Interface device for a vehicle electric motor or electric axle and method for manufacturing an interface device for a vehicle electric motor or electric axle
By precisely positioning the busbar and the magnetic flux concentrator through two injection molding steps, the problems of inaccurate positioning and uneven insulation in the existing technology are solved, resulting in more reliable electrical contact and insulation, and reducing manufacturing costs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- ROBERT BOSCH GMBH
- Filing Date
- 2024-10-16
- Publication Date
- 2026-05-29
AI Technical Summary
In the manufacturing of interface devices for vehicle motors or electric vehicle axles, the positioning of busbars and flux concentrators is inaccurate, resulting in a high risk of sparking and uneven insulation, which increases the instability and manufacturing cost of the interface device.
The process employs a two-step injection molding process. First, the magnetic flux concentrator is partially covered with a first molding material. Then, after the busbar is fixed, it is covered with a second molding material. This ensures the precise positioning of the busbar relative to the magnetic flux concentrator and forms a reliable insulator through uniform distribution of the molding material.
It achieves precise positioning of the busbar and flux concentrator, reduces the risk of sparks, improves the electrical contact reliability and insulation of the interface device, simplifies the manufacturing process, and reduces manufacturing costs.
Smart Images
Figure CN122122791A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to a method for manufacturing an interface device for a vehicle electric motor or an electric drive axle. The invention also relates to an interface device for a vehicle electric motor or an electric drive axle, an electric motor for a vehicle, and an electric drive axle for a vehicle. Background Technology
[0002] Figure 1 The diagram illustrates an interface of the prior art, used to explain a conventional manufacturing method that is known to the applicant as prior art.
[0003] In manufacturing Figure 1 The schematically illustrated interface according to the prior art involves at least partially covering the three busbars 10, the three flux concentrators 12, and the six bushings 14 of the subsequent interface with molding material 16 through an injection molding step. Therefore, in Figure 1 In the prior art interface shown, its bus 10, its flux concentrator 12 and its bushing 14 are all at least partially surrounded by molding material 16. Summary of the Invention
[0004] The present invention provides a method for manufacturing an interface device for a vehicle motor or electric vehicle axle having the features of claim 1, an interface device for a vehicle motor or electric vehicle axle having the features of claim 8, a motor for a vehicle having the features of claim 10, and an electric drive axle for a vehicle having the features of claim 11.
[0005] Advantages of the present invention This invention realizes a variety of different interface devices, each having at least one bus and at least one flux concentrator, all of which can be advantageously used for electrically connecting vehicle motors. For example, in the interface device according to the invention, since at least one flux concentrator has been overmolded with the first molding material before its at least one bus is arranged / added to at least one flux concentrator which is at least partially covered by the solidified first molding material, a more precise positioning of at least one bus of the same interface device relative to at least one flux concentrator can be achieved. In particular, by using the invention, the corresponding positions of at least one bus of the same interface device relative to at least one flux concentrator can be optimized, and during overmolding with the second molding material, at least one bus can be held in its corresponding optimized position in a simple manner. Therefore, the risk of conventionally occurring sparks during subsequent operation of the interface device according to the invention is negligible. Furthermore, by optimizing the positioning of at least one bus of the same interface device relative to at least one flux concentrator, the invention ensures a good / uniform distribution of the second molding material, thereby ensuring reliable insulation for forming the interface device according to the invention. Since the conventional problem of uneven distribution of molding material is eliminated when using the invention described herein, there is no need to worry about deformation of the insulator due to internal stress during operation of the interface device according to the invention. Therefore, compared with conventional interface devices (such as the prior art described above), the interface device according to the invention provides more reliable electrical contact for the electric motor of a vehicle.
[0006] It should also be noted that the present invention is relatively simple and can be implemented without requiring more complex equipment than existing technologies. Therefore, the present invention can also be used to reduce the manufacturing cost of interface devices.
[0007] In an advantageous embodiment of this manufacturing method, during the first injection molding step and / or the second injection molding step, at least one magnetic flux concentrator is completely covered by the first molding material and / or the second molding material. Thus, in the embodiment of the manufacturing method described herein, it is ensured that at least one magnetic flux concentrator, typically made of magnetic steel, is reliably protected from unwanted corrosion during operation of the interface device equipped with it.
[0008] For example, at least one flux concentrator can be partially covered with a first molding material during the first injection molding step, such that after the first injection molding step, at least one portion of the at least one flux concentrator protrudes from the solidified first molding material, and during the second injection molding step, the at least one portion of the at least one flux concentrator protruding from the solidified first molding material is covered by a second molding material. It will be clear from the following description that the process described herein is relatively easy to perform.
[0009] Preferably, after the first injection molding step and before the second injection molding step, at least one busbar is secured to at least one outer surface formed of solidified first molding material, and this outer surface is in at least sectional mechanical contact with the corresponding busbar. In this way, undesirable linear adjustment movement or rotation of at least one busbar can be reliably prevented during overmolding with the second molding material.
[0010] Preferably, during the second injection molding step, at least one busbar is only partially covered with the second molding material, such that after the second injection molding step, at least a portion of the surface of at least one busbar is not covered by the solidified second molding material. This facilitates subsequent electrical contact of the at least one busbar.
[0011] As an advantageous addition, during the second injection molding step, at least one bushing of the subsequent interface device, together with at least one flux concentrator and at least one busbar, which are at least partially surrounded by the first molding material, can be at least partially encapsulated with the second molding material. Here, it is possible to prevent the internal volume of the bushing surrounded by at least one bushing from being filled with the second molding material during the second injection molding step in a simple manner. All the processes listed herein are easy to perform.
[0012] The corresponding interface device for the vehicle motor or electric axle also ensures the advantages described above. In particular, in this interface device, at least one magnetic flux concentrator can be completely covered by a first molding material and / or a second molding material.
[0013] Furthermore, electric motors for vehicles with such interface devices and electric drive axles for vehicles with corresponding interface devices also achieve the aforementioned advantages. Attached Figure Description
[0014] Other features and advantages of the invention will now be described with reference to the accompanying drawings. In the drawings: Figure 1 The diagram illustrates an interface of existing technology to demonstrate a conventional manufacturing method; Figures 2A to 2F Illustrations show initial, intermediate, and final products of a first embodiment illustrating a method for manufacturing an interface device for a vehicle electric motor or electric vehicle axle; and Figure 3A and 3B Illustrations show intermediate and final products of a second embodiment of a method for manufacturing an interface device for a vehicle motor or electric vehicle axle. Detailed Implementation
[0015] Figures 2A to 2FIllustrations show the initial product, intermediate product, and final product of a first embodiment of a method for manufacturing an interface device for a vehicle electric motor or electric vehicle axle.
[0016] In the manufacturing method described below, at least one magnetic flux concentrator 20 of the subsequent interface device (see...) Figure 2A ) and at least one bus 22 of the subsequent interface device (see Figure 2C Each of the following components is at least partially overmolded in at least one injection molding step. At least one flux concentrator 20 may be made of, for example, magnetic steel. At least one busbar 22 may be made of, for example, copper. Typically, to manufacture the corresponding interface device, three buses 22 and three flux concentrators 20 are overmolded, with each flux concentrator disposed on its corresponding busbar 22. However, it should be noted that the feasibility of the method described below is not limited to a specific total number of flux concentrators 20 and busbars 22 in the subsequent interface device.
[0017] In the manufacturing method described below, as at least one injection molding step, a first injection molding step is performed first, followed by a second injection molding step (i.e., after the first injection molding step). During the first injection molding step, at least one magnetic flux concentrator 20 is at least partially covered by a first molding material 24 of a first molding material type. The first injection molding step (Spritzgussschritt) can also be understood as an injection molding step (Spritzgießschritt). The first molding material 24 can be, for example, plastic. During the first injection molding step, at least one magnetic flux concentrator 20 is at least partially covered by the first molding material 24 in mechanical contact with it, such that the at least one magnetic flux concentrator 20 is at least partially covered by the first molding material 24 in mechanical contact with it.
[0018] It should be clearly pointed out that the first injection molding step is performed when at least one bus 22 is not yet in its subsequent operating position relative to the associated flux concentrator 20. This can also be described as the first injection molding step being performed when at least one bus 22 has no subsequent interface device or when at least one bus 22 is missing a subsequent interface device.
[0019] Because only at least one flux concentrator 20 (rather than at least one busbar 22) is covered by the first molding material 24 during the first injection molding step, it is relatively easy to maintain the desired position / location of the multiple flux concentrators 20 relative to each other in subsequent interface devices during the first injection molding step. Therefore, during operation of the subsequent interface device, the magnetic field detected on at least one flux concentrator 20 can be reliably evaluated to determine the current intensity flowing through the associated busbar 22 and causing that magnetic field. The manufacturing method described herein thus ensures that at least one flux concentrator 20 of the interface device manufactured in this way is well-suited as a sensor element for reliably and accurately measuring current intensity during its operation.
[0020] Figure 2B The intermediate product after the first injection molding step is shown. It can be seen that the intermediate product formed by at least one magnetic flux concentrator 20 and solidified first molding material 24 can have a shape in which a plane of symmetry 26 can be defined between each of two adjacent magnetic flux concentrators 20, dividing the intermediate product into partial regions such that every two adjacent partial regions are mirror-symmetric about the plane of symmetry 26 between them.
[0021] At least one busbar 22 is added to the intermediate product only after the first injection molding step. The addition of at least one busbar 22 occurs before the second injection molding step. Advantageously, when adding at least one busbar 22, the external shape of the intermediate product from the first injection molding step can be used to advantageously position the at least one busbar 22, specifically by arranging it so that it at least partially abuts against at least one outer surface 24a formed by solidified first molding material 24 (compare). Figure 2B and Figure 2D For better understanding, at least one outer surface 24a formed by the solidified first molding material 24 (with which at least one busbar 22 forms mechanical contact) is referred to hereinafter as busbar contact surface 24a. In particular, at least one busbar 22 may be arranged on the intermediate product of the first injection molding step such that at least one flux concentrator 20 at least partially surrounds a section of its associated busbar 22.
[0022] Preferably, at least one busbar 22 is fixed to at least one busbar contact surface 24a, the busbar contact surface being in at least partial mechanical contact with the corresponding busbar 22 for fastening / fixing. Figure 2DAs shown, for this purpose, a fastening structure 28 formed from solidified first molding material 24 can be formed on and / or adjacent to the corresponding bus abutment surface 24a. Exemplarily only, in the embodiment described herein, as at least one fastening structure 28, a fastening lug 28 is formed from solidified first molding material 24, which partially spans across the associated bus abutment surface 24a, such that the associated bus 22 can be fastened / secured between the bus abutment surface 24a and the adjacent fastening lug 28. However, as an alternative or supplement, at least one bus 22 can also be fixedly bonded to the associated bus abutment surface 24a. Optionally, at least one bus abutment surface 24a may also be constructed with a recess 30 into which a corresponding section of the associated bus 22 can be placed (compare...). Figure 2B and Figure 2D ).
[0023] In the use of Figure 2E During the second injection molding step, as illustrated in the image, at least one flux concentrator 20 and at least one busbar 22, which are at least partially surrounded by solidified first molding material 24, are at least partially covered by a second molding material 32. The second molding material 32 can be the same type of the first molding material 24 as the first molding material, or a second / different type of molding material. For example, plastic can be used as the second molding material 32. The second injection molding step can also be an injection molding step. Covering injection is performed during the second injection molding step such that at least the solidified first molding material 24 and at least one busbar 22 are at least partially covered by the second molding material 32, which is in mechanical contact with the solidified first molding material 24 and at least one busbar 22.
[0024] If necessary, at least one busbar 22 may be partially covered with the second molding material 32 during the second injection molding step, such that after the second injection molding step, at least a portion of the surface of the at least one busbar 22 is not covered by the solidified second molding material 32. This facilitates subsequent electrical contact / connection of at least one busbar 22 to the finished interface device.
[0025] It should be clearly noted that since at least one bus 22 can be positioned relative to at least one flux concentrator 20 during the second injection step using the solidified first molding material 24 or at least one of its bus abutment surfaces 24a, no insert element, such as a core pin, is required. Even if relatively high pressure occurs in the second molding material 32 during the second injection step, the reliable retention of at least one bus 22 can be ensured by fastening / fixing it to the associated bus abutment surface 24a. Therefore, even relatively high pressure in the second molding material 32 will not cause undesirable movement of the at least one bus 22 during the second injection step. As described above, the advantageous fastening / fixing of at least one bus 22 to the associated bus abutment surface 24a can be easily achieved by means of at least one fastening structure 28, thereby preventing undesirable movement of the at least one bus 22 during the second injection step.
[0026] Alternatively, during the second injection molding step, at least one other component 34 of the subsequent interface device, such as at least one bushing 34 (see...), can also be added. Figure 2C The at least one flux concentrator 20 and at least one busbar 22, together with at least one flux concentrator 20 and at least one busbar 22, which are at least partially surrounded by the solidified first molding material 24, are at least partially encapsulated with the second molding material 32. It should be clearly noted that even when at least one other component 34 is encapsulated with the second molding material 32, the desired distance between the at least one busbar 22, the at least one flux concentrator 20, and the at least one other component 34 can be reliably maintained, thereby reliably preventing the occurrence of sparks during subsequent operation of the finished interface device. If at least one bushing 34 is also encapsulated during the second injection molding step, it is preferable that the internal volume surrounded by the at least one bushing 34 is not filled with the second molding material 32 during the second injection molding step.
[0027] First, the first injection molding step is advantageously performed, followed by a second injection molding step (i.e., after the first injection molding step). This ensures that the molding materials 24 and 32 are evenly distributed. Therefore, an insulator that reliably functions for subsequent interface devices can be formed from the molding materials 24 and 32. Even if relatively high internal stresses occur in the insulator during the operation of the subsequent interface devices, the uniform distribution of the molding materials 24 and 32 ensures that (substantially) no deformation occurs in the insulator. Therefore, the insulator formed from the molding materials 24 and 32 also possesses good insulating properties.
[0028] Since no insert element (e.g., a core pin) is required during the second injection molding step to hold the various components of the subsequent interface assembly together, there is no need to remove the insert element afterwards. Correspondingly, there is no need to fill at least one hole left after the removal of the insert element (at the location of the removed insert element) with filler material. This further improves the insulation performance of the insulator formed by the molding materials 24 and 32. Furthermore, it eliminates the workload and cost required to fill at least one remaining hole with filler material.
[0029] Figure 2F The finished interface device is shown, with the second molding material 32 shown as "transparent material" for better understanding. In this embodiment, the finished interface device is an interface, specifically an AC interface, by means of which an inverter can be electrically connected to the vehicle's electric motor. The manufacturing method described above reliably maintains the desired position of the busbar 22 of the finished interface device, making the fully manufactured interface device ideally suited for electrically connecting the inverter to the electric motor.
[0030] Figure 2F The interface device is manufactured by the manufacturing method described above, as can be seen from the fact that at least one bus 22 and at least one flux concentrator 20 are not only at least partially surrounded by at least one molding material 24 and 32, respectively, but the at least one molding material 24 and 32 include both a first molding material 24 of a first molding material type and a second molding material 32 of a first molding material type or a second molding material type. Furthermore, at least one flux concentrator 20 is at least partially covered by the first molding material 24 in mechanical contact with it, while at least one bus 22 is at least partially abutted against at least one outer surface 24a formed by solidified first molding material 24. Moreover, the solidified first molding material 24, which at least partially covers at least one flux concentrator 20, and at least one bus 22 are at least partially covered by the second molding material 32, which is in mechanical contact with the solidified first molding material 24 and the at least one bus 22.
[0031] The advantageous characteristics of the interface device are also guaranteed in electric motors for vehicles equipped with the interface device and electric drive axles for vehicles equipped with the interface device.
[0032] Figure 3A and 3B Illustrations show intermediate and final products of a second embodiment of a method for manufacturing an interface device for a vehicle motor or electric vehicle axle.
[0033] In the embodiments described herein, during the first injection molding step and / or the second injection molding step, at least one magnetic flux concentrator 20 is completely covered by a first molding material 24 and / or a second molding material 32. By completely covering at least one magnetic flux concentrator 20 with the first molding material 24 and / or the second molding material 32, it can be ensured that even magnetic steel, which is very sensitive to corrosion, can be used as a material for at least one magnetic flux concentrator 20 without any problems. Therefore, embodiments of the manufacturing method described herein expand the range of materials suitable for use with at least one magnetic flux concentrator 20.
[0034] For example, such as Figure 3A As shown in the intermediate product present immediately before the second injection molding step, at least one magnetic flux concentrator 20 can be partially covered with the first molding material 24 during the first injection molding step, such that after the first injection molding step, at least one portion 20a of the at least one magnetic flux concentrator 20 protrudes from the solidified first molding material 24.
[0035] During the second injection molding step, the at least one portion 20a of the at least one magnetic flux concentrator 20 protruding from the solidified first molding material 24 can then be covered with the second molding material 32. (As from...) Figure 3B As can be seen from the finished interface device, at least one magnetic flux concentrator 20 is therefore completely covered by the first molding material 24 and / or the second molding material 32.
[0036] For further method steps of the embodiments described herein, as well as additional features and advantages of the interface device manufactured in this manner, please refer to the... Figures 2A to 2F The description.
Claims
1. A method for manufacturing an interface device for an electric motor or electric vehicle axle in a vehicle. in, At least one bus (22) of the subsequent interface device and at least one flux concentrator (20) of the subsequent interface device arranged on the associated bus (22) are respectively at least partially covered by injection molding in at least one injection molding step. The feature is that the following steps are performed as the at least one injection molding step: During the first injection molding step, the at least one magnetic flux concentrator (20) is at least partially encapsulated with a first molding material (24) of the first molding material type, such that the at least one magnetic flux concentrator (20) is at least partially covered by the first molding material (24) in mechanical contact with the at least one magnetic flux concentrator (20); and During the second injection molding step, at least one flux concentrator (20) and at least one busbar (22) surrounded at least partially by the solidified first molding material (24) are at least partially encapsulated with a second molding material (32) of the first molding material type or the second molding material type, wherein the at least one busbar is at least sectionally abutted against at least one outer surface (24a) formed by the solidified first molding material (24), such that at least the solidified first molding material (24) and the at least one busbar (22) are at least partially covered by the second molding material (32), the second molding material being in mechanical contact with the solidified first molding material (24) and the at least one busbar (22).
2. The manufacturing method according to claim 1, wherein, During the first injection molding step and / or the second injection molding step, the at least one magnetic flux concentrator (20) is completely covered by the first molding material (24) and / or the second molding material (32).
3. The manufacturing method according to claim 2, wherein, During the first injection molding step, the at least one magnetic flux concentrator (20) is partially covered with the first molding material (24) such that after the first injection molding step, at least one portion (20a) of the at least one magnetic flux concentrator (20) protrudes from the solidified first molding material (24), and during the second injection molding step, the at least one portion (20a) of the at least one magnetic flux concentrator (20) protruding from the solidified first molding material (24) is covered with the second molding material (32).
4. The manufacturing method according to any one of the preceding claims, wherein, After the first injection molding step and before the second injection molding step, the at least one busbar (22) is fastened to at least one outer surface (24a) formed by the solidified first molding material (24), and the outer surface is in mechanical contact with the corresponding busbar (22) at least in sections.
5. The manufacturing method according to any one of the preceding claims, wherein, During the second injection molding step, the at least one busbar (22) is only partially covered with the second molding material (32) such that after the second injection molding step, at least a portion of the surface of the at least one busbar (22) is not covered by the solidified second molding material (32).
6. The manufacturing method according to any one of the preceding claims, wherein, During the second injection molding step, at least one bushing (34) of the subsequent interface device, together with at least one flux concentrator (20) at least partially surrounded by the solidified first molding material (24) and the at least one busbar (22), are at least partially encapsulated with the second molding material (32).
7. The manufacturing method according to claim 6, wherein, During the second injection molding step, the internal volume of the bushing surrounded by the at least one bushing (34) is not filled by the second molding material (32).
8. An interface device for an electric motor or electric vehicle axle in a vehicle, comprising: At least one busbar (22); and At least one flux concentrator (20) is arranged on an associated busbar (22); in, The at least one busbar (22) and the at least one flux concentrator (20) are each at least partially surrounded by at least one molding material (24, 32). Its features are, The at least one molding material (24, 32) includes a first molding material (24) of a first molding material type and a second molding material (32) of the first molding material type or a second molding material type; The at least one flux concentrator (20) is at least partially covered by a first molding material (24) in mechanical contact with the at least one flux concentrator (20); and The solidified first molding material (24) that at least partially covers the at least one flux concentrator (20) and the at least one busbar (22) are at least partially covered by the second molding material (32), wherein the at least one busbar is at least sectionally abutted against at least one outer surface (24a) formed by the solidified first molding material (24), and the second molding material is in mechanical contact with the solidified first molding material (24) and the at least one busbar (32).
9. The interface device according to claim 8, wherein, The at least one magnetic flux concentrator (20) is completely covered by the first molding material (24) and / or the second molding material (32).
10. An electric motor for a vehicle, comprising: The interface device according to claim 8 or 9.
11. An electric drive axle for a vehicle, comprising: The interface device according to claim 8 or 9.