provided by the embodiment of the present application;

[0073] FIG. 15 is another structural schematic diagram of the motor controller module provided in the embodiments of the present application. DETAILED DESCRIPTION

[0074] The technical solutions in the embodiments of the present application will be described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, but not all of the embodiments of the present application.

[0075] In order to improve the heat dissipation efficiency of the motor controller and miniaturize the layout of the motor controller module, the present application provides a motor controller module, which includes a bus capacitor and a heat dissipation plate. An inner cavity of a shell of the bus capacitor is used to accommodate a capacitor core package. The heat dissipation plate is laminated on the outer side of the shell. The heat dissipation plate includes two side surfaces in the laminating direction of the heat dissipation plate and the shell. One side surface is used to fix a three-phase bridge arm. The three-phase bridge arm is used to receive power supply of a power battery of an electric vehicle through the capacitor core package and output three-phase current to drive a motor of the electric vehicle. The shell includes a groove. The groove is used to accommodate a partition plate. The partition plate includes two surfaces. One surface is used to form a liquid cooling cavity with the groove bottom and a part of the groove peripheral wall of the groove. The other surface is used to form another liquid cooling cavity with the other side surface of the heat dissipation plate and another part of the groove peripheral wall of the groove. The maximum distance between the other surface and the groove bottom is less than the depth of the groove. Two liquid cooling cavities are formed by using the heat dissipation plate, the partition plate and the groove of the shell of the bus capacitor. The two liquid cooling cavities are used to circulate cooling liquid to form a double-layer flow channel. The bus capacitor and the three-phase bridge arm are cooled to improve the cooling efficiency of the motor controller module. The groove formed by the shell of the bus capacitor is used to form the liquid cooling cavity, which can also improve the integration of the motor controller module and is conducive to the miniaturization of the motor controller module, thereby being conducive to the miniaturization of the motor controller.

[0076] The motor controller module provided in the embodiments of the present application is used for the motor controller, which is applied to the power assembly. The power assembly is applied to the electric vehicle to improve the overall performance of the electric vehicle.

[0077] FIG. 1 is a structural schematic diagram of an electric vehicle 1 provided in the embodiments of the present application. FIG. 2 is a structural schematic diagram of a power assembly 10 provided in the embodiments of the present application. FIG. 3 is a structural schematic diagram of a motor controller module 100 provided in the embodiments of the present application.

[0078] In one embodiment, the electric vehicle 1 includes the power assembly 10, a vehicle frame 20 and a power battery 30. As shown in FIG. 1, the vehicle frame 20 is used to fix the power battery 30 and the power assembly 10. In the embodiments of the present application, the power assembly 10 is used to receive power supply of the power battery 30 and drive the wheels 40.

[0079] In the embodiments of the present application, the power battery 30 can also be referred to as a battery pack. In the embodiments of the present application, the electric vehicle 1 refers to a wheeled device driven or towed by a power device.

[0080] In an embodiment, the power assembly 10 comprises a motor 11, a reducer 12 and a motor controller 13. As shown in FIG. 2, in the embodiments of the present application, the motor 11 comprises a motor shaft (not shown), a motor stator (not shown) and a motor rotor (not shown), the motor rotor is fixedly sleeved on the motor shaft, and the motor stator drives the motor rotor to rotate after receiving alternating current, thereby driving the motor shaft to rotate. The reducer 12 comprises a gear assembly (not shown), an input shaft (not shown) and an output shaft (not shown), the motor shaft of the motor 11 is used for driving connection with the input shaft of the reducer 12, the input shaft receives the power transmitted by the motor shaft of the motor 11 and transmits the power to the output shaft through the gear assembly. The gear assembly can be set as required, which can be a single-gear reducer, a two-gear reducer or a multi-gear reducer.

[0081] In the embodiments of the present application, the motor controller 13 is used to control the motor 11 of the electric vehicle 1 to drive the wheels 40 of the electric vehicle 1. The motor controller 13 is used to receive direct current transmitted by the power battery 30 and convert the direct current into alternating current to be transmitted to the motor 11, and the power battery 30 is connected to the winding of the motor 11 through the motor controller 13 to drive the motor 11.

[0082] In an embodiment, the motor controller 13 is also used to charge and discharge the power battery 30. The motor controller 13 is also used to integrate at least one of an on-board charger, a vehicle controller and a power distribution device.

[0083] In an embodiment, as shown in FIGS. 2 and 3, the motor controller 13 comprises a shell (not shown) and a motor controller module 100, the shell is used to accommodate the motor controller module 100, and the motor 11 is used to receive power supply of the motor controller module 100 of the motor controller 13. The motor controller module 100 comprises a radiator, a bus capacitor 101 and a three-phase bridge arm 103, and the radiator is used to cool the bus capacitor 101 and the three-phase bridge arm 103.

[0084] In an embodiment, the motor controller 13 further comprises a direct current filter, a Hall copper bar assembly, a circuit board and other components.

[0085] The motor controller of the electric vehicle needs to arrange many electronic and electrical components, such as a direct current filter, a bus capacitor, a power module, a radiator and the like. The large number of components makes the motor controller bulky and low in integration. The bus capacitor and the power module generate heat during work, and the cooling effect of the radiator on the bus capacitor and the power module needs to be improved.

[0086] In the embodiment of the present application, two liquid cooling cavities are formed by using the heat sink, the partition plate and the recess of the shell of the bus capacitor, the two liquid cooling cavities are used for circulating the cooling liquid to form double-layer flow channels, the bus capacitor and the three-phase bridge arm are cooled and cooled, and the cooling efficiency of the motor controller module is improved. The recess formed by the shell of the bus capacitor is used to form a liquid cooling cavity, which can also improve the integration of the motor controller module, which is beneficial to the miniaturization of the motor controller module, thereby being beneficial to the miniaturization of the motor controller.

[0087] The motor controller module 100 provided by the capacitor shell forming double liquid cooling cavities according to the embodiment of the present application will be described in detail below.

[0088] FIG. 4 is an exploded view of the motor controller module 100 provided by the embodiment of the present application, FIG. 5 is a sectional view of the motor controller module 100 provided by the embodiment of the present application, and FIG. 6 is a partial enlarged view of M1 part of the motor controller module 100 in FIG. 5.

[0089] In an embodiment, the motor controller module 100 includes a bus capacitor 101 and a heat sink 102, as shown in FIGS. 1 to 4, an inner cavity of a shell 110 of the bus capacitor 101 is used to accommodate a capacitor core package 111, the heat sink 102 is stacked on the outer side of the shell 110, the heat sink 102 includes two side surfaces 121, 122 in the stacking direction Z of the heat sink 102 and the shell 110, one side surface 121 is used to fix a three-phase bridge arm 103, and the three-phase bridge arm 103 is used to receive power supply of the power battery 30 of the electric vehicle 1 through the capacitor core package 111 and output three-phase current to drive the motor 11 of the electric vehicle 1.

[0090] In the embodiment of the present application, the bus capacitor 101 is used to smooth the bus voltage, reduce the inductance parameter, absorb the high pulse current or prevent the overcharge and the transient voltage influence, so as to guarantee the safe operation of the motor controller 13. The three-phase bridge arm 103 is used to realize the mutual conversion of three-phase alternating current and direct current.

[0091] In an embodiment, the shell 110 includes a recess 113, as shown in FIGS. 5 and 6, the slot opening 113a of the recess 113 faces the heat sink 102 in the stacking direction Z of the heat sink 102 and the shell 110, the recess 113 is used to accommodate a partition plate 104, the partition plate 104 includes two surfaces 141, 142, one surface 141 is used to form a liquid cooling cavity 105a with the groove bottom 113b of the recess 113 and a part of the groove wall 113c of the recess 113, the other surface 142 is used to form another liquid cooling cavity 105b with the other side surface 122 of the heat sink 102 and another part of the groove wall 113d of the recess 113, and the maximum distance between the other surface 142 and the groove bottom 113b is less than the depth of the recess 113.

[0092] In the embodiment of the present application, the shell 110 comprises a groove 113, the groove mouth 113a of the groove 113 faces the heat dissipation plate 102 in the stacking direction Z of the heat dissipation plate 102 and the shell 110, and the groove 113 is used to accommodate a partition plate 104, so that the groove 113, the heat dissipation plate 102 and the partition plate 104 can enclose two liquid cooling cavities 105a and 105b, the liquid cooling cavities 105a and 105b are used to flow through the cooling liquid, the liquid cooling cavities 105a and 105b are stacked, the cooling liquid in the liquid cooling cavity 105a is used to cool the bus capacitor 101, and the cooling liquid in the liquid cooling cavity 105b is used to cool the three-phase bridge arm 103. The double-layer flow channel is used to cool the three-phase bridge arm 103 and the bus capacitor 101, which can improve the heat dissipation efficiency of the motor controller module 100 and make the motor controller module 100 work smoothly.

[0093] In the embodiment of the present application, one surface 141 is used to form a liquid cooling cavity 105a with the groove bottom 113b of the groove 113 and a part of the groove wall 113c of the groove 113, and the other surface 142 is used to form another liquid cooling cavity 105b with the other side 122 of the heat dissipation plate 102 and another part of the groove wall 113d of the groove 113. The groove bottom 113b and a part of the groove wall 113c of the groove 113 formed by directly using the shell 110 form the liquid cooling cavity 105a with the surface 141 of the partition plate 104, and then the surface 142 of the partition plate 104 and the side 122 of the heat dissipation plate 102 and another part of the groove wall 113d of the groove 113 form the liquid cooling cavity 105b, so that the bus capacitor 101 and the heat dissipation plate 102 in the motor controller module 100 have higher integration. Directly using the groove 113 of the shell 110 to form two liquid cooling cavities 105a and 105b can not only improve the integration of the motor controller module 100, but also make the motor controller module 100 have smaller volume in the stacking direction Z of the heat dissipation plate 102 and the shell 110, which is beneficial to the miniaturization of the motor controller module 100 and the miniaturization of the motor controller 13.

[0094] In the embodiment of the present application, as shown in FIG. 6, the maximum distance between the surface 142 and the groove bottom 113b of the groove 113 is L1, the depth of the groove 113 is L2, and L1 < L2, so that a part of the groove wall 113c of the groove 113 can participate in forming the liquid cooling cavity 105a, and another part of the groove wall 113d of the groove 113 can participate in forming the liquid cooling cavity 105b. When the double-layer flow channel is formed, it will not occupy too much space of the motor controller module 100 in the stacking direction Z of the heat dissipation plate 102 and the shell 110, which is beneficial to improving the heat dissipation efficiency of the motor controller module 100 while having smaller volume.

[0095] In an embodiment, as shown in FIG. 6, the distance between surface 141 and the groove bottom 113b of the groove 113 along the stacking direction Z of the heat sink 102 and the housing 110 is greater than the distance between surface 142 and the groove opening 113a of the groove 113.

[0096] In the embodiment of the present application, the distance between surface 141 and the groove bottom 113b of the groove 113 along the stacking direction Z of the heat sink 102 and the housing 110 is denoted as L3, and the distance between surface 142 and the groove opening 113a of the groove 113 is denoted as L4, L3>L4, so that the liquid cooling cavity 105a formed by surface 141 and the groove bottom 113b of the groove 113 has a larger space, which is conducive to the circulation of more cooling liquid in the liquid cooling cavity 105a, and is conducive to improving the heat dissipation effect of the liquid cooling cavity 105a on the bus capacitor 101, thereby improving the cooling efficiency of the motor controller module 100. L4 is smaller, which is conducive to making the partition plate 104 and the groove 113 not too much occupy the space of the motor controller module 100 along the stacking direction Z of the heat sink 102 and the housing 110, and is conducive to the miniaturization of the motor controller module 100.

[0097] In an embodiment, the distance between surface 141 and the groove bottom 113b of the groove 113 along the stacking direction Z of the heat sink 102 and the housing 110 is equal to the distance between surface 142 and the groove opening 113a of the groove 113. So that the liquid cooling cavity 105b formed by surface 142 and the other part of the groove wall 113d of the groove 113 can have a larger volume with the side surface 122 of the heat sink 102, and improve the heat dissipation and cooling effect of the three-phase bridge arm 103.

[0098] In an embodiment, when the side surface 122 of the heat sink 102 is a plane, L3=L4 can be made, so that the liquid cooling cavity 105b and the liquid cooling cavity 105a are equal in height, and the overall heat dissipation effect on the bus capacitor 101 and the three-phase bridge arm 103 is improved.

[0099] In an embodiment, when L3>L4, the side surface 122 of the heat sink 102 can be formed as a groove facing away from the partition plate (not shown), and the liquid cooling cavity 105b is formed by the groove of the side surface 122 of the heat sink 102, surface 142, and the other part of the groove wall 113d of the groove 113, thereby improving the height of the liquid cooling cavity 105b and improving the heat dissipation and cooling effect of the three-phase bridge arm 103.

[0100] FIG. 7 is a structural schematic view of the housing 110 provided in an embodiment of the present application, and FIG. 8 is a sectional view of the housing 110 provided in an embodiment of the present application.

[0101] In an embodiment, the shell 110 further comprises a plurality of turbulence teeth 115, as shown in FIG. 7 and FIG. 8, each of the turbulence teeth 115 extends from the groove bottom 113b of the groove 113 towards the groove opening 113a along the stacking direction Z of the heat dissipation plate 102 and the shell 110, and the height of each of the turbulence teeth 115 is less than the depth of the groove 113, as shown in FIG. 6 and FIG. 8.

[0102] In the embodiment, each of the turbulence teeth 115 extends from the groove bottom 113b of the groove 113 towards the groove opening 113a along the stacking direction Z of the heat dissipation plate 102 and the shell 110, so that the turbulence teeth 115 can stir the cooling liquid in the liquid cooling cavity 105a formed in the groove bottom 113b of the groove 113, increase the heat dissipation area of the cooling liquid and the shell 110, and prolong the flow path of the cooling liquid in the liquid cooling cavity 105a, which is conducive to improving the heat dissipation effect of the liquid cooling cavity 105a on the bus capacitor 101 and improving the cooling efficiency of the motor controller module 100.

[0103] In the embodiment, the height of each of the turbulence teeth 115 is L5, and the depth of the groove 113 is L2, and L5 < L2, so that the turbulence teeth 115 have space above for accommodating the partition plate 104 and forming the liquid cooling cavity 105b, as shown in FIG. 6 and FIG. 8.

[0104] In an embodiment, the height of each of the turbulence teeth 115 is greater than the distance between the surface 142 and the groove opening 113a of the groove 113. In the embodiment, the height of each of the turbulence teeth 115 is L5, the distance between the surface 142 and the groove opening 113a of the groove 113 is L4, and L5 > L4, so that each of the turbulence teeth 115 has a higher height in the groove 113 and makes more full use of the space of the liquid cooling cavity 105a, which is conducive to each of the turbulence teeth 115 having a greater contact area with the cooling liquid in the liquid cooling cavity 105a, improving the heat dissipation effect of the liquid cooling cavity 105a on the bus capacitor 101, and further improving the heat dissipation efficiency of the motor controller module 100.

[0105] In an embodiment, the height of each of the turbulence teeth 115 is equal to the maximum distance between the partition plate 104 and the groove bottom 113b of the groove 113, and the maximum distance between the partition plate 104 and the groove bottom 113b of the groove 113 is L6, and L5 is equal to L6, so that the partition plate 104 can fit each of the turbulence teeth 115, and the cooling liquid flows through the gap between each of the turbulence teeth 115, improving the heat dissipation effect and avoiding the gap between the turbulence teeth 115 and the partition plate 104 to form laminar flow and reduce the cooling effect.

[0106] FIG. 9 is a structural schematic diagram of the partition plate 104 provided in the embodiment.

[0107] In an embodiment, the three-phase bridge arm 103 includes a plurality of power modules 131 arranged along the length direction X of the three-phase bridge arm 103, as shown in FIG. 4, each of the plurality of power modules 131 includes two groups of copper bars 131a, 131b, the two groups of copper bars 131a, 131b are opposite along the width direction Y of the three-phase bridge arm 103, and the length of the three-phase bridge arm 103 along the length direction X is greater than the length of the three-phase bridge arm 103 along the width direction Y. As shown in FIG. 4 and FIG. 9, the partition plate 104 includes a plurality of pairs of through holes 143a for connecting the liquid cooling cavities 105a and 105b, the plurality of pairs of through holes 143a penetrate the partition plate 104 along the stacking direction Z of the heat sink 102 and the shell 110, each pair of through holes 143a includes two through holes 143, the plurality of pairs of through holes 143a are arranged along the length direction X of the three-phase bridge arm 103, and the two through holes 143 of each pair of through holes 143a are arranged along the width direction Y of the three-phase bridge arm 103, and each power module 131 is aligned with a pair of through holes 143a along the stacking direction Z of the heat sink 102 and the shell 110.

[0108] In an embodiment, the plurality of power modules 131 are arranged along the length direction X of the three-phase bridge arm 103, so that the plurality of power modules 131 can work relatively independently and do not interfere with each other. Each power module 131 includes two groups of copper bars 131a, 131b, the two groups of copper bars 131a, 131b are opposite along the width direction Y of the three-phase bridge arm 103, one group of copper bars 131a of the power module 131 receives the direct current supplied by the power battery 30, converts the direct current into alternating current, and outputs the alternating current to the motor 11 through the other group of copper bars 131b, the two groups of copper bars 131a, 131b are arranged opposite along the width direction Y of the three-phase bridge arm 103, which facilitates the arrangement of the circuit in the motor controller 13, and also facilitates the current of the power battery 30 to drive the motor 11 to run more smoothly.

[0109] In an embodiment, the length of the three-phase bridge arm 103 along the length direction X is greater than the length of the three-phase bridge arm 103 along the width direction Y, so that the three-phase bridge arm 103 does not occupy too much space of the motor controller module 100 along the width direction Y of the three-phase bridge arm 103.

[0110] In an embodiment, the plurality of pairs of through holes 143a are used to connect the liquid cooling cavities 105a and 105b, and the plurality of pairs of through holes 143a penetrate the partition plate 104 along the stacking direction Z of the heat sink 102 and the shell 110, so that the two liquid cooling cavities 105a, 105b in the motor controller module 100 have higher integration, and the plurality of pairs of through holes 143a connecting the liquid cooling cavities 105a and 105b enable the cooling liquid flowing into the motor controller module 100 to flow in parallel in the liquid cooling cavities 105a and 105b, so as to cool the three-phase bridge arm 103 and the bus capacitor 101, which is conducive to improving the cooling efficiency of the motor controller module 100.

[0111] In the embodiment of the present application, each pair of through holes 143a includes two through holes 143, and multiple pairs of through holes 143a are arranged along the length direction X of the three-phase bridge arm 103, so that more cooling liquid in the liquid cooling cavities 105a and 105b can flow through the multiple pairs of through holes 143a, which is conducive to accelerating the exchange speed of the cooling liquid in the liquid cooling cavities 105a and 105b and improving the heat dissipation efficiency. The two through holes 143 of each pair of through holes 143a are arranged along the width direction Y of the three-phase bridge arm 103, so that the cooling liquid in the liquid cooling cavity 105b can flow through each pair of through holes 143a to realize parallel flow, which is conducive to faster flow of the cooling liquid from the liquid cooling cavity 105b and rapid removal of the heat of the three-phase bridge arm 103, and is conducive to improving the heat dissipation efficiency of the motor controller module 100.

[0112] In the embodiment of the present application, each power module 131 is aligned with a pair of through holes 143a along the stacking direction Z of the heat dissipation plate 102 and the shell 110, which means that the projection of each power module 131 and the pair of through holes 143a along the stacking direction Z of the heat dissipation plate 102 and the shell 110 at least partially overlaps. In the embodiment of the present application, each power module 131 is aligned with a pair of through holes 143a along the stacking direction Z of the heat dissipation plate 102 and the shell 110, and the two through holes 143 of each pair of through holes 143a are arranged along the width direction Y of the three-phase bridge arm 103, so that each pair of through holes 143a has the same arrangement direction as the two groups of copper bars 131a and 131b of each power module 131, and the flow direction of the cooling liquid between the two through holes 143 of each pair of through holes 143a is the same as the current flow direction of each power module 131, which is conducive to improving the heat dissipation efficiency. Each power module 131 is aligned with a pair of through holes 143a along the stacking direction Z of the heat dissipation plate 102 and the shell 110, which is also conducive to each power module 131 having a larger heat dissipation area with the cooling liquid in the liquid cooling cavity 105b, and is conducive to improving the heat dissipation efficiency.

[0113] FIG. 10 is a structural schematic diagram of the partition plate 104 provided in another embodiment of the present application.

[0114] In one embodiment, as shown in FIG. 10, each through hole 143 of the multiple pairs of through holes 143a on the partition plate 104 can be a slot opening along the width direction Y of the three-phase bridge arm 103, and the processing technology is simple.

[0115] In an embodiment, as shown in FIG. 9, each through hole 143 has a length along the length direction X of the three-phase bridge arm 103 that is greater than a width along the width direction Y of the three-phase bridge arm 103. As shown in FIG. 5 and FIG. 9, the distance between the two through holes 143 of each pair of through holes 143a along the width direction Y of the three-phase bridge arm 103 is greater than half the width of the groove 113 along the width direction Y of the three-phase bridge arm 103.

[0116] In an embodiment, as shown in FIG. 9, each through hole 143 has a length along the length direction X of the three-phase bridge arm 103 that is greater than a width along the width direction Y of the three-phase bridge arm 103. As shown in FIG. 5 and FIG. 9, the distance between the two through holes 143 of each pair of through holes 143a along the width direction Y of the three-phase bridge arm 103 is greater than half the width of the groove 113 along the width direction Y of the three-phase bridge arm 103.

[0117] In an embodiment, as shown in FIG. 5 and FIG. 9, the distance between the two through holes 143 of each pair of through holes 143a along the width direction Y of the three-phase bridge arm 103 is L9, and the width of the groove 113 along the width direction Y of the three-phase bridge arm 103 is L10, L9>0.5L10, which is conducive to increasing the flow distance of the cooling liquid between the two through holes 143 of each pair of through holes 143a, thereby effectively removing the flow of the turbulence teeth 115, so that the cooling liquid in the liquid cooling cavity 105a and the liquid cooling cavity 105b flows uniformly.

[0118] In an embodiment, the shell 110 further comprises a plurality of reinforcing ribs 116, as shown in FIG. 4 and FIG. 7, each reinforcing rib 116 protrudes from the groove bottom 113b of the groove 113 to the partition plate 104 along the stacking direction Z of the heat dissipation plate 102 and the shell 110. Among them, the height of each reinforcing rib 116 along the stacking direction Z of the heat dissipation plate 102 and the shell 110 is less than the depth of the groove 113. As shown in FIG. 7 and FIG. 9, part of the through holes 143 and part of the reinforcing ribs 116 are arranged alternately along the length direction X of the three-phase bridge arm 103.

[0119] In the embodiment of the present application, the shell 110 further comprises a plurality of reinforcing ribs 116, each of which protrudes from the groove bottom 113b of the groove 113 towards the partition plate 104 along the stacking direction Z of the heat dissipation plate 102 and the shell 110, and the reinforcing rib 116 protrudes from the groove bottom 113b of the groove 113 towards the partition plate 104, which can reinforce the partition plate 104 to make up for the reduced structural strength of the partition plate 104 due to the formation of the through hole 143a, thereby facilitating the improvement of the overall structural strength of the motor controller module 100.

[0120] In the embodiment of the present application, the height of each reinforcing rib 116 is less than the depth of the groove 113 along the stacking direction Z of the heat dissipation plate 102 and the shell 110, avoiding the reinforcing rib 116 being too high to support the partition plate 104 at a higher position, so that there is space above the partition plate 104 to form the liquid cooling cavity 105b.

[0121] In the embodiment of the present application, part of the through holes 143 and part of the reinforcing ribs 116 are arranged alternately along the length direction X of the three-phase bridge arm 103, so that the reinforcing rib 116 can reinforce the partition plate 104 whose structural strength is weakened due to the opening of the through hole 143, which is conducive to improving the structural strength of the motor controller module 100, and part of the through holes 143 and part of the reinforcing ribs 116 are arranged alternately, avoiding the reinforcing rib 116 blocking the through hole 143 to affect the flow of the cooling liquid.

[0122] FIG. 11 is a partial enlarged view of the M2 part of the motor controller module 100 in FIG. 5.

[0123] In one embodiment, the shell 110 further comprises a protrusion 117 and two inlets and outlets 114a, 114b, as shown in FIGS. 7 and 8, the protrusion 117 protrudes from the groove bottom 113b of the groove 113 towards the groove opening 113a of the groove 113 along the stacking direction Z of the heat dissipation plate 102 and the shell 110, as shown in FIGS. 5 and 11, the partition plate 104 is stacked on the protrusion 117, as shown in FIG. 7, the protrusion 117 is used to divide the liquid cooling cavity 105a into two liquid cooling sub-cavities 151, 152 and to divide the two inlets and outlets 114a, 114b, each liquid cooling sub-cavity 150 is used to communicate the liquid cooling cavity 105b with one inlet and outlet 114a or with the other inlet and outlet 114b, and the two inlets and outlets 114a, 114b are used to communicate with the external flow channel. As shown in FIG. 11, the height of the protrusion 117 is less than the depth of the groove 113 along the stacking direction Z of the heat dissipation plate 102 and the shell 110. As shown in FIG. 7, the length of the protrusion 117 is greater than or equal to the length of the groove 113 along the length direction X of the three-phase bridge arm 103.

[0124] In the embodiment of the present application, the protrusion 117 protrudes from the groove bottom 113b of the groove 113 towards the groove opening 113a of the groove 113 along the stacking direction Z of the heat sink 102 and the shell 110, and the partition plate 104 is stacked on the protrusion 117, so that the protrusion 117 can separate the liquid cooling cavity 105a into two liquid cooling sub-cavities 151 and 152. The protrusion 117 is used to separate the two inlets and outlets 114a and 114b, each liquid cooling sub-cavity 150 is used to communicate the liquid cooling cavity 105b and one inlet and outlet 114a or the liquid cooling cavity 105b and the other inlet and outlet 114b, and the two inlets and outlets 114a and 114b are used to communicate the external flow channels. The protrusion 117 makes the cooling liquid in the liquid cooling cavity 105a not directly flow through the two inlets and outlets 114a and 114b, and the protrusion 117 makes the cooling liquid in the liquid cooling cavity 105a and the liquid cooling cavity 105b communicate through the through hole 143. For example, the cooling liquid flows into the liquid cooling sub-cavity 151 from the inlet and outlet 114a, flows into the liquid cooling cavity 105b through part of the through hole 143, flows in the liquid cooling cavity 105b through another part of the through hole 143, and then flows out of the shell 110 from the inlet and outlet 114b and flows into the cooling system of the whole vehicle.

[0125] In the embodiment of the present application, as shown in FIGS. 6 and 11, along the stacking direction Z of the heat sink 102 and the shell 110, the height of the protrusion 117 is L11, and the depth of the groove 113 is L2, L11 < L2, so that the partition plate 104 is stacked on the protrusion 117, and the groove 113 above the partition plate 104 has space for forming the liquid cooling cavity 105b. In an embodiment, the sum of the height of the protrusion 117 and the thickness of the part of the partition plate 104 in contact with the protrusion 117 is less than the depth of the groove 113, so that the groove 113 above the partition plate 104 has space for forming the liquid cooling cavity 105b.

[0126] In the embodiment of the present application, as shown in FIG. 7, along the length direction X of the three-phase bridge arm 103, the length of the protrusion 117 is L12, and the length of the groove 113 is L13, L12 ≥ L13, so that the protrusion 117 can play a role in enhancing the structural strength of the groove 113, and also so that the protrusion 117 can effectively separate the two inlets and outlets 114a and 114b.

[0127] In an embodiment, the two inlets and outlets 114a and 114b are formed on the heat sink 102. In another embodiment, one inlet and outlet 114a is formed on the shell 110 of the bus capacitor 101, and one inlet and outlet 114b is formed on the heat sink 102, and the two liquid cooling cavities 105a and 105b form two layers of flow channels in series.

[0128] In an embodiment, the protrusion 117 comprises a sealing groove 117a, as shown in FIG. 8 and FIG. 11, which is recessed away from the partition plate 104 in the stacking direction Z of the heat dissipation plate 102 and the housing 110, and the sealing groove 117a is used to accommodate a sealing member 1171. The side surface 122 of the heat dissipation plate 102 comprises a plurality of heat dissipation teeth 123, which are protruded towards the partition plate 104 in the stacking direction Z of the heat dissipation plate 102 and the housing 110. The sealing member 1171 is used to seal the gap between the partition plate 104 and the protrusion 117, and to abut the surface 142 of the partition plate 104 with the plurality of heat dissipation teeth 123. In this embodiment, the distance between the plurality of heat dissipation teeth 123 and the bottom of the sealing groove 117a in the stacking direction Z of the heat dissipation plate 102 and the housing 110 is less than the sum of the free length of the sealing member 1171 and the length of the portion of the partition plate 104 that is in contact with the sealing member 1171.

[0129] In the embodiment, the sealing groove 117a is recessed away from the partition plate 104 in the stacking direction Z of the heat dissipation plate 102 and the housing 110, and the sealing groove 117a is used to accommodate the sealing member 1171, so that the sealing member 1171 can seal the gap between the partition plate 104 and the protrusion 117, and the cooling liquid in the two liquid cooling sub-cavities 151, 152 can be effectively isolated, so that the cooling liquid in the liquid cooling sub-cavity 151 needs to flow back into the liquid cooling sub-cavity 152 after flowing through the liquid cooling cavity 105b. In an embodiment, the sealing member 1171 is a sealing ring or a glue joint.

[0130] In the embodiment, the side surface 122 of the heat dissipation plate 102 comprises a plurality of heat dissipation teeth 123, which are protruded towards the partition plate 104 in the stacking direction Z of the heat dissipation plate 102 and the housing 110. The plurality of heat dissipation teeth 123 are located in the liquid cooling cavity 105b, and are used to increase the heat dissipation area in the liquid cooling cavity 105b, improve the heat dissipation effect of the cooling liquid in the liquid cooling cavity 105b, improve the cooling efficiency of the cooling liquid on the three-phase bridge arm 103, and further improve the cooling efficiency of the motor controller module 100.

[0131] In the embodiment of the present application, the sealing member 1171 is used to seal the gap between the partition plate 104 and the protrusion 117 and to abut the surface 142 of the partition plate 104 with the plurality of heat dissipation teeth 123, so that the sealing member 1171 can not only relatively seal the two liquid cooling sub-cavities 151, 152 independently, but also can make the cooling liquid flowing into the liquid cooling cavity 105b not have a gap between the tooth surface of the heat dissipation teeth 123 and the surface 142 of the partition plate 104 to generate a laminar flow. The cooling liquid laminar flow has smaller resistance than the cooling liquid flowing between the heat dissipation teeth 123. If the laminar flow is generated, the cooling liquid will flow more from the tooth surface of the heat dissipation teeth 123, not more contact with the heat dissipation teeth 123, and not be stirred by the heat dissipation teeth 123, thereby reducing the cooling effect of the cooling liquid in the liquid cooling cavity 105b on the three-phase bridge arm 103, which is not conducive to improving the cooling efficiency of the motor controller module 100.

[0132] In the embodiment of the present application, as shown in FIG. 11, along the stacking direction Z of the heat dissipation plate 102 and the shell 110, the spacing between the plurality of heat dissipation teeth 123 and the groove bottom of the sealing groove 117a is denoted as L14, and the sum of the free length of the sealing member 1171 and the length of the part of the partition plate 104 contacted with the sealing member 1171 is denoted as L15, L14 < L15, so that the sealing member 1171 in the sealing groove 117a can exert an elastic force on the partition plate 104 along the stacking direction Z of the heat dissipation plate 102 and the shell 110, so that the surface 142 of the partition plate 104 can abut the plurality of heat dissipation teeth 123, thereby making the cooling liquid flowing from the liquid cooling cavity 105 into the liquid cooling cavity 105b through the through hole 143 not generating a laminar flow on the tooth surface of the heat dissipation teeth 123, which is conducive to increasing the contact area of the cooling liquid with the heat dissipation teeth 123, thereby improving the cooling effect of the liquid cooling cavity 105b on the three-phase bridge arm 103, and further improving the cooling efficiency of the motor controller module 100.

[0133] In one embodiment, the surface 142 of the partition plate 104 has vulcanized rubber or other cushioning layer for abutting the tooth surface of the plurality of heat dissipation teeth 123, preventing the gap between the surface 142 and the heat dissipation teeth 123 from generating a laminar flow and affecting the heat dissipation effect.

[0134] FIG. 12 is another structural schematic view of the partition plate 104 provided in the embodiment of the present application.

[0135] In one embodiment, the surface 141 of the partition plate 104 includes a sealing protrusion 144, as shown in FIGS. 11 and 12, the sealing protrusion 144 protrudes towards the sealing groove 117a along the stacking direction Z of the heat dissipation plate 102 and the shell 110, the sealing groove 117a is used to accommodate the sealing protrusion 144, and the sealing protrusion 144 is used to press the sealing member 1171. Wherein, along the stacking direction Z of the heat dissipation plate 102 and the shell 110, the sum of the length of the sealing protrusion 144 and the free length of the sealing member 1171 is greater than the depth of the sealing groove 117a.

[0136] In the embodiment of the present application, the sealing protrusion 144 protrudes towards the sealing groove 117a in the stacking direction Z of the heat dissipation plate 102 and the shell 110, the sealing groove 117a is used to accommodate the sealing protrusion 144, the sealing protrusion 144 is used to extrude the sealing member 1171, and the sealing protrusion 144 cooperates with the sealing groove 117a and the sealing member 1171, so that the sealing connection between the partition plate 104 and the protrusion 117 is more stable, not only can the liquid cooling cavity 105a be divided into two liquid cooling sub-cavities 151 and 152, but also the sealing member 1171 can better apply force to the partition plate 104, so that the surface 142 of the partition plate 104 abuts against the plurality of heat dissipation teeth 123, avoiding the cooling liquid in the liquid cooling cavity 105b from flowing between the heat dissipation teeth 123 and the partition plate 104, so that the cooling liquid flows more between the heat dissipation teeth 123, thereby improving the cooling effect of the liquid cooling cavity 105b on the three-phase bridge arm 103.

[0137] In the embodiment of the present application, as shown in FIG. 11, the sum of the length of the sealing protrusion 144 and the free length of the sealing member 1171 is L16, and the depth of the sealing groove 117a is L17 in the stacking direction Z of the heat dissipation plate 102 and the shell 110, L16>L17, so that the sealing member 1171 can have an upward elastic force on the partition plate 104, so that the surface 142 of the partition plate 104 abuts against the plurality of heat dissipation teeth 123, avoiding the cooling liquid in the liquid cooling cavity 105b from flowing between the heat dissipation teeth 123 and the partition plate 104, so that the cooling liquid flows more between the heat dissipation teeth 123, thereby improving the cooling effect of the liquid cooling cavity 105b on the three-phase bridge arm 103.

[0138] In one embodiment, the sealing protrusion 144 and the partition plate 104 are independent components, the sealing protrusion 144 is a separate component, and the sealing protrusion 144 is accommodated in the sealing groove 117a to achieve the separation of the two liquid cooling sub-cavities 151 and 152.

[0139] In one embodiment, the surface 141 of the partition plate 104 is free of the sealing protrusion 144, the surface 141 is a plane, the thickness of the sealing member 1171 is greater than the distance between the groove bottom of the sealing groove 117a and the partition plate 104 or the thickness of the sealing member 1171 is greater than the depth of the sealing groove 117a in the stacking direction Z of the heat dissipation plate 102 and the shell 110. The sealing member 1171 can abut against and seal the partition plate 104, and the sealing member 1171 can also apply force to the partition plate 104 so that the surface 142 of the partition plate 104 abuts against the plurality of heat dissipation teeth 123, avoiding the cooling liquid in the liquid cooling cavity 105b from flowing between the tooth surface of the heat dissipation teeth 123 and the surface 142 of the partition plate 104 to generate laminar flow.

[0140] In an embodiment, the sealing protrusion 144 of the partition plate 104 comprises a sealing groove for accommodating a sealing member and the protrusion 117, the sealing member has an elastic force downward along the stacking direction Z of the heat dissipation plate 102 and the housing 110 to the protrusion 117, so that the sealing protrusion 144 separates the two liquid cooling sub-cavities 151, 152 and the surface 142 of the partition plate 104 abuts against the heat dissipation teeth 123 to eliminate the gap between the tooth surface of the heat dissipation teeth 123 and the surface 142 of the partition plate 104.

[0141] In an embodiment, as shown in FIG. 7, the protrusion 117 comprises a first segment 117b, a second segment 117c and a third segment 117d connected in sequence. The first segment 117b and the second segment 117c are arranged on both sides of the two inlets and outlets 114a, 114b along the length direction X of the three-phase bridge arm 103. The two ends of the second segment 117c are arranged on different sides of the two inlets and outlets 114a, 114b along the width direction Y of the three-phase bridge arm 103.

[0142] In the embodiment, the first segment 117b and the second segment 117c are arranged on both sides of the two inlets and outlets 114a, 114b along the length direction X of the three-phase bridge arm 103, so that the protrusion 117 can better isolate the two inlets and outlets 114a, 114b, and also improve the problem of strength reduction of the housing 110 due to the opening of the two inlets and outlets 114a, 114b.

[0143] In the embodiment, the two ends of the second segment 117c along the length direction are arranged on different sides of the two inlets and outlets 114a, 114b along the width direction Y of the three-phase bridge arm 103, so that the two inlets and outlets 114a, 114b can be isolated in the two liquid cooling sub-cavities 151, 152 respectively, so that the cooling liquid flowing into the liquid cooling cavity 105a will not only flow between the two inlets and outlets 114a, 114b but also flow through the liquid cooling cavity 105b, which is conducive to the construction of the double-layer flow channel of the motor controller module 100, so that the three-phase bridge arm 103 and the bus capacitor 101 of the motor controller module 100 can be cooled at the same time, thereby improving the cooling efficiency of the motor controller module 100.

[0144] In an embodiment, the two ends of the protrusion 117 are connected with the two groove side walls of the groove 113 along the length direction X of the three-phase bridge arm 103, and a part of the groove peripheral wall 113c of the protrusion 117 and the groove 113 encloses a liquid cooling sub-cavity 151, and another part of the groove peripheral wall 113d of the protrusion 117 and the groove 113 encloses another liquid cooling sub-cavity 152.

[0145] In an embodiment, as shown in FIGS. 6 and 7, the groove wall of the groove 113 comprises a plurality of latching protrusions 113e for limiting the partition plate 104. Wherein, along the stacking direction Z of the heat dissipation plate 102 and the shell 110, the spacing between each latching protrusion 113e and the groove bottom 113b of the groove 113 is greater than the spacing between the surface 142 of the partition plate 104 and the groove bottom 113b of the groove 113.

[0146] In the embodiment of the present application, the groove wall of the groove 113 comprises a plurality of latching protrusions 113e for limiting the partition plate 104, and the plurality of latching protrusions 113e enable the partition plate 104 to be fixedly placed above the shell 110, which is conducive to forming two more stable liquid cooling cavities 105a and 105b, improving the structural reliability of the motor controller module 100, and further improving the structural reliability of the motor controller 13. The latching protrusions 113e are located on the groove wall of the groove 113 and are used to latch the partition plate 104 below the latching protrusions 113, so that the other part of the groove wall 113d where the latching protrusions 113 are located, the surface 142 of the partition plate 104, and the heat dissipation plate 102 enclose to form the liquid cooling cavity 105b, improving the fusion and integration between the structures of the motor controller module 100.

[0147] In the embodiment of the present application, as shown in FIG. 6, along the stacking direction Z of the heat dissipation plate 102 and the shell 110, the spacing between each latching protrusion 113e and the groove bottom 113b of the groove 113 is L18, and the spacing between the surface 142 of the partition plate 104 and the groove bottom 113b of the groove 113 is L1, L18>L1, so that the latching protrusion 113e can be stacked on the partition plate 104 along the stacking direction Z of the heat dissipation plate 102 and the shell 110. Along the stacking direction Z of the heat dissipation plate 102 and the shell 110, the latching protrusion 113e, the partition plate 104, and the groove opening 113a of the groove 113 are arranged in sequence, so that the latching protrusion 113e can limit the partition plate 104, fix the partition plate 104 on the groove 113, and make the structure of the motor controller module 100 more stable.

[0148] FIG. 13 is a partial enlarged view of the M1 part of the motor controller module 100 in FIG. 5.

[0149] In an embodiment, the side surface 122 of the heat sink 102 further comprises another groove 124 and a plurality of heat dissipation fins 123, as shown in FIG. 5 and FIG. 13, the groove 124 is recessed away from the partition plate 104 along the stacking direction Z of the heat sink 102 and the housing 110, the plurality of heat dissipation fins 123 protrude from the groove bottom of the groove 124 towards the partition plate 104, and the surface 142 is used to form the liquid cooling cavity 105b with another part of the groove wall 113d of the groove 113 of the side surface 122 of the heat sink 102. Wherein, along the stacking direction Z of the heat sink 102 and the housing 110, the depth of the groove 124 is less than the length of at least part of the plurality of heat dissipation fins 123, the depth of the groove 124 is less than the maximum distance between the groove bottom 113b of the groove 113 and the partition plate 104, and the length of the plurality of heat dissipation fins 123 is less than the depth of the groove 113.

[0150] In the embodiments of the present application, as shown in FIG. 3, FIG. 5 and FIG. 13, the groove 124 is recessed away from the partition plate 104 along the stacking direction Z of the heat sink 102 and the housing 110, so that the groove 124 of the heat sink 102 can form a larger liquid cooling cavity 105b with the partition plate 104, and also provide sufficient space for the arrangement of the plurality of heat dissipation fins 123, and more cooling liquid can flow in the liquid cooling cavity 105b, thereby improving the cooling effect of the cooling liquid on the three-phase bridge arm 103. The plurality of heat dissipation fins 123 protrude from the groove bottom of the groove 124 towards the partition plate 104, so that the heat dissipation fins 123 can be arranged in the liquid cooling cavity 105b to stir the cooling liquid flowing in the liquid cooling cavity 105b, thereby improving the cooling efficiency of the motor controller module 100.

[0151] In the embodiments of the present application, the surface 142 is used to form the liquid cooling cavity 105b with the groove 124 of the side surface 122 of the heat sink 102 and another part of the groove wall 113d of the groove 113, and the groove wall of the groove 113 is used not only to form the liquid cooling cavity 105a but also to form the liquid cooling cavity 105b, so that the formation of the two liquid cooling cavities 105a and 105b does not excessively occupy the space of the motor controller module 100 along the stacking direction Z of the heat sink 102 and the housing 110, which is conducive to the miniaturization arrangement of the motor controller module 100 and can also improve the integration of the motor controller module 100.

[0152] In the embodiment of the present application, as shown in FIG. 13, the depth of the groove 124 is L19, and the length of the at least partial heat dissipation teeth 123 is L20, L19 < L20, so that the at least partial heat dissipation teeth 123 can abut against the surface 142 of the partition plate 104, avoiding the cooling liquid in the liquid cooling cavity 105b to have a gap between the tooth surface of the heat dissipation teeth 123 and the surface 142 of the partition plate 104 to generate laminar flow, thereby improving the heat dissipation efficiency. The length of the heat dissipation teeth 123 is relatively long, which is also beneficial to increase the contact area of the cooling liquid with the heat dissipation teeth 123, thereby improving the cooling effect of the cooling liquid and the cooling efficiency of the motor controller module 100.

[0153] In the embodiment of the present application, as shown in FIG. 13, the depth of the groove 124 is L19, and the maximum distance between the groove bottom 113b of the groove 113 and the partition plate 104 is L6, L19 < L6, so that after forming the liquid cooling cavities 105a and 105b, the motor controller module 100 does not occupy too much space along the stacking direction Z of the heat dissipation plate 102 and the shell 110, which is beneficial to the miniaturization arrangement of the motor controller module 100.

[0154] In the embodiment of the present application, as shown in FIG. 13, the length of the plurality of heat dissipation teeth 123 is L20, and the depth of the groove 113 is L2, L20 < L2, so that when the heat dissipation plate 102 forms the liquid cooling cavity 105b by borrowing the groove 113, the liquid cooling cavity 105b does not occupy too much space along the stacking direction Z of the heat dissipation plate 102 and the shell 110, which is beneficial to the miniaturization arrangement of the motor controller module 100.

[0155] FIG. 14 is another exploded view of the motor controller module 100 provided by the embodiment of the present application.

[0156] In one embodiment, the capacitor core package 111 includes two groups of capacitor cores 111a and 111b, as shown in FIGS. 4 and 14, and one group of capacitor cores 111a and the other group of capacitor cores 111b are arranged adjacent to each other along the width direction Y of the three-phase bridge arm 103. Along the length direction X of the three-phase bridge arm 103, the length of one group of capacitor cores 111a is less than the length of the other group of capacitor cores 111b, and the other group of capacitor cores 111b is stacked with the groove 113 along the stacking direction Z of the heat dissipation plate 102 and the shell 110.

[0157] In the embodiment of the present application, along the length direction X of the three-phase bridge arm 103, the length of one group of capacitor cores 111a is less than the length of the other group of capacitor cores 111b, so that the portion of one group of capacitor cores 111a along the length direction X of the three-phase bridge arm 103 which is less than the length of the other group of capacitor cores 111b provides space for the arrangement of other components of the motor controller module 100, which is beneficial to improve the integration of the motor controller module 100.

[0158] In the embodiment of the present application, the other group of capacitor cores 111b is arranged in the stacking direction Z of the heat dissipation plate 102 and the shell 110 with the grooves 113, so that the cooling liquid flowing in the grooves 113 can directly take away the heat of the capacitor core package 111, which is beneficial to the cooling of the bus capacitor 101 and the improvement of the heat dissipation efficiency of the motor controller module 100.

[0159] In an embodiment, the shell 110 of the bus capacitor 101 further comprises a window 118, as shown in FIG. 4 and FIG. 14, the window 118 is used to accommodate the bus capacitor 101, the bus capacitor 101 further comprises two input copper sheets 112, the opening of the window 118 is directed along the width direction Y of the three-phase bridge arm 103 and the stacking direction Z of the heat dissipation plate 102 and the shell 110, the two input copper sheets 112 are stacked on the bus capacitor 101, the two input copper sheets 112 are bent from the window 118 towards the three-phase bridge arm 103, and the two input copper sheets 112 are electrically connected with a group of copper bars 131a of the plurality of power modules 131.

[0160] In the embodiment of the present application, the opening of the window 118 along the width direction Y of the three-phase bridge arm 103 is arranged on the same side as the group of copper bars 131a of the plurality of power modules 131, which facilitates the two input copper sheets 112 to be bent from the window 118 to the three-phase bridge arm 103 in a short path and electrically connected with the group of copper bars 131a of the plurality of power modules 131, so that the direct current of the power battery 30 can be transmitted to the three-phase bridge arm 103 for conversion from direct current to alternating current output, and the integration and integration of the motor controller module 100 can be improved.

[0161] FIG. 15 is another structural schematic diagram of the motor controller module 100 provided by the embodiment of the present application.

[0162] In an embodiment, the motor controller module 100 further comprises a filter groove 119, as shown in FIG. 4, FIG. 14 and FIG. 15, along the stacking direction Z of the heat dissipation plate 102 and the shell 110, the slot opening of the filter groove 119 is directed away from the slot opening 113a of the groove 113, the filter groove 119 is used to accommodate an EMC filter assembly 106 and two input connection copper bars 107, the two input connection copper bars 107 are used to receive the direct current of the direct current power supply and transmit the direct current to the two input copper sheets 112 of the bus capacitor 101 after filtering by the EMC filter assembly 106. Along the length direction X of the three-phase bridge arm 103, along the length direction X of the three-phase bridge arm 103, the filter groove 119 is arranged adjacent to a group of capacitor cores 111a.

[0163] In the embodiment of the present application, the filter groove 119 is formed by borrowing the space of the part of the one group of capacitor cores 111a which is smaller than the length of the other group of capacitor cores 111b along the length direction X of the three-phase bridge arm 103, but occupies more space of the motor controller module 100 along the width direction Y of the three-phase bridge arm 103 and along the length direction X of the three-phase bridge arm 103, which is conducive to the miniaturization layout of the motor controller module 100 and can also improve the integration of the motor controller module 100.

[0164] In the embodiment of the present application, the filter groove 119 is used to accommodate the EMC filter assembly 106 and the two input connection copper bars 107. The direct current input from the direct current power supply is input into the motor controller module 100 through the two input connection copper bars 107, filtered and stabilized by the EMC filter assembly 106, so that the current signal transmitted to the bus capacitor 101 is more stable and accurate.

[0165] In one embodiment, the motor controller module 100 further comprises an output copper sheet 108, as shown in FIGS. 3, 4 and 14, which is used to electrically connect the other group of copper bars 131b of the plurality of power modules 131 and is laminated with the one group of capacitor cores 111a along the lamination direction Z of the heat sink 102 and the shell 110. Along the width direction Y of the three-phase bridge arm 103, the output copper sheet 108 is arranged adjacent to the groove 113.

[0166] In one embodiment, the motor controller module 100 further comprises a plurality of reinforcing ribs 109, as shown in FIGS. 4 and 7, which are laminated with the window 118 along the lamination direction Z of the heat sink 102 and the shell 110. The opening of the window 118 and the groove 113 in the shell 110 will reduce the structural strength of the shell 110, and the reinforcing ribs 109 are arranged to compensate for the structural strength, which is conducive to the stability of the overall structure of the motor controller module 100.

[0167] In one embodiment, as shown in FIGS. 5 and 6, the heat sink 102 and the shell 110 are sealed by a sealing ring 102a, so that the cooling liquid in the two liquid cooling cavities 105a, 105b does not leak, avoiding short circuit of other electrical components in the motor controller module 100 and affecting the normal operation of the motor controller module 100.

[0168] The motor controller module, the motor controller, the powertrain and the electric vehicle provided in the embodiments of the present application are described in detail above, and specific examples are applied in the present application to describe the principles and embodiments of the present application. The above description of the embodiments is only used to help understand the method and core idea of the present application; meanwhile, for those skilled in the art, the specific embodiments and application range can be changed according to the idea of the present application, and the above description of the present application should not be understood as a limitation.

Claims

1. A motor controller module, characterized by The motor controller module includes a bus capacitor and a heat sink, an inner cavity of a shell of the bus capacitor is used to accommodate a capacitor core package, the heat sink is laminated on the outer side of the shell, the heat sink includes two side surfaces along the laminating direction of the heat sink and the shell, one of the side surfaces is used to fix a three-phase bridge arm, the three-phase bridge arm is used to receive power supply of a power battery of an electric vehicle through the capacitor core package and output three-phase current to drive the motor of the electric vehicle, wherein: The shell includes a groove, the groove is used to accommodate a partition plate, the groove includes two surfaces, one of the surfaces is used to form a liquid cooling cavity with the groove bottom and a part of the groove wall, the other surface is used to form another liquid cooling cavity with the other side surface of the heat sink and another part of the groove wall, the maximum distance between the other surface and the groove bottom is less than the depth of the groove.

2. The motor controller module of claim 1, wherein, The distance between the one surface and the groove bottom is greater than or equal to the distance between the other surface and the groove opening along the laminating direction of the heat sink and the shell.

3. The motor controller module according to claim 1 or 2, characterized in that The shell further includes a plurality of turbulence teeth, each of the turbulence teeth extends from the groove bottom to the groove opening along the laminating direction of the heat sink and the shell, and the height of each of the turbulence teeth is less than the depth of the groove.

4. The motor controller module according to any one of claims 1-3, wherein, The three-phase bridge arm includes a plurality of power modules, the power modules are arranged at intervals along the length direction of the three-phase bridge arm, each of the power modules includes two groups of copper bars, the two groups of copper bars are opposite along the width direction of the three-phase bridge arm, and the length of the three-phase bridge arm along the length direction is greater than the length along the width direction, wherein: The partition plate includes a plurality of pairs of through holes, the pairs of through holes are used to communicate the one liquid cooling cavity and the other liquid cooling cavity, the pairs of through holes penetrate the partition plate along the laminating direction of the heat sink and the shell, each pair of through holes includes two through holes, the pairs of through holes are arranged at intervals along the length direction of the three-phase bridge arm, the two through holes of each pair of through holes are arranged at intervals along the width direction of the three-phase bridge arm, and each of the power modules is aligned with a pair of the through holes along the laminating direction of the heat sink and the shell.

5. The motor controller module of claim 4, wherein, The length of each of the through holes along the length direction of the three-phase bridge arm is greater than the width along the width direction of the three-phase bridge arm; The distance between the two through holes of each pair of the through holes along the width direction of the three-phase bridge arm is greater than half of the width of the groove along the width direction of the three-phase bridge arm.

6. The motor controller module of claim 4, wherein, The shell further includes a plurality of reinforcing ribs, each of the reinforcing ribs protrudes from the groove bottom to the partition plate along the laminating direction of the heat sink and the shell, and wherein: The height of each of the reinforcing ribs is less than the depth of the groove along the stacking direction of the one heat sink and the one housing. Part of the through holes and part of the reinforcing ribs are arranged alternately along the length direction of the three-phase bridge arm.

7. The motor controller module according to any one of claims 1-6, wherein, The one housing further comprises a protrusion and two inlets and outlets, the protrusion protrudes from the groove bottom of the one groove to the groove opening of the one groove along the stacking direction of the one heat sink and the one housing, the one partition plate is stacked on the protrusion, the protrusion is used for separating the one liquid cooling cavity into two liquid cooling sub-cavities and separating the two inlets and outlets, each of the liquid cooling sub-cavities is used for connecting the other liquid cooling cavity and one of the inlets and outlets, and the two inlets and outlets are used for connecting external flow channels, wherein: The height of the protrusion is less than the depth of the groove along the stacking direction of the one heat sink and the one housing. The length of the protrusion is greater than or equal to the length of the groove along the length direction of the three-phase bridge arm.

8. The motor controller module of claim 7, wherein, The protrusion comprises a sealing groove, the sealing groove is recessed away from the one partition plate along the stacking direction of the one heat sink and the one housing, the sealing groove is used for accommodating a sealing member, the other side surface of the one heat sink comprises a plurality of heat dissipation teeth, the plurality of heat dissipation teeth protrude toward the one partition plate along the stacking direction of the one heat sink and the one housing, and the sealing member is used for sealing the gap between the one partition plate and the protrusion and abutting the other surface of the one partition plate and the plurality of heat dissipation teeth, wherein: The distance between the plurality of heat dissipation teeth and the groove bottom of the sealing groove is less than the sum of the free length of the sealing member and the length of the part of the partition plate in contact with the sealing member along the stacking direction of the one heat sink and the one housing.

9. The motor controller module of claim 8, wherein, The one surface of the one partition plate comprises a sealing protrusion, the sealing protrusion protrudes toward the sealing groove along the stacking direction of the one heat sink and the one housing, the sealing groove is used for accommodating the sealing protrusion, and the sealing protrusion is used for extruding the sealing member, wherein: The sum of the length of the sealing protrusion and the free length of the sealing member is greater than the depth of the sealing groove along the stacking direction of the one heat sink and the one housing.

10. The motor controller module of claim 7, wherein, The protrusion comprises a first segment, a second segment and a third segment connected in sequence, wherein: The first segment and the second segment are arranged on both sides of the two inlets and outlets along the length direction of the three-phase bridge arm. The two ends of the second segment are arranged on different sides of the two inlets and outlets along the width direction of the three-phase bridge arm.

11. The motor controller module according to any one of claims 1-10, wherein, The groove wall of the one groove comprises a plurality of clamping protrusions, the clamping protrusions are used for limiting the one partition plate, wherein: The distance between each of the clamping protrusions and the groove bottom of the one groove is greater than the distance between the other surface of the one partition plate and the groove bottom of the one groove along the stacking direction of the one heat sink and the one housing.

12. The motor controller module of any one of claims 1-11, wherein, The other side of the one heat sink further comprises another groove and a plurality of heat dissipation teeth, the other groove is recessed away from the one partition plate in the stacking direction of the one heat sink and the one housing, the plurality of heat dissipation teeth are protruded toward the one partition plate from the groove bottom of the other groove, the other surface is used to form the other liquid cooling cavity with the other groove of the other side of the one heat sink, another part of the groove wall of the one groove, wherein: In the stacking direction of the one heat sink and the one housing, the depth of the other groove is less than the length of at least part of the heat dissipation teeth, the depth of the other groove is less than the maximum distance between the groove bottom of the one groove and the one partition plate, and the length of the plurality of heat dissipation teeth is less than the depth of the one groove.

13. An electric machine controller characterized by The motor controller comprises a housing and the motor controller module as claimed in any one of claims 1-12, the housing is used to accommodate the motor controller module, and the internal flow channel of the housing is used to communicate the two inlets and outlets of the one housing of the one bus capacitor in the motor controller module.

14. A powertrain, characterized by, The power assembly comprises a motor and the motor controller as claimed in claim 13, and the motor is used to receive power supply of the motor controller module of the motor controller.

15. An electric vehicle characterized by comprising: The electric vehicle comprises a frame, a power battery, and the power assembly as claimed in claim 14, the frame is used to fix the power battery and the power assembly, and the motor of the power assembly is used to receive power supply of the power battery through the motor controller to drive the wheels. The motor controller comprises a housing and the motor controller module as claimed in any one of claims 1-12, the housing is used to accommodate the motor controller module, and the internal flow channel of the housing is used to communicate the two inlets and outlets of the one housing of the one bus capacitor in the motor controller module. The power assembly comprises a motor and the motor controller as claimed in claim 13, and the motor is used to receive power supply of the motor controller module of the motor controller. The electric vehicle comprises a frame, a power battery, and the power assembly as claimed in claim 14, the frame is used to fix the power battery and the power assembly, and the motor of the power assembly is used to receive power supply of the power battery through the motor controller to drive the wheels.

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