A capacitor for new energy vehicles
By adopting a tight fit design of the heat dissipation parts and the capacitor core in the capacitor capacitor in the new energy vehicle capacitor, the problem of insufficient heat dissipation of the capacitor is solved, the effect of effectively reducing the temperature of the capacitor core is achieved, and the reliability and safety of the capacitor are improved.
Patent Information
- Application Number
- CN202421103358.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-05-20
- Publication Date
- 2025-04-08
- Estimated Expiration
- 2034-05-20
AI Technical Summary
The DC bus capacitors in the motor controller of new energy vehicles are insufficient to dissipate heat, resulting in serious heat generation, which may cause capacitor failure and affect the stability and safety of the vehicle power system.
A capacitor for new energy vehicles is designed, and a heat dissipation part and a capacitor core are arranged in the shell. The heat dissipation part includes a bottom plate and a number of vertically connected heat dissipation plates. Both sides of each capacitor core are closely connected with the heat dissipation plate. Heat is transmitted to the bottom plate through the heat dissipation plate to achieve rapid heat dissipation.
It effectively reduces the temperature of the capacitor core, avoids capacitor failure caused by insufficient heat dissipation, and improves the reliability and safety of the capacitor.
Smart Images
Figure CN222734816U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the field of film capacitors for new energy vehicles, in particular to a capacitor for new energy vehicles. Background Art
[0002] The DC bus capacitor currently used in the motor controller of new energy vehicles usually adopts a design structure of plastic shell plus epoxy packaging, and the plastic shell material is usually PPS. The thermal conductivity of PPS and epoxy resin is relatively low, and the heat generated by the core cannot be well conducted out, and the heat is easily accumulated inside the core. Once the accumulated heat exceeds the tolerance range of the core, the core will bulge and short-circuit. Once the capacitor is short-circuited, it may cause the vehicle power system to malfunction, lose control, and even threaten personal safety and cause property damage. Therefore, it is necessary to solve the problem of insufficient heat dissipation and severe heating of the DC bus capacitor in the motor controller of new energy vehicles. Utility Model Content
[0003] The present invention mainly solves the problem of insufficient heat dissipation of capacitors used in new energy vehicles and severe heating causing capacitor failure.
[0004] In order to achieve the above object, the utility model is realized by the following technical solutions:
[0005] A capacitor for new energy vehicles includes a housing, a heat sink and a plurality of capacitor cores arranged in the housing. The heat sink includes a bottom plate and a plurality of heat sinks vertically connected to the upper surface of the bottom plate and arranged in a row along the length direction of the bottom plate. A capacitor core is inserted between each two adjacent heat sinks, and the two sides of the capacitor core are tightly fitted with the two heat sinks respectively. The heat generated by the capacitor core is conducted to the bottom plate through the heat sinks tightly fitted on both sides, effectively reducing the temperature of the capacitor core.
[0006] As a preferred solution, the bottom plate of the heat sink is flush with the bottom surface of the housing, and the bottom of the housing is provided with an opening to expose the bottom plate of the heat sink. The bottom plate of the heat sink has a large area, and its outer dimensions are only slightly smaller than the bottom surface dimensions of the housing. The large exposed area is conducive to rapid heat dissipation.
[0007] As a preferred solution, the gap between the bottom opening of the housing and the bottom plate of the heat sink is sealed by a sealing ring.
[0008] As a preferred solution, the edges of the bottom surface of the bottom plate of the heat sink are concave around to form a first step, the bottom opening of the housing is concave around to form a second step, the first step and the second step are combined to form a sealing ring groove, and the sealing ring is embedded in the sealing ring groove. The opening of the sealing ring groove is located in the visible area of the bottom surface of the capacitor, which can avoid missing the sealing ring.
[0009] As a preferred solution, two insulating sleeves and two busbars are further provided in the shell, and the insulating sleeves are provided with a plurality of slots for matching with the capacitor cores one by one. The slots penetrate the two end surfaces of the insulating sleeves along the width direction of the heat sink, and the two ends of the capacitor core pass through the outside of the heat sink from the two ends in the width direction of the base plate. The heat sink and all the capacitor cores are combined to form a square core module, and the two insulating sleeves are respectively embedded in the two ends of the core module through the slots. The outer end surfaces of the insulating sleeves are flush with the end surfaces of the core module. Metal layers are provided at both ends of the core module as lead-out electrodes of the core module, and the two lead-out electrodes of the core module are respectively welded to the two busbars.
[0010] As a preferred embodiment, the shell has a accommodating cavity with an opening at the top. After the core module, two insulating sleeves and two busbars are assembled, they are loaded into the accommodating cavity and encapsulated with epoxy resin. The connection terminals of the two busbars extend out of the accommodating cavity from the top opening of the accommodating cavity in the same direction, and the top opening of the accommodating cavity is sealed with epoxy resin.
[0011] As a preferred solution, the two busbars are separated by an insulating sheet.
[0012] The utility model has the following beneficial effects:
[0013] 1. The two sides of each capacitor core are tightly fitted with the heat sink of the heat sink. The heat generated by the capacitor core is transferred to the bottom plate through the heat sinks on both sides, which effectively reduces the temperature of the capacitor core and ensures the normal operation of the capacitor core.
[0014] 2. An opening is provided at the bottom of the shell to expose the bottom plate of the heat sink. The bottom plate of the heat sink is exposed. The bottom plate area of the heat sink is large, and its outer dimensions are only slightly smaller than the bottom size of the shell. When the capacitor is working, the bottom surface of the capacitor (that is, the bottom plate of the heat sink) is the cooling surface. The large exposed area of the bottom plate of the heat sink is conducive to rapid heat dissipation.
[0015] 3. After the core module, two insulating sleeves and two busbars are assembled, a module is formed, which is then placed in the shell for glue encapsulation. The module can be assembled automatically and then placed in the shell by a robot, thus realizing the automation of the entire capacitor assembly and improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Figure 1 It is a structural schematic diagram of a capacitor according to an embodiment of the utility model;
[0017] Figure 2 yes Figure 1 The internal structure assembly diagram of the capacitor after removing the outer shell;
[0018] Figure 3 yes Figure 2 An exploded view of the internal structure of a capacitor with the outer casing removed. DETAILED DESCRIPTION
[0019] The utility model is further described below in conjunction with the accompanying drawings and embodiments.
[0020] In the description of the present invention, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "top", "bottom", "inside", "outside", etc., indicating directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore should not be understood as a limitation on the present invention.
[0021] like Figures 1 to 3 As shown, this embodiment discloses a capacitor for new energy vehicles, including a housing 1, a plurality of capacitor cores 2, a heat sink 3, two insulating sleeves 4, two busbars 5, and a sealing ring.
[0022] like Figure 3 The heat sink 3 includes a base plate 31 and a plurality of heat sinks 32 vertically connected to the upper surface of the base plate 31 and spaced in a row along the length direction of the base plate 31, and a capacitor core 2 is inserted between each two adjacent heat sinks 32. The base plate 31 and the heat sink 32 can be integrally formed or assembled and connected, preferably integrally formed. The heat sink 3 is preferably made of aluminum and has good thermal conductivity. Since the two sides of each capacitor core 2 are tightly fitted with the heat sink 32 of the heat sink 3, the heat generated by the capacitor core 2 is conducted to the base plate 31 through the heat sinks 32 tightly attached on both sides, effectively reducing the temperature of the capacitor core 2 and ensuring the normal operation of the capacitor core 2. The several capacitor cores 2 described in this embodiment can be one, two or more capacitor cores 2.
[0023] The bottom plate 31 of the heat sink 3 is flush with the bottom surface of the housing 1, and an opening is provided at the bottom of the housing 1 to expose the bottom plate 31 of the heat sink 3. The outer dimensions of the bottom plate 31 of the heat sink 3 are only slightly smaller than the outer dimensions of the bottom of the housing 1, and the opening at the bottom of the housing 1 matches the bottom plate 31 of the heat sink 3, so that the bottom plate 31 of the heat sink 3 is exposed as much as possible. Therefore, the bottom plate 31 of the heat sink 3 serves as a cooling surface of the capacitor, and has a large exposed area, which is conducive to rapid heat dissipation.
[0024] The housing 1 is also provided with two insulating sleeves 4 and two busbars 5. The insulating sleeve 4 is provided with a plurality of slots 41 (the number of slots is consistent with the number of capacitor cores) for matching one by one with the capacitor core 2. The slots 41 penetrate the two end faces of the insulating sleeve 4 along the width direction of the heat sink 3. The two ends of the capacitor core 2 pass through the outside of the heat sink 3 from the two ends in the width direction of the bottom plate 31. The heat sink 3 and all the capacitor cores 2 are combined to form a square core module. The two insulating sleeves 4 are respectively embedded in the two ends of the core module through the slots 41. The outer end faces of the insulating sleeves 4 are flush with the end faces of the core module. The two ends of the core module are provided with metal layers 6 as the lead-out electrodes of the core module. The two lead-out electrodes of the core module are respectively welded to the two busbars 5. The metal layer 6 connects multiple "blade" type cores in parallel to form a square core group. The two busbars are separated by an insulating sheet 9.
[0025] The metal layer 6 can be formed by spraying, electroplating, etc. a metal film on the end face of the core module with metal powder, and the outer end face of the insulating sleeve 4 is flush with the end face of the core module, and after spraying the metal powder, a metal layer 6 covering the entire end face of the insulating sleeve 4 is formed. In other embodiments, the metal layer 6 can also be a metal sheet.
[0026] The insulating sleeve 4 is preferably an integrally formed plastic part, and is used to separate adjacent capacitor cores 2 .
[0027] The housing 1 has a receiving cavity 8 with an opening at the top. The core module, two insulating sleeves 4 and two busbars 5 are assembled and loaded into the receiving cavity 8 and encapsulated by epoxy resin 7. The connection terminals 51 of the two busbars 5 extend out of the receiving cavity 8 from the top opening of the receiving cavity 8 in the same direction. The epoxy resin 7 seals the top opening of the receiving cavity 8. The core module, two insulating sleeves 4 and two busbars 5 are assembled to form a module, which is then loaded into the housing 1 for glue encapsulation. The module can be assembled automatically and then loaded into the housing 1 by a robot, so as to realize the automation of the entire capacitor assembly and improve production efficiency.
[0028] The bottom plate 31 of the heat sink 3 matches the opening at the bottom of the accommodating cavity 8, and the opening at the bottom of the accommodating cavity 8 (that is, the opening at the bottom of the housing 1 mentioned above) exposes the heat sink 3. The bottom plate 31 of the heat sink 3 and the bottom opening of the accommodating cavity 8 are sealed by a sealing ring. Specifically, the edges of the bottom surface of the bottom plate 31 are concave to form a first step, and the bottom opening of the accommodating cavity 8 is concave to form a second step. The first step and the second step are combined to form a sealing ring groove, and the sealing ring is embedded in the sealing ring groove, thereby closing the gap between the bottom plate 31 and the housing 1. Of course, the setting of the sealing ring groove is not limited to this. For example, the sealing ring groove can be separately set on the side of the housing 1 or the bottom plate 31 of the heat sink 3. The sealing ring is installed first, and then the capacitor core 2, the heat sink 3, etc. are installed in the accommodating cavity 8. The bottom plate 31 of the heat sink 3 is exposed. When the capacitor is working, the bottom surface of the capacitor (that is, the bottom plate 31 of the heat sink 3) is the cooling surface. The heat generated by the capacitor core 2 is conducted to the cooling surface through the heat dissipation aluminum plates tightly attached on both sides, effectively reducing the temperature of the capacitor core 2 and ensuring the normal operation of the capacitor core 2.
[0029] The capacitor of the present invention is designed with a plurality of "blade" type capacitor cores 2 (the capacitor core 2 is thin, that is, the size along the length direction of the bottom plate 31 is small, and multiple capacitor cores 2 are arranged side by side to make the structure compact, and the side area of the capacitor core 2 is large, that is, the contact surface with the heat sink 32 is large, which is conducive to heat dissipation). Each "blade" type capacitor core 2 is embedded in the heat sink in an orderly manner according to the design requirements. The "blade" type capacitor core 2 is closely fitted with the heat sink to form a square core module. The insulating sleeve 4 is embedded at both ends of the core module, and one end face of the insulating sleeve 4 is flush with the end face of the capacitor core 2. The metal layer 6 is sprayed on both ends of the core module as the lead-out electrode of the core module. The two lead-out electrodes of the core module are connected to the busbar 5 by welding. The capacitor module welded with the busbar 5 is embedded in the shell 1, and a sealing ring is embedded in the sealing groove formed by the shell 1 and the heat dissipation aluminum plate at the bottom. The epoxy resin 7 is filled in the cavity of the shell 1 to complete the packaging of the capacitor.
[0030] As described above, the embodiments are only used to illustrate the technical solutions of the utility model, rather than to limit it. Although the utility model has been described in detail with reference to the aforementioned embodiments, ordinary technicians in the field should understand that they can still modify the technical solutions recorded in the aforementioned embodiments, or replace some of the technical features therein with equivalents. These modifications or replacements do not make the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the utility model. Therefore, all other embodiments obtained by ordinary technicians in the field without making creative work belong to the protection scope of the utility model.
Claims
1. A capacitor for new energy vehicles, characterized in that: It comprises a housing, a heat sink and a plurality of capacitor cores arranged in the housing, wherein the heat sink comprises a bottom plate and a plurality of heat sinks vertically connected to the upper surface of the bottom plate and arranged in a row along the length direction of the bottom plate, a capacitor core is inserted between every two adjacent heat sinks, and two sides of the capacitor core are respectively tightly fitted with the two heat sinks; Two insulating sleeves are also provided in the shell, and the insulating sleeves are provided with a plurality of slots for matching with the capacitor cores one by one. The slots penetrate the two end surfaces of the insulating sleeves along the width direction of the heat sink, and the two ends of the capacitor core pass through the outside of the heat sink from the two ends in the width direction of the bottom plate. The heat sink and all the capacitor cores are combined to form a square core module. The two insulating sleeves are respectively embedded in the two ends of the core module through the slots. The outer end surfaces of the insulating sleeves are flush with the end surfaces of the core module. Metal layers are provided at both ends of the core module as lead-out electrodes of the core module.
2. The capacitor for new energy vehicles according to claim 1, characterized in that: The bottom plate of the heat sink is flush with the bottom surface of the shell, and an opening is provided at the bottom of the shell to expose the bottom plate of the heat sink.
3. The capacitor for new energy vehicles according to claim 2, characterized in that: The gap between the bottom opening of the housing and the bottom plate of the heat sink is sealed by a sealing ring.
4. The capacitor for new energy vehicles according to claim 3, characterized in that: The edges of the bottom surface of the bottom plate of the heat sink are concave around to form a first step, and the bottom opening of the shell is concave around to form a second step. The first step and the second step are combined to form a sealing ring groove, and the sealing ring is embedded in the sealing ring groove.
5. The capacitor for new energy vehicles according to claim 1, characterized in that: Two busbars are also arranged in the shell, and two lead-out electrodes of the core module are respectively welded to the two busbars.
6. The capacitor for new energy vehicles according to claim 5, characterized in that: The shell has a housing cavity with an opening at the top. The core module, two insulating sleeves and two busbars are assembled and loaded into the housing cavity and encapsulated by epoxy resin. The connection terminals of the two busbars extend out of the housing cavity from the top opening of the housing cavity in the same direction, and the top opening of the housing cavity is sealed with epoxy resin.
7. The capacitor for new energy vehicles according to claim 5, characterized in that: The two busbars are separated by an insulating sheet.