Integrated film capacitor and drive controller

Abstract

The utility model relates to the technical field of film capacitors for electric vehicle motor controllers, and discloses an integrated film capacitor and a drive controller. The film capacitor may include a terminal mounting plate, a heat dissipation channel, a film capacitor assembly, and a filter assembly; a terminal interface may be provided on the front end of the terminal mounting plate, a heat dissipation channel may be provided on the rear end of the terminal mounting plate, and the film capacitor assembly may be provided at the bottom of the heat dissipation channel, and the top of the heat dissipation channel may be used to install a power board; the film capacitor is used to install a battery high-voltage busbar with different outlet modes by integrating a terminal interface at the front end of the terminal mounting plate, and is connected to both sides of the battery pack to meet the requirements of the front and rear drive systems of new energy vehicles, without the need to design a variety of copper busbar structures for film capacitors, thereby reducing costs and improving versatility; and the heat dissipation channel provides multiple heat dissipation for the film capacitor assembly and the power board.

Description

Technical Field

[0001] The utility model relates to the technical field of film capacitors for electric vehicle motor controllers, in particular to an integrated film capacitor and a drive controller. Background Art

[0002] Existing film capacitors are mainly composed of a capacitor shell, a capacitor core, positive and negative copper bars, etc. First, the two ends of the capacitor core are welded to the positive and negative copper bars respectively, and then the welded core is placed in the capacitor shell as a whole. Finally, the capacitor core and the shell are potted and fixed to form a finished film capacitor, which provides energy storage, buffering, charging and discharging functions for the motor controller. However, the heat dissipation of this type of finished film capacitor is poor, which can easily lead to limited functions of the capacitor. At the same time, the capacitor is large in size, and it is necessary to design and install the support feet to fix them in the motor controller housing, occupying the space of the controller housing and wasting the space of the whole machine. In addition, for the front and rear drive systems of new energy vehicles, due to the different positions relative to the battery pack, the installation of the front and rear drive busbars is not satisfied, and two copper bar structures need to be designed, resulting in additional design costs and poor versatility. Utility Model Content

[0003] In order to overcome the above-mentioned technical problems, the utility model provides an integrated thin film capacitor and a drive controller. The integrated thin film capacitor is used to install battery high-voltage busbars with different wiring modes by integrating a terminal interface at the front end of a terminal mounting plate, and is connected to both sides of a battery pack to meet the requirements of the front and rear drive systems of new energy vehicles. There is no need to design a variety of copper busbar structures for thin film capacitors, thereby reducing costs and improving versatility. At the same time, a heat dissipation water channel is set at the rear end of the terminal mounting plate, and the thin film capacitor assembly can be set at the bottom of the heat dissipation water channel. The top of the heat dissipation water channel is used to install a power board, thereby realizing multiple heat dissipation of the thin film capacitor assembly and the power board by the heat dissipation water channel.

[0004] In order to achieve the above object, the utility model provides an integrated film capacitor, comprising:

[0005] A terminal mounting plate, wherein a terminal interface is provided at the front end of the terminal mounting plate;

[0006] A heat dissipation channel, arranged at the rear end of the terminal mounting plate;

[0007] A film capacitor assembly is arranged at the bottom of the heat dissipation channel, the top of the heat dissipation channel is used to install a power board, and the terminal interface is electrically connected to the film capacitor assembly;

[0008] The filter component is arranged near the terminal interface.

[0009] Preferably, the film capacitor assembly includes:

[0010] A capacitor shell, the top of which is in close contact with the bottom of the heat dissipation channel;

[0011] A plurality of film capacitor packages, wherein the plurality of film capacitors are vertically arranged in a capacitor shell;

[0012] A positive copper bar, the positive copper bar is electrically connected to the positive electrodes of the plurality of film capacitor packs, and the positive copper bar is closely attached to the top of the capacitor shell;

[0013] A negative copper busbar, the negative copper busbar being electrically connected to the negative electrodes of the plurality of film capacitor packs;

[0014] A plurality of groups of heat-conducting fins, one end of each group of heat-conducting fins is vertically connected relative to the positive copper bar, and the heat-conducting fins are closely attached to the film capacitor pack, and the other end of each group of heat-conducting fins is close to the negative electrode of the film capacitor pack.

[0015] Preferably, the film capacitor also includes:

[0016] A separator, arranged on the top of the positive copper busbar;

[0017] A plurality of mounting studs are arranged around the heat dissipation channel and are used to place the power board.

[0018] Preferably, the terminal mounting plate further comprises:

[0019] A first filtering cavity is arranged at the bottom of the terminal mounting plate and close to the terminal interface;

[0020] The second filtering cavity is arranged on a side of the first filtering cavity away from the terminal interface.

[0021] Preferably, the filter assembly includes:

[0022] A filter magnetic ring, sleeved on the inner side of the terminal interface;

[0023] A plurality of X capacitors are arranged in the first filter cavity, and two pins of the X capacitors are respectively welded to the positive electrode welding pin on the positive copper busbar and the negative electrode welding copper busbar on the negative copper busbar;

[0024] A plurality of Y capacitors are arranged in the second filter cavity, and one pin of the Y capacitor is welded to one of the positive electrode welding pin on the positive copper busbar or the negative electrode welding pin on the negative copper busbar, and another pin of the Y capacitor is welded to the ground copper busbar.

[0025] Preferably, the positive copper busbar further comprises a positive input terminal and a positive output terminal, the positive input terminal is arranged at the positive terminal of the terminal interface, and the positive output terminal is electrically connected to the positive terminal of the power board;

[0026] The negative copper busbar comprises a negative input terminal and a negative output terminal, wherein the negative input terminal is arranged at the negative terminal of the terminal interface, and the negative output terminal is electrically connected to the negative terminal of the power board.

[0027] Preferably, two clips are provided on the terminal mounting plate, and the two clips are arranged side by side at the rear end of the terminal interface, and are respectively used to fix the positive input end of the positive copper busbar and the negative input end of the negative copper busbar.

[0028] Preferably, the terminal mounting plate further comprises a copper busbar groove, which is arranged at the bottom of the terminal mounting plate close to one end edge of the heat dissipation channel and is used for positioning and assembling the positive copper busbar.

[0029] Preferably, the heat dissipation water channel also includes:

[0030] A water inlet and a water outlet, wherein the water inlet and the water outlet are symmetrically distributed on both sides of the film capacitor assembly and are connected to the heat dissipation water channel;

[0031] A sealing groove, wherein the sealing groove is equipped with a sealing ring for sealing the water inlet and the water outlet;

[0032] The sealing cover plate is arranged between the heat dissipation water channel and the power board, cooperates with the heat dissipation water channel, and is used to seal the heat dissipation water channel.

[0033] A second aspect of the utility model provides a drive controller, comprising:

[0034] An integrated film capacitor as described in any one of the above:

[0035] A drive control board, electrically connected to the integrated film capacitor;

[0036] A high-voltage battery busbar, one end of which is connected to the terminal interface of the integrated film capacitor.

[0037] The battery module, the integrated film capacitor is arranged on at least one of the two sides of the battery module, and is connected to the battery module through the other end of the high-voltage battery busbar.

[0038] Through the above technical scheme, the film capacitor can be used to install battery high-voltage busbars with different wiring modes by integrating a terminal interface at the front end of the terminal mounting plate, and connected to both sides of the battery pack to meet the requirements of the front and rear drive systems of new energy vehicles. There is no need to design a variety of copper busbar structures for film capacitors, which reduces costs and improves versatility; at the same time, a heat dissipation water channel is set at the rear end of the terminal mounting plate, and the film capacitor assembly can be set at the bottom of the heat dissipation water channel, and the top of the heat dissipation water channel is used to install the power board, so that the heat dissipation water channel can achieve multiple heat dissipation of the film capacitor assembly and the power board, and the terminal interface is electrically connected to the film capacitor assembly; and a heat-conducting fin is set to guide the heat of the film capacitor to the positive copper busbar, and the positive copper busbar exchanges heat with the heat dissipation water channel to further improve the heat dissipation efficiency; an isolation plate is set between the positive copper busbar and the heat dissipation water channel to protect the film capacitor from moisture; the position of the filter assembly is reasonably set to meet the filtering requirements; at the same time, pins and terminals are set on the positive and negative copper buses to meet the electrical connection structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1 It is a structural schematic diagram of an integrated film capacitor according to an embodiment of the utility model;

[0040] Figure 2 It is a schematic diagram of the bottom structure of an integrated film capacitor according to an embodiment of the utility model;

[0041] Figure 3 It is a schematic diagram of the exploded structure of an integrated film capacitor according to one embodiment of the utility model;

[0042] Figure 4 It is a connection diagram of a drive controller according to one embodiment of the utility model.

[0043] Description of Reference Numerals

[0044] 1. Terminal mounting plate 2. Cooling channel

[0045] 3. Film capacitor components 4. Filter components

[0046] 5. Isolation board 6. Install studs

[0047] 7. Drive control board 8. High voltage bus

[0048] 9. Battery module 10. Integrated film capacitor

[0049] 101, filter first cavity 102, filter second cavity

[0050] 103, buckle 104, copper bar groove

[0051] 105, terminal interface 21, water inlet

[0052] 22. Water outlet 23. Sealing groove

[0053] 31. Capacitor shell 32. Film capacitor package

[0054] 33. Positive copper busbar 34. Negative copper busbar

[0055] 35. Grounding copper bar 36. Thermal fins

[0056] 331, positive electrode welding pin 332, positive electrode input terminal

[0057] 333, positive output terminal 341, negative welding pin

[0058] 342. Negative electrode welding copper bar 343. Negative electrode input terminal

[0059] 344, negative output terminal 41, filter magnetic ring

[0060] 42. X capacitor 43. Y capacitor DETAILED DESCRIPTION

[0061] The specific implementation of the embodiment of the utility model is described in detail below in conjunction with the accompanying drawings. It should be understood that the specific implementation described here is only used to illustrate and explain the embodiment of the utility model, and is not used to limit the embodiment of the utility model.

[0062] like Figure 1 FIG. 1 is a schematic diagram of the structure of an integrated film capacitor according to an embodiment of the present utility model; Figure 1 In the figure, the integrated film capacitor may include a terminal mounting plate 1, a heat dissipation water channel 2, a film capacitor assembly 3, and a filter assembly 4; specifically, a terminal interface 105 may be provided on the front end of the terminal mounting plate 1, a heat dissipation water channel 2 may be provided at the rear end of the terminal mounting plate 1, the film capacitor assembly 3 may be provided at the bottom of the heat dissipation water channel 2, and the top of the heat dissipation water channel 2 may be used to install a power board (not marked in the figure), the terminal interface 105 may be electrically connected to the film capacitor assembly 3, and the filter assembly 4 may be provided near the terminal interface 105; both the top and the bottom of the heat dissipation water channel 2 may be utilized to improve the utilization rate of heat dissipation, and the terminal mounting plate 1 is close to the heat dissipation water channel 2, and the film capacitor assembly 3 is electrically connected to the integrated terminal interface 105 on the terminal mounting plate 1, so that the space of the integrated film capacitor 10 is compact and the space utilization rate is high.

[0063] Through the above technical solution, the integrated film capacitor can be used to install battery high-voltage busbars with different wiring methods by integrating the terminal interface at the front end of the terminal mounting plate, and connected to both sides of the battery pack to meet the requirements of the front and rear drive systems of new energy vehicles. There is no need to design a variety of copper busbar structures for film capacitors, which reduces costs and improves versatility. At the same time, a heat dissipation water channel is set at the rear end of the terminal mounting plate, and the film capacitor assembly can be set at the bottom of the heat dissipation water channel. The top of the heat dissipation water channel is used to install the power board, so as to realize multiple heat dissipation of the film capacitor assembly and the power board by the heat dissipation water channel.

[0064] like Figure 2 FIG. 1 is a schematic diagram of the bottom structure of an integrated film capacitor according to an embodiment of the present utility model; Figure 3 FIG. 1 is a schematic diagram of an exploded structure of an integrated film capacitor according to an embodiment of the present utility model; Figure 1 And 2, considering the connection of various components inside the film capacitor assembly, the copper bar structure is reasonably and simply arranged to improve the heat dissipation efficiency. In one embodiment of the utility model, the film capacitor assembly may include a capacitor shell 31, multiple film capacitor packs 32, a positive copper bar 33, a negative copper bar 34 and multiple groups of heat-conducting fins 36; the top of the capacitor shell 31 can be close to the bottom of the heat dissipation water channel 2, and the multiple film capacitor packs 32 are vertically arranged in the capacitor shell 31, the positive copper bar 33 is electrically connected to the positive poles of the multiple film capacitor packs 32, and the positive copper bar 33 is close to the top of the capacitor shell 31, and the negative copper bar 34 is electrically connected to the negative poles of the multiple film capacitor packs 32; the film capacitor packs 32 are vertically arranged in the capacitor shell 31, which can facilitate the transmission of heat along the core winding gap of the film capacitor packs 32, and at the same time, the capacitor shell 31, the positive copper bar 33 and the negative copper bar 34 are electrically connected to the negative poles of the multiple film capacitor packs 32. And the top of the film capacitor package 32 is tightly connected, and heat can also be smoothly conducted; in order to further improve the heat dissipation efficiency, in one embodiment of the present invention, the heat of the negative end of the film capacitor package 32 is far away from the heat dissipation water channel 2, because of the long distance, it is easy to store a large amount of heat at the negative end, resulting in limited function of the film capacitor assembly 3, and the film capacitor assembly 3 also includes a thermal fin 36, one end of the multiple groups of thermal fins 36 is vertically connected relative to the positive copper bus 33, and the thermal fins 36 are closely attached to the film capacitor package 32, and the other end of the thermal fins 36 is close to the negative electrode of the film capacitor package 32, so that the heat in the middle of the film capacitor package 32 and even the negative end can also be smoothly conducted through the thermal fins 36, thereby improving the heat dissipation effect.

[0065] exist Figure 3In order to prevent the film capacitor package 32 of the film capacitor assembly 3 from getting damp, in one embodiment of the utility model, the film capacitor also includes an isolation plate 5, which can be arranged on the top of the positive copper bar 33; the isolation plate 5 can not only conduct heat, but also isolate the leakage of the heat dissipation channel 2 from invading the film capacitor package 32, thereby protecting the film capacitor package 32. At the same time, in order to facilitate the installation of the power board (not shown in the figure) above the heat dissipation channel 2, in one embodiment of the utility model, the film capacitor also includes a plurality of mounting studs 6, which can be arranged around the heat dissipation channel 2. The heat dissipation channel 2 and the power board are in contact with each other, which can ensure the heat dissipation effect of the power board.

[0066] exist Figure 2 In order to reasonably set the position of the filter component, in one embodiment of the utility model, the terminal mounting plate 1 also includes a first filter cavity 101 and a second filter cavity 102. The first filter cavity 101 can be set at the bottom of the terminal mounting plate 1 and close to the terminal interface 105, and the second filter cavity 102 can be set on the side of the first filter cavity 101 away from the terminal interface 105, and can be close to the thin film capacitor component 3.

[0067] exist Figure 1 , 2 In addition, in 3, the filter component 4 is reasonably set considering the shape of the terminal mounting plate 1, and the circuit connection structure of the filter component 4 is reasonably arranged; in one embodiment of the utility model, the filter component 4 includes a filter magnetic ring 41, a plurality of X capacitors 42 and a plurality of Y capacitors 43; the filter magnetic ring 41 can be sleeved on the inner side of the terminal interface 105 according to the shape of the terminal interface 105, a plurality of X capacitors 42 can be set in the first filter cavity 101, and the two pins of the X capacitor 42 can be respectively welded to the positive welding pin 331 on the positive copper bus 33 and the negative welding copper bus 342 on the negative copper bus 34, a plurality of Y capacitors 43 can be set in the second filter cavity, and one pin of the Y capacitor 43 is welded to one of the positive welding pin 331 on the positive copper bus 33 or the negative welding pin 341 on the negative copper bus 34, and the other pin of the Y capacitor 43 is welded to the grounding copper bus 35.

[0068] exist Figure 3 In the figure, taking into account the connection relationship between the terminal interface 105 and the copper busbar, and satisfying the connection structure between the copper busbar and the power board (not shown in the figure), in one embodiment of the utility model, the positive copper busbar 33 may also include a positive input terminal 332 and a positive output terminal 333, the positive input terminal 31 is arranged at the positive end of the terminal interface 105, and the positive output terminal 32 is electrically connected to the positive terminal of the power board; the negative copper busbar 34 may include a negative input terminal 343 and a negative output terminal 344, the negative input terminal 343 may be arranged at the negative end of the terminal interface 105, and the negative output terminal 344 is electrically connected to the negative terminal of the power board.

[0069] exist Figure 2 and 3 In order to fix the positive and negative ends of the terminal interface 105, in one embodiment of the utility model, two clips 103 can be provided on the terminal mounting plate 1, and the two clips 103 are arranged side by side at the rear end of the terminal interface 1, and are respectively used to fix the positive input terminal 332 of the positive copper busbar 33 and the negative input terminal 343 of the negative copper busbar 34.

[0070] exist Figure 2 In order to meet the positioning and installation requirements of the positive copper busbar 33, in one embodiment of the present invention, the terminal mounting plate 1 may further include a copper busbar groove 104, which may be disposed at the bottom of the terminal mounting plate 1 near one end edge of the heat dissipation channel 2. The copper busbar groove 104 may eliminate the positioning tooling of the traditional film capacitor and reduce the cost.

[0071] exist Figure 2 In order to ensure the sealing of the heat dissipation water channel 2, the water inlet and outlet of the heat dissipation water channel 2 are reasonably arranged. In one embodiment of the utility model, the heat dissipation water channel 2 also includes a water inlet 21, a water outlet 22, a sealing groove 23 and a sealing cover plate (not marked in the figure). The water inlet 21 and the water outlet 22 can be symmetrically distributed on both sides of the film capacitor component 3, and are connected with the heat dissipation water channel 2; the sealing groove 23 is equipped with a sealing ring, which can be used to seal the water inlet 21 and the water outlet 22. The sealing cover plate can be arranged between the heat dissipation water channel 2 and the power board (not marked in the figure), and cooperates with the heat dissipation water channel 2 to seal the heat dissipation water channel 2 to prevent the coolant in the heat dissipation water channel 2 from directly contacting the power board (not marked in the figure) and causing damage to the power board.

[0072] On the other hand, the utility model provides a drive controller, which includes an integrated thin film capacitor 10, a drive control board 7, a high-voltage battery bus 8, and a battery module 9 as described above; a terminal interface 105 can be provided on the integrated thin film capacitor 10, one end of the high-voltage battery bus 8 can be connected to the terminal interface of the integrated thin film capacitor 10, and the integrated thin film capacitor 10 can be provided on at least one side of the two sides of the battery module 9, and connected to the battery module 9 through the other end of the high-voltage battery bus 8.

[0073] Through the above technical scheme, the film capacitor can be used to install battery high-voltage busbars with different wiring modes by integrating a terminal interface at the front end of the terminal mounting plate, and connected to both sides of the battery pack to meet the requirements of the front and rear drive systems of new energy vehicles. There is no need to design a variety of copper busbar structures for film capacitors, which reduces costs and improves versatility; at the same time, a heat dissipation water channel is set at the rear end of the terminal mounting plate, and the film capacitor assembly can be set at the bottom of the heat dissipation water channel, and the top of the heat dissipation water channel is used to install the power board, so that the heat dissipation water channel can achieve multiple heat dissipation of the film capacitor assembly and the power board, and the terminal interface is electrically connected to the film capacitor assembly; and a heat-conducting fin is set to guide the heat of the film capacitor to the positive copper busbar, and the positive copper busbar exchanges heat with the heat dissipation water channel to further improve the heat dissipation efficiency; an isolation plate is set between the positive copper busbar and the heat dissipation water channel to protect the film capacitor from moisture; the position of the filter assembly is reasonably set to meet the filtering requirements; at the same time, pins and terminals are set on the positive and negative copper buses to meet the electrical connection structure.

[0074] The preferred embodiments of the present invention are described in detail above in conjunction with the accompanying drawings. However, the present invention is not limited to the specific details in the above embodiments. Within the technical concept of the present invention, the technical solution of the present invention can be subjected to a variety of simple modifications, and these simple modifications all belong to the protection scope of the present invention. It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, the present invention will not further describe various possible combinations.

[0075] In addition, various embodiments of the present invention may be arbitrarily combined, and as long as they do not violate the concept of the present invention, they should also be regarded as the contents disclosed by the present invention.

Claims

1. An integrated film capacitor, characterized in that: include: A terminal mounting plate, wherein a terminal interface is provided at the front end of the terminal mounting plate; A heat dissipation channel, arranged at the rear end of the terminal mounting plate; A film capacitor assembly is arranged at the bottom of the heat dissipation channel, the top of the heat dissipation channel is used to install a power board, and the terminal interface is electrically connected to the film capacitor assembly; The filter component is arranged near the terminal interface.

2. The film capacitor according to claim 1, characterized in that: The film capacitor assembly comprises: A capacitor shell, the top of which is in close contact with the bottom of the heat dissipation channel; A plurality of film capacitor packages, wherein the plurality of film capacitors are vertically arranged in a capacitor shell; A positive copper bar, the positive copper bar is electrically connected to the positive electrodes of the plurality of film capacitor packs, and the positive copper bar is closely attached to the top of the capacitor shell; A negative copper busbar, the negative copper busbar being electrically connected to the negative electrodes of the plurality of film capacitor packs; A plurality of groups of heat-conducting fins, one end of each group of heat-conducting fins is vertically connected relative to the positive copper bar, and the heat-conducting fins are closely attached to the film capacitor pack, and the other end of each group of heat-conducting fins is close to the negative electrode of the film capacitor pack.

3. The film capacitor according to claim 2, characterized in that: The film capacitor also includes: A separator, arranged on the top of the positive copper busbar; A plurality of mounting studs are arranged around the heat dissipation channel and are used to place the power board.

4. The film capacitor according to claim 2, characterized in that: The terminal mounting plate also includes: A first filtering cavity is arranged at the bottom of the terminal mounting plate and close to the terminal interface; The second filtering cavity is arranged on a side of the first filtering cavity away from the terminal interface.

5. The film capacitor according to claim 4, characterized in that: The filter assembly comprises: A filter magnetic ring, sleeved on the inner side of the terminal interface; A plurality of X capacitors are arranged in the first filter cavity, and two pins of the X capacitors are respectively welded to the positive electrode welding pin on the positive copper busbar and the negative electrode welding copper busbar on the negative copper busbar; A plurality of Y capacitors are arranged in the second filter cavity, and one pin of the Y capacitor is welded to one of the positive electrode welding pin on the positive copper busbar or the negative electrode welding pin on the negative copper busbar, and another pin of the Y capacitor is welded to the ground copper busbar.

6. The film capacitor according to claim 2, characterized in that: The positive copper busbar further comprises a positive input terminal and a positive output terminal, wherein the positive input terminal is arranged at the positive terminal of the terminal interface, and the positive output terminal is electrically connected to the positive terminal of the power board; The negative copper busbar comprises a negative input terminal and a negative output terminal, wherein the negative input terminal is arranged at the negative terminal of the terminal interface, and the negative output terminal is electrically connected to the negative terminal of the power board.

7. The film capacitor according to claim 6, characterized in that: Two buckles are arranged on the terminal mounting plate, and the two buckles are arranged side by side at the rear end of the terminal interface, and are respectively used to fix the positive input end of the positive copper busbar and the negative input end of the negative copper busbar.

8. The film capacitor according to claim 6, characterized in that: The terminal mounting plate also includes a copper busbar groove, which is arranged at the bottom of the terminal mounting plate near one end edge of the heat dissipation water channel and is used for positioning and assembling the positive copper busbar.

9. The film capacitor according to claim 1, characterized in that: The heat dissipation water channel also includes: A water inlet and a water outlet, wherein the water inlet and the water outlet are symmetrically distributed on both sides of the film capacitor assembly and are connected to the heat dissipation water channel; A sealing groove, wherein the sealing groove is equipped with a sealing ring for sealing the water inlet and the water outlet; The sealing cover plate is arranged between the heat dissipation water channel and the power board, cooperates with the heat dissipation water channel, and is used to seal the heat dissipation water channel.

10. A drive controller, characterized in that: include: The integrated film capacitor according to any one of claims 1 to 9; A drive control board, electrically connected to the integrated film capacitor; A high-voltage battery busbar, one end of which is connected to a terminal interface of the integrated film capacitor; The battery module, the integrated film capacitor is arranged on at least one of the two sides of the battery module, and is connected to the battery module through the other end of the high-voltage battery busbar.

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