Bus capacitor module, inverter, motor controller and automobile

Abstract

The utility model discloses a bus capacitor module, an inverter, a motor controller and an automobile, and the bus capacitor module comprises an electric connecting piece, a capacitor core bag electrically connected with the electric connecting piece, and a protection body used for wrapping the capacitor core bag and the electric connecting piece. The electric connecting piece and the capacitor core package are at least partially embedded into the protection body, and the electric connecting piece, the capacitor core package and the protection body are integrally formed. According to the technical scheme of the utility model, the technical problem that the size of the existing bus capacitor module is large is solved.

Description

Technical Field

[0001] The utility model relates to the technical field of busbar capacitor modules, and in particular to a busbar capacitor module, an inverter, a motor controller and a car. Background Art

[0002] The motor controller receives the DC power provided by the battery pack and converts it into AC power, which drives the motor to run and drive the electric vehicle. The busbar capacitor module is a major electronic device of the motor controller, which usually includes individual components such as the capacitor core package, copper busbar and shell, and the components are fixed together by glue filling. The shell is usually made of plastic or metal. The epoxy resin is liquid before curing, and the shell is needed to act as a container. When the epoxy resin is cured, there is functional overlap between the epoxy resin and the shell (insulation and fixing functions), resulting in a large overall volume of the busbar capacitor module and high cost. Moreover, due to the long curing time of epoxy resin potting, usually more than 4 hours, the production efficiency is low.

[0003] Therefore, it is necessary to improve the structure of the busbar capacitor module. Utility Model Content

[0004] The main purpose of the utility model is to provide a bus capacitor module, an inverter, a motor controller and a car, aiming to solve the technical problem that the existing bus capacitor module is relatively large in size.

[0005] To achieve the above-mentioned purpose, an embodiment of the utility model proposes a busbar capacitor module, which includes an electrical connector, a capacitor core package connected to the electrical connector, and a protective body for covering the capacitor core package and the electrical connector, wherein the electrical connector and the capacitor core package are at least partially embedded in the protective body, and the electrical connector, the capacitor core package and the protective body are integrally formed.

[0006] Optionally, in an embodiment of the utility model, the busbar capacitor module further includes a temperature measuring element, the temperature measuring element is at least partially embedded in the protective body, and the protective body fixes the electrical connector, the capacitor core package and the temperature measuring element combination;

[0007] And / or, the busbar capacitor module further includes a filter element, the filter element is at least partially embedded in the protective body, and the protective body fixes the electrical connector, the capacitor core package and the filter element combination.

[0008] Optionally, in an embodiment of the present invention, the electrical connector is a three-phase component.

[0009] Optionally, in one embodiment of the utility model, the electrical connector includes a positive electrical connector and a negative electrical connector, one end of the positive electrical connector is connected to the capacitor core package, and the other end of the positive electrical connector is at least exposed on the outer peripheral surface of the protective body, one end of the negative electrical connector is connected to the capacitor core package, and the other end of the negative electrical connector is at least partially exposed on the outer peripheral surface of the protective body, and the protective body fixes the positive electrical connector, the negative electrical connector and the capacitor core package together.

[0010] Optionally, in an embodiment of the utility model, the capacitor core package is provided in plurality, and the plurality of capacitor core packages are arranged in parallel.

[0011] Optionally, in one embodiment of the utility model, a plurality of the capacitor core packages are arranged in two rows to form a first core package group and a second core package group, the plurality of core packages in the first core package group are arranged in parallel, and the core packages in the second core package group are arranged obliquely relative to the core packages in the first core package group.

[0012] To achieve the above objective, an embodiment of the utility model provides an inverter, wherein the inverter includes the bus capacitor module described above.

[0013] To achieve the above objectives, an embodiment of the utility model provides a motor controller, which includes the bus capacitor module described above.

[0014] To achieve the above objectives, an embodiment of the utility model provides a car, which includes a drive motor and a motor controller electrically connected to the drive motor, and the motor controller is the motor controller described above.

[0015] Compared with the prior art, in a technical solution proposed by the utility model, the injection molding material is directly injected into the injection mold, and the electrical connector and the capacitor core package are fixed together after the injection molding material is solidified. At the same time, the injection molding material forms a protective body after solidification, which can provide protection for the electrical connector and the capacitor core package. It can be understood that the injection molding material forms a protective body after solidification. During the injection molding or molding process, the electrical connector and the capacitor core package are at least partially embedded in the protective body, so that the electrical connector, the capacitor core package and the protective body form an integrated structure, which not only directly realizes the fixation of the electrical connector and the capacitor core package, saves the number of parts used, and can effectively reduce the volume of the busbar capacitor module; and the protective body formed after the injection molding material is solidified can play a protective role of the shell, replace the original shell and potting glue, reduce the functional overlap between different components, and further reduce the volume of the busbar capacitor module. In addition, the curing molding time of the protective body is less than 10 minutes, which can achieve one-time injection molding compared with the curing time of other materials such as epoxy resin, which is usually greater than 4 hours, and improves production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the embodiments of the utility model or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the embodiments of the utility model. For ordinary technicians in this field, other drawings can be obtained based on the structures shown in these drawings without paying creative work.

[0017] Figure 1 This is a schematic diagram of the exploded structure of an embodiment of the busbar capacitor module of the utility model;

[0018] Figure 2 This is a structural schematic diagram of another embodiment of the busbar capacitor module of the utility model;

[0019] Figure 3 for Figure 2 Schematic diagram of the explosion structure.

[0020] Description of Figure Numbers:

[0021] Label name Label name 10 Electrical connector 11 Positive electrical connector 12 Negative electrical connector 20 Capacitor core pack 21 The first core package group 22 The second core package group 30 Protective body 31 Buffer tank 40 Temperature measuring element 50 Filter components

[0022] The realization of the purpose, functional features and advantages of the utility model will be further explained in conjunction with embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0023] The following will be combined with the drawings in the embodiments of the utility model to clearly and completely describe the technical solutions in the embodiments of the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, not all of the embodiments. Based on the embodiments of the utility model, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the embodiments of the utility model.

[0024] It should be noted that all directional indications in the embodiments of the present invention (such as up, down, left, right, front, back...) are only used to explain the relative position relationship, movement status, etc. between the components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0025] In addition, in the embodiments of the present invention, the descriptions of "first", "second", etc. are only for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" or "second" may explicitly or implicitly include at least one of the features. In the description of the embodiments of the present invention, the meaning of "multiple" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0026] In the embodiments of the present invention, unless otherwise clearly specified and limited, the terms "connection", "fixation", etc. should be understood in a broad sense. For example, "fixation" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements, unless otherwise clearly defined. For ordinary technicians in this field, the specific meanings of the above terms in the embodiments of the present invention can be understood according to specific circumstances.

[0027] In addition, the technical solutions between the various embodiments of the present utility model can be combined with each other, but it must be based on the fact that ordinary technicians in this field can implement it. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such combination of technical solutions does not exist and is not within the scope of protection required by the embodiments of the present utility model.

[0028] The busbar capacitor module is a major electronic device of the motor controller, which usually includes individual components such as capacitor core package, electrical connectors and housing. The capacitor core package, electrical connectors and other components are fixed to the housing by epoxy resin potting. Since the epoxy resin potting curing time is long, usually more than 4 hours, the production efficiency is low. In addition, the housing is usually made of plastic or metal. The epoxy resin is liquid before curing, and the housing needs to be used as a container. When the epoxy resin is cured, there is functional overlap between the epoxy resin and the housing (insulation and fixing functions), resulting in a large overall volume of the busbar capacitor module and high cost.

[0029] In view of this, the embodiments of the utility model provide a busbar capacitor module, an inverter, a motor controller and a car, wherein a protective body is formed by injection molding or molding, that is, a mold is used to inject an injection molding material on the outside of the electrical connector and the capacitor core package, and the protective body is made by injection molding or molding. The protective body can protect and insulate the electrical connector and the capacitor core package. Moreover, during the injection molding or molding process, the electrical connector and the capacitor core package are partially embedded in the protective body, thereby achieving the fixation of the electrical connector and the capacitor core package. It can be understood that the protective body made by injection molding or molding eliminates the original shell and potting glue, which can prevent the functional overlap of components and reduce the volume of the busbar capacitor module. In addition, compared with potting fixation, the injection molding or molding process has a shorter curing time, which effectively improves production efficiency.

[0030] In order to better understand the above technical solution, the above technical solution is described in detail below with reference to the accompanying drawings.

[0031] like Figure 1-Figure 3As shown, an embodiment of the utility model proposes a busbar capacitor module, which includes an electrical connector 10, a capacitor core package 20 connected to the electrical connector 10, and a protective body 30 for covering the capacitor core package 20 and the electrical connector 10, the electrical connector 10 and the capacitor core package 20 are at least partially embedded in the protective body 30, and the electrical connector 10, the capacitor core package 20 and the protective body 30 are integrally formed.

[0032] In the technical solution adopted in this embodiment, the injection molding material is directly injected into the injection mold, and the electrical connector 10 and the capacitor core package 20 are fixed together after the injection molding material is solidified. At the same time, the protective body 30 is formed after the injection molding material is solidified, which can provide protection for the electrical connector 10 and the capacitor core package 20. It can be understood that the injection molding material forms the protective body 30 after solidification. During the injection molding or molding process, the electrical connector 10 and the capacitor core package 20 are at least partially embedded in the protective body 30, so that the electrical connector 10, the capacitor core package 20 and the protective body 30 form an integrated structure, which not only directly realizes the fixation of the electrical connector 10 and the capacitor core package 20, but also saves the number of parts used, and can effectively reduce the volume of the busbar capacitor module; and the protective body 30 formed after the injection molding material is solidified can play a protective role of the shell, but replaces the original shell and potting glue, reduces the functional overlap between different components, and further reduces the volume of the busbar capacitor module. In addition, the curing molding time of the protection body 30 is less than 10 minutes, which is usually more than 4 hours compared with other materials such as epoxy resin, so that one-time injection molding can be achieved to improve production efficiency.

[0033] As an optional manner, the electrical connector 10 may be a copper bar, an aluminum bar, or other materials capable of conducting electricity, which is not limited here.

[0034] In one embodiment, the outer peripheral surface of the protection body 30 has a buffer structure, which can absorb and buffer the external collision force, thereby improving the structural strength of the protection body 30. Figure 3 Specifically, the buffer structure is a buffer groove 31, and the process of injection molding or molding is simple, and molding is convenient, which can further improve production efficiency. As an optional method, the opening of the buffer groove 31 changes in a decreasing state in the inner direction close to the protective body 30, so that more external force can be absorbed on the side close to the external environment, while improving the protection of the electrical connector 10 and the capacitor core package 20.

[0035] For example, in one embodiment of the present invention, the molding temperature of the protective body 30 is between 90 degrees and 150 degrees. In this way, the curing molding time can be further reduced and the production efficiency can be improved. As an optional method, the molding temperature of the protective body 30 is between 105 degrees and 150 degrees.

[0036] For example, refer to Figure 2 and Figure 3 In one embodiment of the utility model, the busbar capacitor module also includes a temperature measuring element 40, which is at least partially embedded in the protective body 30, and the protective body 30 combines and fixes the electrical connector 10, the capacitor core package 20 and the temperature measuring element 40.

[0037] Specifically, the temperature of the coolant in the cooling water channel can be detected by the set temperature measuring element 40, and the temperature information can be transmitted to the vehicle system to ensure the safe operation of the vehicle. The temperature measuring element 40 can be a thermistor, a thermocouple, a thermal resistor, a semiconductor temperature sensor, etc., which are not limited here. In this embodiment, during the injection molding or compression molding process of the protective body 30, the temperature measuring element 40 is partially embedded in the protective body 30 to fix and protect the temperature measuring element 40, but replaces the use of the original shell and potting glue, reduces the functional overlap between different components, and further reduces the volume of the busbar capacitor module.

[0038] For example, refer to Figure 2 and Figure 3 In one embodiment of the utility model, the bus capacitor module also includes a filter element 50, and the filter element 50 is at least partially embedded in the protective body 30, and the protective body 30 combines and fixes the electrical connector 10, the capacitor core package 20 and the filter element 50.

[0039] Specifically, the filter element 50 is provided to filter waves, so that useful signals can pass through without attenuation as much as possible, and useless signals can be attenuated as much as possible. As an optional method, the filter element can be a filter capacitor or a filter magnetic ring, which is not limited here. In this embodiment, during the injection molding or compression molding process of the protective body 30, the filter element 50 is partially embedded in the protective body 30 to fix and protect the filter element 50, but replaces the use of the original housing and potting glue, reduces the functional overlap between different components, and further reduces the volume of the busbar capacitor module.

[0040] In one embodiment, the busbar capacitor module further includes a temperature measuring element 40 and a filter element 50 . It is understandable that the protective body 30 combines and fixes the electrical connector 10 , the capacitor core package 20 and the filter element 50 .

[0041] For example, in one embodiment of the utility model, the electrical connector 10 is a three-phase component, and the interior of the three-phase component contains a Hall core. In this way, the Hall core uses its own magnetic focusing properties to convert the current flowing through into a magnetic field, and the magnetic field information is then converted into an electrical signal through the Hall chip and transmitted to the vehicle system. Compared with the traditional solution, this solution highly integrates the Hall core in the bus capacitor module, improves the simplicity of the system, and avoids the diversified design caused by the change of the external three-phase port.

[0042] For example, refer to Figure 1 In one embodiment of the utility model, the electrical connector 10 includes a positive electrical connector 11 and a negative electrical connector 12, one end of the positive electrical connector 11 is connected to the capacitor core package 20, and the other end of the positive electrical connector 11 is exposed on the outer peripheral surface of the protective body 30, one end of the negative electrical connector 12 is connected to the capacitor core package 20, and the other end of the negative electrical connector 12 is exposed on the outer peripheral surface of the protective body 30, and the protective body 30 combines and fixes the positive electrical connector 11, the negative electrical connector 12 and the capacitor core package 20.

[0043] Specifically, the electrical connector 10 includes a positive electrical connector 11 and a negative electrical connector 12, which can realize the input or output of direct current. As an optional method, the positive electrical connector 11 and the negative electrical connector 12 are arranged on opposite sides of the capacitor core package 20, so as to improve the heat dissipation efficiency of the positive electrical connector 11 and the negative electrical connector 12, and prevent heat from accumulating on the same side of the capacitor core package 20, thereby preventing the local temperature of the busbar capacitor module from being too high.

[0044] For example, in one embodiment of the present invention, a plurality of capacitor core packages 20 are provided, and the plurality of capacitor core packages 20 are arranged in parallel. Figure 1 Specifically, multiple capacitor core packages 20 are arranged in two rows, that is, multiple capacitor core packages 20 are arranged according to the first core package group 21 and the second core package group 22, multiple core packages in the first core package group 21 are arranged in parallel, and the core packages in the second core package group 22 are arranged tilted relative to the core packages in the first core package group 21, so that the arrangement of the space can be optimized, so that the core packages in the capacitor core package 20 are arranged more compactly, effectively reducing the volume of the capacitor core package 20, and thus reducing the volume of the busbar capacitor module. As an optional method, three core packages are provided in the first core package group 21, and two core packages are provided in the second core package group 22, and the two core packages in the second core package group 22 are tilted in a direction close to each other, so that the space occupied can be further reduced, thereby reducing the volume of the busbar capacitor module.

[0045] For example, in one embodiment of the present invention, the cross-sectional shape of the capacitor core package 20 is an ellipse. The elliptical capacitor core package 20 occupies less space and can further reduce the volume of the busbar capacitor module. Of course, in other embodiments, the cross-sectional shape of the capacitor core package 20 can also be a circle or a rectangle, which is not limited here.

[0046] To achieve the above purpose, the embodiment of the utility model proposes an inverter, and the inverter includes the bus capacitor module described above. Specifically, the specific structure of the bus capacitor module refers to the above embodiment. Since the inverter adopts all the technical solutions of the above embodiment, it at least has all the beneficial effects brought by the technical solutions of the above embodiment, which will not be repeated here one by one.

[0047] To achieve the above purpose, the embodiment of the utility model proposes a motor controller, which includes the bus capacitor module described above. Specifically, the specific structure of the bus capacitor module refers to the above embodiment. Since the motor controller adopts all the technical solutions of the above embodiment, it at least has all the beneficial effects brought by the technical solutions of the above embodiment, which will not be repeated here.

[0048] To achieve the above purpose, the embodiment of the utility model provides a car, the car includes a drive motor and a motor controller electrically connected to the drive motor, and the motor controller is the motor controller described above. Specifically, the specific structure of the motor controller refers to the above embodiment. Since the car adopts all the technical solutions of the above embodiment, it at least has all the beneficial effects brought by the technical solutions of the above embodiment, which will not be repeated here one by one.

[0049] The above description is only a preferred embodiment of the present invention, and does not limit the patent scope of the embodiment of the present invention. All equivalent structural changes made by using the description and drawings of the embodiment of the present invention under the inventive concept of the embodiment of the present invention, or directly / indirectly applied in other related technical fields are included in the patent protection scope of the embodiment of the present invention.

Claims

1. A busbar capacitor module, characterized in that: The busbar capacitor module includes an electrical connector, a capacitor core package connected to the electrical connector, and a protective body for covering the capacitor core package and the electrical connector. The electrical connector and the capacitor core package are at least partially embedded in the protective body. The electrical connector, the capacitor core package and the protective body are integrally formed.

2. The busbar capacitor module according to claim 1, characterized in that: The busbar capacitor module further includes a temperature measuring element, which is at least partially embedded in the protective body, and the protective body fixes the electrical connector, the capacitor core package and the temperature measuring element together; And / or, the busbar capacitor module further includes a filter element, the filter element is at least partially embedded in the protective body, and the protective body fixes the electrical connector, the capacitor core package and the filter element combination.

3. The busbar capacitor module according to claim 1, characterized in that: The electrical connector is a three-phase component.

4. The busbar capacitor module according to claim 1, characterized in that: The electrical connector includes a positive electrical connector and a negative electrical connector, one end of the positive electrical connector is connected to the capacitor core package, and the other end of the positive electrical connector is at least partially exposed to the outer peripheral surface of the protective body, one end of the negative electrical connector is connected to the capacitor core package, and the other end of the negative electrical connector is at least partially exposed to the outer peripheral surface of the protective body, and the protective body fixes the positive electrical connector, the negative electrical connector and the capacitor core package together.

5. The busbar capacitor module according to claim 1, characterized in that: The capacitor core packs are provided in plurality, and the plurality of capacitor core packs are arranged in parallel.

6. The busbar capacitor module according to claim 5, characterized in that: The plurality of capacitor core packages are arranged in two rows to form a first core package group and a second core package group. The plurality of core packages in the first core package group are arranged in parallel, and the core packages in the second core package group are arranged obliquely relative to the core packages in the first core package group.

7. An inverter, characterized in that: The inverter comprises a bus capacitor module as described in any one of claims 1-6.

8. A motor controller, characterized in that: The motor controller comprises a bus capacitor module as described in any one of claims 1-6.

9. A car, characterized in that: The automobile comprises a drive motor and a motor controller electrically connected to the drive motor, and the motor controller is the motor controller as claimed in claim 8.

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