Thin-film capacitor assembly, electric control system and vehicle

Abstract

The utility model relates to a thin-film capacitor assembly, an electric control system and a vehicle, relates to the field of automobiles, and is used for solving the problem that the number of manufacturing molds of all parts in a thin-film system is large. The thin-film capacitor assembly comprises an integrated shell, a thin-film capacitor main body and a high-voltage branching main body, the thin-film capacitor body is arranged on the integrated shell. And the high-voltage branching main body is arranged on the integrated shell and is electrically connected with the thin-film capacitor main body. The thin-film capacitor assembly is used for filtering the current.

Description

Technical Field

[0001] The present application relates to the automotive field, and in particular to a film capacitor assembly, an electronic control system and a vehicle. Background Art

[0002] With the increasing popularity of new energy vehicles, vehicles have higher and higher requirements for electronic control systems. The electronic control system is one of the core components of electric vehicles and is the core part to ensure the normal operation of the vehicle and efficient energy management. The electronic control system has high and low voltage electrical control systems to distribute the power demand of various devices.

[0003] Among them, the distribution of high-voltage current requires a film capacitor assembly to filter the high-voltage current, thereby reducing the electromagnetic interference of the current and providing a smooth and safe current.

[0004] In the related art, different components in the film capacitor assembly need to be molded separately and then assembled, which requires more molding molds and relatively higher time and cost. Utility Model Content

[0005] The first object of the utility model is to provide a film capacitor assembly to solve the problem of a large number of molds for manufacturing each component in the film capacitor assembly. The second object is to provide an electric control system. The third object is to provide a vehicle.

[0006] In order to achieve the above purpose, the technical solution adopted by the utility model is as follows:

[0007] According to the first aspect of the present application, a film capacitor assembly is provided, comprising an integrated housing, a film capacitor body and a high-voltage branch line body. The film capacitor body is arranged on the integrated housing. The high-voltage branch line body is arranged on the integrated housing and is electrically connected to the film capacitor body.

[0008] According to the above-mentioned technical means, in the thin film capacitor assembly provided in the embodiment of the present application, the thin film capacitor body and the high-voltage branch line body are integrally injection molded on the integrated housing by an injection molding machine. While forming the thin film capacitor and the high-voltage branch line module, the positions of the two are also fixed so that the two are located on the same integrated housing. This not only reduces the number and cost of injection molds, but also eliminates the assembly and fixing process. The high-voltage branch line body is connected to a high-voltage battery and is used to distribute high-voltage current to power devices that need to use high-voltage current. Before the high-voltage current is distributed to the power device, it is necessary to pass the high-voltage current through the thin film capacitor body so that the thin film capacitor body can filter the high-voltage current and reduce the impact of power supply noise on the circuit.

[0009] In some embodiments, the film capacitor body has a film positive electrode and a film negative electrode. The high-voltage branch line body has a high-voltage branch line positive electrode and a high-voltage branch line negative electrode. The film positive electrode is welded to the high-voltage branch line positive electrode, and the film negative electrode is welded to the high-voltage branch line negative electrode.

[0010] According to the above technical means, the current distributed by the high-voltage branch line body can be filtered.

[0011] In some embodiments, the film capacitor assembly further includes a filter capacitor having a positive filter electrode and a negative filter electrode, the positive filter electrode is welded to the positive electrode of the film capacitor, and the negative filter electrode is welded to the negative electrode of the film.

[0012] According to the above technical means, the output voltage can be made smoother and the noise and electromagnetic interference can be reduced.

[0013] In some embodiments, the film capacitor assembly further includes a first welding piece and a second welding piece, wherein the first welding piece is welded to the filter positive electrode and the film positive electrode, and the second welding piece is welded to the filter negative electrode and the film negative electrode.

[0014] According to the above technical means, short circuit can be prevented and the circuit can be protected from oxidation and mechanical damage.

[0015] According to the second aspect of the present application, there is also provided an electric control system, comprising an electric control housing and any one of the above-mentioned film capacitor assemblies. The electric control housing forms a receiving space. The film capacitor assembly is located in the receiving space.

[0016] According to the above technical means, high voltage current can be distributed and filtered.

[0017] In some embodiments, the electric control system further comprises a separator. The separator is located in the accommodation space and connected to the inner wall of the electric control housing. Two ends of the separator are connected to each other to form a cooling area. The cooling area is used to accommodate cooling water. The film capacitor body is connected to the separator to cover the cooling area.

[0018] According to the above technical means, the temperature of the film capacitor body can be reduced.

[0019] In some embodiments, the partition has a plurality of side walls, one of which is formed with a partition recess, and the partition recess is used to limit the flow path of the cooling water.

[0020] According to the above technical means, the cooling efficiency of the film capacitor body by the cooling water is increased.

[0021] In some embodiments, the electric control system further comprises a plurality of baffles, which are located in the cooling area and connected to the electric control housing.

[0022] According to the above technical means, water flow can be guided to flow in the expected direction.

[0023] In some embodiments, a plurality of recessed portions are formed on the baffle.

[0024] According to the above technical means, the flow velocity uniformity and hydraulic efficiency can be improved.

[0025] According to a third aspect of the present application, a vehicle is also provided, comprising the above-mentioned electronic control system.

[0026] According to the above technical means, the performance of the vehicle can be guaranteed through precise control.

[0027] Therefore, the above technical features of the present application have the following beneficial effects:

[0028] (1) It not only reduces the number and cost of injection molds, but also eliminates the assembly and fixing process.

[0029] (2) The current distributed by the high-voltage branch line body can be filtered.

[0030] (3) It can make the output voltage smoother and reduce noise and electromagnetic interference.

[0031] (4) It can prevent short circuits and protect circuits from oxidation and mechanical damage.

[0032] It should be noted that the technical effects brought about by the second and third aspects can refer to the technical effects brought about by the corresponding implementation methods in the first aspect, and will not be repeated here.

[0033] It should be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The drawings herein are incorporated into the specification and constitute a part of the specification, illustrate embodiments consistent with the present application, and together with the specification are used to explain the principles of the present application, and do not constitute an improper limitation on the present application.

[0035] Figure 1 A schematic diagram of the structure of a film capacitor assembly provided by the prior art;

[0036] Figure 2 A partial structural schematic diagram of an electric control housing provided by the prior art;

[0037] Figure 3 A schematic diagram of the structure of a film capacitor assembly provided in an embodiment of the present application;

[0038] Figure 4 A partial structural schematic diagram of an electric control housing provided in an embodiment of the present application.

[0039] Reference numerals

[0040] 010-film capacitor assembly; 020-high-voltage branching module; 030-film capacitor; 040-bolt; 050-electrical control housing; 100-film capacitor assembly; 10-integrated housing; 20-film capacitor body; 21-film positive electrode; 22-film negative electrode; 30-high-voltage branching body; 31-high-voltage branching positive electrode; 32-high-voltage branching negative electrode; 40-first welding piece; 50-second welding piece; 60-filter capacitor; 70-electrical control housing; 80-partitioning piece; 801-cooling area; 802-water inlet; 803-water outlet; 81-side wall; 82-partitioning recess; 90-baffle; 901-recess. DETAILED DESCRIPTION

[0041] In order to enable ordinary persons in the art to better understand the technical solution of the present application, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the accompanying drawings.

[0042] It should be noted that the terms "first", "second", etc. in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the data used in this way can be interchangeable where appropriate, so that the embodiments of the present application described herein can be implemented in an order other than those illustrated or described herein. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with the present application. On the contrary, they are merely examples of devices and methods consistent with some aspects of the present application as detailed in the attached claims.

[0043] With the development of automobile manufacturing technology, the usage rate of automobiles in people's lives is getting higher and higher. At the same time, with the promotion and popularization of new energy vehicles, more and more people have chosen new energy vehicles. At present, automobiles have become an indispensable part of modern life.

[0044] New energy vehicles mainly include power supply system, electronic control system, auxiliary system and other systems, etc. Among them, the electronic control system is responsible for managing and controlling the operation of the entire vehicle electrical system, ensuring efficient collaboration and safe operation between batteries, motors and other key components.

[0045] The electric control system has high and low voltage electrical control systems to distribute the power demand of each device. Figure 1 As shown, Figure 1 The structure diagram of a film capacitor assembly 010 provided in the prior art is shown in FIG. 010 , wherein the film capacitor assembly 010 is required to smooth and filter the distributed current. The film capacitor assembly 010 mainly includes a high-voltage distribution module 020 and a film capacitor 030 .

[0046] High-voltage distribution module 020 is a key component in new energy vehicles, especially electric vehicles. It is usually located in the center of the vehicle's high-voltage electrical system. Its main function is to distribute the high voltage output by the power battery and provide stable and safe power to various high-voltage loads such as the electronic control system, air-conditioning compressor, and on-board charger.

[0047] The film capacitor 030 is connected to the high-voltage branching module 020 to buffer the fluctuation in the current and provide a stable current for the electrical equipment.

[0048] In the related art, for the film capacitor assembly 010, when the high-voltage branching module 020 and the film capacitor 030 are connected, the high-voltage branching module 020 and the film capacitor 030 are first formed separately, and then the bolts 040 are used to electrically connect them. This method of separate forming and then connecting requires many different forming molds, which increases the cost of making the molds. It is also necessary to assemble the formed high-voltage branching module 020 and the film capacitor 030, which makes the assembly process more complicated.

[0049] Furthermore, the use of bolts 040 to electrically connect the high-voltage distribution module 020 and the film capacitor 030 may cause metal debris to fall during assembly and disassembly, and the falling metal debris may easily cause a short circuit inside the electronic control system, and in severe cases, electronic control ablation may occur, affecting the performance of the electronic control system.

[0050] At the same time, the film capacitor 030 generates a lot of heat when filtering the high voltage current. Figure 2 As shown, Figure 2 A partial structural diagram of an electric control housing 050 provided by the prior art, a film capacitor 030 ( Figure 1 ) is directly connected to the electric control housing 050, and no separate cooling device is provided for the film capacitor 030. The service life of the film capacitor 030 in a high temperature environment for a long time will be greatly shortened. Excessive temperature will cause irreversible changes in the internal structure of the film capacitor 030, such as film shrinkage, dielectric layer separation or thermal cracking, which may cause the film capacitor 030 to fail in its own function.

[0051] Based on this, an embodiment of the present application provides a vehicle that may include an electronic control system.

[0052] The electronic control system is a highly integrated and complex system that ensures the vehicle's performance, driving safety and energy efficiency through precise control. The performance of the electronic control system can directly affect the performance of the vehicle.

[0053] In some embodiments, the present application also provides an electric control system, including an electric control housing and a thin film capacitor assembly. The electric control housing forms a storage space. The thin film capacitor assembly is located in the storage space. The thin film capacitor assembly may include a high-voltage branch line body and a thin film capacitor body.

[0054] In the high and low voltage electrical control system in the electric control system, the high voltage current needs to be distributed, so the film capacitor body needs to filter the distributed high voltage current to make the high voltage current smoother.

[0055] The main body of the film capacitor is inside the electronic control housing. It reduces the voltage ripple of the high-voltage current to be output in the electronic control system, improves the quality of the output power supply, and assists the high-voltage battery in providing current for transient high-power requirements, ensuring that the equipment that requires electricity in the electronic control system can input smooth and stable high-voltage electricity.

[0056] At the same time, the film capacitor assembly can also effectively suppress high-frequency noise and surge voltage, protect the circuit from electromagnetic interference (EMI), and improve the overall anti-electromagnetic interference performance of the electronic control system.

[0057] In some embodiments, Figure 3 As shown, Figure 3 The structure diagram of a film capacitor assembly 100 provided in an embodiment of the present application is shown in FIG. The film capacitor assembly 100 provided in an embodiment of the present application further comprises an integrated housing 10 , a film capacitor body 20 and a high-voltage branch line body 30 .

[0058] The film capacitor body 20 is disposed on the integrated housing 10 . The high-voltage branch line body 30 is disposed on the integrated housing 10 and is electrically connected to the film capacitor body 20 .

[0059] The film capacitor body 20 and the high-voltage branch line body 30 can be integrally injection molded on the integrated housing 10 by an injection molding machine. While forming the film capacitor and the high-voltage branch line module, the positions of the two are also fixed, so that the two are located on the same integrated housing 10. This not only reduces the number and cost of injection molds, but also eliminates the process of assembly and fixing.

[0060] The high-voltage branch line body 30 is connected to the high-voltage battery and is used to distribute the high-voltage current to the power equipment that needs to use the high-voltage current. Before the high-voltage current is distributed to the power equipment, it needs to pass through the film capacitor body 20 to allow the film capacitor body 20 to filter the high-voltage current and reduce the impact of power supply noise on the circuit.

[0061] In some embodiments, Figure 3As shown, the film capacitor body 20 may include a film positive electrode 21 and a film negative electrode 22. The high voltage branch line body 30 includes a high voltage branch line positive electrode 31 and a high voltage branch line negative electrode 32. The film positive electrode 21 is welded to the high voltage branch line positive electrode 31, and the film negative electrode 22 is welded to the high voltage branch line negative electrode 32.

[0062] In order to filter the current distributed by the high-voltage branch line body 30, the film positive electrode 21 and the film negative electrode 22 of the film capacitor body 20 can be electrically connected to the high-voltage branch line positive electrode 31 and the high-voltage branch line negative electrode 32 of the high-voltage branch line, respectively. The electrical connection can be made by welding.

[0063] Welding has good firmness, integrity and economy. No metal debris will be generated during installation to cause short circuit in the electronic control system.

[0064] Exemplarily, the type of welding can be laser welding. Laser welding technology has many unique advantages over traditional welding methods. For example, the laser beam can be precisely focused to the micron level, thereby achieving very fine welds. Since the laser energy is highly concentrated and the heating and cooling speeds are fast, the heat input is small, reducing the impact on the surrounding material structure. At the same time, compared with other welding methods, laser welding is faster, and more welding tasks can be completed per unit time, greatly improving assembly efficiency.

[0065] In other embodiments, the welding type may also be other types, as long as the high-voltage branch line positive electrode 31 and the high-voltage branch line negative electrode 32 of the high-voltage branch line body 30 can be electrically connected to the thin film positive electrode 21 and the thin film negative electrode 22 of the thin film capacitor body 20.

[0066] In other embodiments, the high voltage branch line body 30 and the film capacitor body 20 may be electrically connected in other ways, as long as the high voltage branch line body 30 and the film capacitor body 20 can be stably electrically connected without any safety hazard during the connection.

[0067] Exemplarily, the positive electrode and negative electrode of the thin film capacitor can be a positive copper bar and a negative copper bar of the thin film capacitor. The high voltage branch line positive electrode 31 and the high voltage branch line negative electrode 32 can be a DC busbar of the high voltage branch line positive electrode 31 and the high voltage branch line negative electrode 32.

[0068] Copper has excellent electrical conductivity, low resistivity, and can carry large currents without overheating. This allows copper busbars to effectively transmit and distribute large amounts of electrical energy, making them more suitable as the material for the positive and negative electrodes of the film capacitor in this application.

[0069] The DC busbar is usually made of copper, which has good conductivity and a large cross-sectional area. It can effectively carry and distribute large currents to meet the high power requirements of equipment. In addition, compared with cables, the busbar reduces the complexity of multiple wires. The centralized wiring method can greatly reduce the occupied space and facilitate the internal layout and heat dissipation management of the equipment.

[0070] In some embodiments, Figure 3 As shown, the film capacitor assembly 100 may further include a filter capacitor 60. The filter capacitor 60 has a filter positive electrode and a filter negative electrode, the filter positive electrode is welded to the film capacitor positive electrode 21, and the filter negative electrode is welded to the film negative electrode 22.

[0071] The filter capacitor 60 also has a filtering function, but the filter capacitor 60 and the film capacitor body 20 are respectively suitable for filtering ripples in different frequency bands. Specifically, the filter capacitor 60 can filter the ripples in the current, and the film capacitor 20 can filter the peaks in the current.

[0072] The ripple in the current refers to the periodic or random fluctuation part of the current superimposed on the DC average value. In actual circuits, the ideal DC current should be constant, but in actual situations, due to the influence of various factors, the DC current often has certain fluctuations. The ripple in the current will increase the power loss of the equipment using the current.

[0073] A current spike is a transient pulse that occurs in a circuit in a short period of time and has an amplitude much greater than the normal operating current. This current change is very fast and drastic, and may last only a few microseconds to hundreds of nanoseconds, but its peak current can reach several times or even dozens of times the normal operating current. In a switching power supply or power electronic device, when the switch device is turned on or off quickly, a very high transient voltage and current will be generated in the circuit, thus forming a current spike. The current spike will generate strong electromagnetic radiation, increasing the electromagnetic compatibility problem between systems.

[0074] Therefore, the high-voltage current can pass through both the film capacitor body 20 and the filter capacitor 60. The ripples of different frequency bands in the current can be eliminated, so that the current output from the film capacitor body 20 is smoother. The smooth current means that the current fluctuation is small, avoiding the instantaneous power loss caused by the rapid change of the current. This helps to improve the efficiency of the electrical equipment and reduce the energy consumption of the electrical equipment.

[0075] In some embodiments, Figure 3 As shown, the film capacitor assembly 100 may further include a first welding piece 40 and a second welding piece 50. The first welding piece 40 is welded to the filter positive electrode and the film positive electrode 21. The second welding piece 50 is welded to the filter negative electrode and the film negative electrode 22.

[0076] The solder tab can precisely control the soldering position, prevent the non-soldering area from being covered by solder, and ensure that soldering occurs only where it is needed. This can prevent short circuits and protect the circuit from oxidation and mechanical damage.

[0077] For example, according to different metal combinations, suitable welding pieces can be selected for welding, such as using copper, steel, cast iron, cemented carbide and other materials to ensure welding strength and durability of the joint.

[0078] In some embodiments, Figure 4 As shown, Figure 4 A partial structural schematic diagram of an electric control housing 70 provided in an embodiment of the present application, wherein the electric control system further includes a separator 80. The separator 80 is located in the accommodation space and is connected to the inner wall of the electric control housing 70. The two ends of the separator 80 are connected to each other to form a cooling area 801. The cooling area 801 is used to accommodate cooling water. Among them, the film capacitor body 20 is connected to the separator 80 and covers the cooling area 801.

[0079] The film capacitor body 20 generates a lot of heat when filtering high voltage current, so a cooling device is required. The cooling area 801 surrounded by the partition 80 is located between the film capacitor body 20 and the electric control housing 70, and the cooling water contained in the cooling area 801 can cool the film capacitor body 20.

[0080] Excessively high operating temperature is one of the main reasons for shortening the life of film capacitors. Reducing the operating temperature helps keep the electrical parameters of film capacitors stable, which is critical for applications such as high-frequency filtering, energy storage, and pulse current processing.

[0081] The separator 80 is also provided with a water inlet 802 and a water outlet 803. The water inlet 802 and the water outlet 803 are both connected to the original cooling system of the electric control system, so that a portion of cooling water in the cooling system of the electric control system enters the cooling area 801 surrounded by the separator 80 to cool the film capacitor body 20. In this way, the film capacitor body 20 can be cooled without setting up an additional cooling system, thereby reducing the waste of energy and space.

[0082] In some embodiments, Figure 4 As shown, the partition 80 has a plurality of side walls 81, and a partition recess 82 is formed on one of the side walls 81. The partition recess 82 is used to limit the flow path of the cooling water.

[0083] The partition recess 82 is disposed between the water inlet 802 and the water outlet 803, so that the cooling water can flow around the partition recess 82 after entering the cooling space through the water inlet 802, and then be discharged from the cooling space through the water outlet 803. In this way, the distance that the cooling water passes through in the cooling space can be lengthened, thereby lengthening the time that the cooling water stays in the cooling space, and increasing the cooling efficiency of the film capacitor body 20 by the cooling water.

[0084] In other embodiments, Figure 4 As shown, the partition 80 may not form the partition recess 82, and the electric control system may include a partition plate. The partition plate is located in the cooling space, between the water inlet 802 and the water outlet 803, and is connected to the electric control housing 70 and the side wall 81 of the partition provided with the water inlet 802 and the water outlet 803. In this way, the time for the cooling water to stay in the cooling space can be prolonged.

[0085] In some embodiments, Figure 4 As shown, the electric control system further includes a plurality of baffles 90. The plurality of baffles 90 are located in the cooling area 801 and connected to the electric control housing 70.

[0086] Among them, multiple baffles 90 are arranged according to the expected flow direction of the water flow, which can guide the water flow in the expected direction, so that the water flow passes through a longer path in the cooling space as much as possible, thereby increasing the cooling effect on the film capacitor body 20.

[0087] In some embodiments, Figure 4 As shown, a plurality of recessed portions 901 are formed on the baffle plate 90 .

[0088] The baffle 90 with the recessed portion 901 can reduce eddies and disordered turbulence in the cooling water flow, reduce energy loss by guiding and dispersing the cooling water flow, and thus improve flow rate uniformity and hydraulic efficiency.

[0089] The above are only specific implementations of the present application, but the protection scope of the present application is not limited thereto, and any changes or substitutions within the technical scope disclosed in the present application should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be based on the protection scope of the claims.

Claims

1. A film capacitor assembly (100), characterized in that: include: Integrated housing (10); A film capacitor body (20) is arranged on the integrated housing (10); as well as, The high-voltage branch line body (30) is arranged on the integrated housing (10) and is electrically connected to the film capacitor body (20).

2. The film capacitor assembly (100) according to claim 1, characterized in that: The thin film capacitor body (20) comprises a thin film positive electrode (21) and a thin film negative electrode (22); the high voltage branch line body (30) comprises a high voltage branch line positive electrode (31) and a high voltage branch line negative electrode (32); the thin film positive electrode (21) is welded to the high voltage branch line positive electrode (31), and the thin film negative electrode (22) is welded to the high voltage branch line negative electrode (32).

3. The film capacitor assembly (100) according to claim 2, characterized in that: The film capacitor assembly (100) further comprises: The filter capacitor (60) comprises a filter positive electrode and a filter negative electrode, wherein the filter positive electrode is welded to the thin film positive electrode (21), and the filter negative electrode is welded to the thin film negative electrode (22).

4. The film capacitor assembly (100) according to claim 3, characterized in that: The film capacitor assembly (100) further comprises: A first welding sheet (40) is welded to the filter positive electrode and the thin film positive electrode (21); and The second welding sheet (50) is welded to the filter negative electrode and the thin film negative electrode (22).

5. An electronic control system, characterized in that: The electronic control system comprises: An electric control housing (70) forms a receiving space; and The film capacitor assembly (100) according to any one of claims 1 to 4 is located in the accommodating space.

6. The electronic control system according to claim 5, characterized in that: The electronic control system further comprises: A partition (80) is located in the accommodating space and connected to the inner wall of the electric control housing (70); two ends of the partition (80) are connected to each other to form a cooling area (801); the cooling area (801) is used to accommodate cooling water; Wherein, the thin film capacitor body (20) is connected to the separator (80) and covers the cooling area (801).

7. The electronic control system according to claim 6, characterized in that: The partition (80) has a plurality of side walls (81), one of the side walls (81) being provided with a partition recess (82); the partition recess (82) is used to limit the flow path of the cooling water.

8. The electronic control system according to claim 6, characterized in that: The electronic control system further comprises: A plurality of baffles are located in the cooling area (801) and connected to the electrical control housing (70).

9. The electronic control system according to claim 8, characterized in that: A plurality of recessed portions (901) are formed on the baffle.

10. A vehicle, characterized in that: The invention comprises the electronic control system as claimed in any one of claims 5 to 9.

Images