Alternating current busbar, power module, electronic equipment and vehicle

Abstract

The utility model discloses an AC busbar, a power module, an electronic device and a vehicle, and the AC busbar comprises an AC terminal; a current sensor for detecting a current flowing through the AC terminal; and the plastic package shell wraps the alternating current terminal and the current sensor, and the input end and the output end of the alternating current terminal both extend out of the plastic package shell. According to the alternating current busbar, the independent plastic package of the alternating current terminal and the current sensor is realized, the integration level is high, the occupied internal space of the power module is reduced, the relative position of the current sensor is fixed, the measurement error is reduced, and the risk of burning the power chip is avoided when the current sensor is calibrated.

Description

Technical Field

[0001] The utility model relates to the technical field of semiconductors, in particular to an AC busbar, a power module, an electronic device and a vehicle. Background Art

[0002] In the electric drive system of new energy vehicles, in order to realize the current detection function inside the power semiconductor module, some power modules use current sensors based on the principle of magnetic current sensing. This type of current sensor is directly encapsulated inside the power module during the power module manufacturing process, which occupies a large space inside the power module and is inconvenient to install, resulting in large assembly errors of the current sensor, thus causing large measurement errors, and there is a risk of burning the power chip in the power module when calibrating the current sensor for large currents. Utility Model Content

[0003] The utility model aims to solve at least one of the technical problems existing in the prior art. To this end, one purpose of the utility model is to propose an AC busbar, which realizes the separate plastic packaging of AC terminals and current sensors, has high integration, reduces the internal space occupied by the power module, makes the relative position of the current sensor fixed, reduces the measurement error, and avoids the risk of burning the power chip when calibrating the current sensor.

[0004] The second objective of the present invention is to provide a power module.

[0005] The third objective of the present invention is to provide an electronic device.

[0006] A fourth objective of the present invention is to provide a vehicle.

[0007] In order to achieve the above-mentioned purpose, the AC busbar of the first aspect of the utility model embodiment includes: an AC terminal; a current sensor, used to detect the current flowing through the AC terminal; a plastic shell, the plastic shell wraps the AC terminal and the current sensor, and the input end and the output end of the AC terminal both extend out of the plastic shell.

[0008] According to the AC busbar of the embodiment of the utility model, a plastic-sealed shell is used to wrap the AC terminal and the current sensor, wherein the input and output ends of the AC terminal both extend out of the plastic-sealed shell, that is, the current sensor and the AC terminal are separately plastic-sealed to form a compact overall structure, which can reduce the space occupied inside the power module and has a high degree of integration. In addition, this separate packaging design makes the current sensor easier to install, reduces assembly errors, and further reduces measurement errors, thereby improving the accuracy and stability of current detection. When calibrating the current sensor, the independent plastic sealing of the current sensor effectively isolates other components in the power module, reducing the risk of burning the power chip.

[0009] In some embodiments, the AC terminal is configured with a first through hole along a thickness direction; the current sensor is inserted into the first through hole, and the current sensor is insulated from the AC terminal.

[0010] In some embodiments, the plastic-encapsulated housing is constructed with: a limiting portion, which is suitable for limiting the AC busbar at an installation position.

[0011] In some embodiments, the limiting portion includes a housing cavity with openings at both ends along the length direction of the AC terminal; the AC terminal passes through the housing cavity, and the input end and the output end of the AC terminal extend out of the housing cavity through the openings at both ends respectively.

[0012] In some embodiments, a protrusion is configured at an exit of the accommodating cavity corresponding to the exit side of the AC terminal, for fixing the AC terminal.

[0013] In some embodiments, along the thickness direction of the AC terminal, a second through hole is configured on the upper cavity wall of the accommodating cavity at a position corresponding to the first through hole, and a portion of the current sensor extends out of the accommodating cavity through the second through hole.

[0014] In some embodiments, the current sensor includes a substrate, a detection chip and a signal lead-out terminal, and the detection chip and the signal lead-out terminal are both located on the substrate; the substrate is vertically inserted into the first through-hole; the detection chip includes a first detection chip and a second detection chip, and in the thickness direction of the AC terminal, the first detection chip and the second detection chip are symmetrically arranged with respect to the center line of the AC terminal to sense the current flowing through the AC terminal; one end of the substrate and the signal lead-out terminal extend out of the accommodating cavity through the second through-hole, and the signal lead-out terminal is used to be electrically connected to an external drive control board.

[0015] In some embodiments, the gap between the current sensor and the AC terminal in the accommodating cavity is filled with a portion of the plastic package shell.

[0016] In some embodiments, at least one corner of the accommodating cavity is configured with a step.

[0017] In some embodiments, the limiting portion further includes: an extending portion, the extending portion and the accommodating cavity are connected to each other, and along the width direction of the AC terminal, the extending portion is located at one side of the accommodating cavity.

[0018] In some embodiments, in the thickness direction of the AC terminal, the upper surface of the extension portion is flush with the upper surface of the accommodating cavity, and the thickness of the extension portion is smaller than the thickness of the accommodating cavity; in the length direction of the AC terminal, the width of the extension portion is smaller than the width of the accommodating cavity.

[0019] In some embodiments, the plastic package shell is further configured with: a first fixing portion, which is located on the limiting portion and is used to fix the AC busbar and the power module.

[0020] In some embodiments, the first fixing portion includes: a first card slot, which is arranged on the outer surface of the upper cavity wall of the accommodating cavity, and in the width direction of the AC terminal, the first card slot is located on a side of the second through hole away from the extension portion.

[0021] In some embodiments, the first fixing portion includes: a first elastic buckle, and the first elastic buckle is located on the bottom surface of the extending portion.

[0022] In some embodiments, the first elastic buckle includes four evenly distributed hook structures.

[0023] In some embodiments, in the thickness direction of the AC terminal, the input end of the AC terminal is bent toward the bottom surface of the plastic package shell.

[0024] In order to achieve the above-mentioned purpose, the power module of the second embodiment of the utility model includes: an AC busbar as described in the above embodiment; and a plastic-sealed outer frame, wherein the plastic-sealed outer frame is configured with an installation structure at an installation position corresponding to the AC busbar to assemble the AC busbar.

[0025] According to the power module of the embodiment of the utility model, a compact overall structure is formed by first separately sealing the current sensor and the AC terminal with a plastic-sealed shell, and the plastic-sealed outer frame is constructed with a mounting structure at the mounting position corresponding to the AC busbar to ensure that the AC busbar can be correctly installed on the power module, thereby reducing the occupied space inside the power module and improving the integration of the power module. In addition, the separate packaging design makes the current sensor easier to install, reduces assembly errors, and further reduces measurement errors, thereby improving the accuracy and stability of current detection. When calibrating the current sensor, due to the independent plastic sealing of the current sensor, other components in the power module are effectively isolated, reducing the risk of burning the power chip.

[0026] In some embodiments, the plastic-encapsulated shell of the AC busbar is constructed with a limiting portion for limiting the AC busbar at the installation position; the installation structure includes a limiting groove, and the limiting groove is matched with the limiting portion.

[0027] In some embodiments, the plastic-encapsulated shell of the AC busbar is configured with a first fixing portion for fixing the AC busbar and the power module; the mounting structure includes a second fixing portion, and the second fixing portion is matched with the first fixing portion.

[0028] In some embodiments, the first fixing portion includes a first card slot; the second fixing portion includes a second elastic card buckle, the second elastic card buckle is located on one side of the limiting slot, and the second elastic card buckle is matched and connected with the first card slot.

[0029] In some embodiments, the first fixing portion includes a first elastic buckle; the second fixing portion includes a second clip groove, the second clip groove is arranged opposite to the second elastic buckle, and the second clip groove is matched and connected with the first elastic buckle.

[0030] In some embodiments, the power module also includes: a metal-clad ceramic substrate, the conductive layer of the metal-clad ceramic substrate is provided with multiple conductive areas; the IGBT chip, the FRD chip, the temperature sensor and the drive control signal pin are all arranged on the metal-clad ceramic substrate, and the IGBT chip, the FRD chip and the temperature sensor are respectively connected to the corresponding conductive areas.

[0031] In some embodiments, the power module further includes: a heat dissipation base plate, the metal-clad ceramic substrate is located on the heat dissipation base plate, and the plastic package frame surrounds the heat dissipation base plate.

[0032] In order to achieve the above object, an electronic device according to an embodiment of the third aspect of the utility model includes at least one power module as described in the above embodiment.

[0033] According to the electronic device of the embodiment of the utility model, by adopting the power module described in the above embodiment, the power module is first separately sealed with the current sensor and the AC terminal before assembly to form a compact overall structure, which can reduce the space occupied inside the power module and has high integration. In addition, this separate packaging design makes the current sensor easier to install, reduces assembly errors, and further reduces measurement errors, thereby improving the accuracy and stability of current detection. When calibrating the current sensor, due to the independent plastic sealing of the current sensor, other components in the power module are effectively isolated, reducing the risk of burning the power chip.

[0034] In order to achieve the above-mentioned object, a vehicle according to an embodiment of the fourth aspect of the utility model comprises at least one power module as described in the above embodiment.

[0035] According to the vehicle of the embodiment of the utility model, by adopting the power module described in the above embodiment, before assembling the power module, the current sensor and the AC terminal are separately sealed to form a compact overall structure, which can reduce the space occupied inside the power module and has high integration. In addition, this separate packaging design makes the current sensor easier to install, reduces assembly errors, and further reduces measurement errors, improves the accuracy and stability of current detection, and when calibrating the current sensor, due to the independent plastic sealing of the current sensor, other components in the power module are effectively isolated, reducing the risk of burning the power chip, thereby improving the overall performance of the vehicle.

[0036] Additional aspects and advantages of the present invention will be given in part in the following description, and in part will become apparent from the following description, or will be learned through the practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] The above and / or additional aspects and advantages of the present invention will become apparent and easily understood from the description of the embodiments in conjunction with the following drawings, in which:

[0038] Figure 1 It is a front schematic diagram of an AC busbar according to an embodiment of the utility model;

[0039] Figure 2 is a schematic diagram of the back side of an AC busbar according to an embodiment of the utility model;

[0040] Figure 3 This is a schematic diagram of the position of a current sensor in an AC busbar according to an embodiment of the utility model;

[0041] Figure 4 is a schematic structural diagram of a power module according to an embodiment of the utility model;

[0042] Figure 5 It is a schematic diagram of a power module before an AC busbar and a current sensor are installed according to an embodiment of the utility model;

[0043] Figure 6 This is a front exploded view of a power module assembled with an AC busbar according to an embodiment of the utility model;

[0044] Figure 7 This is an exploded view of the back of a power module assembled with an AC busbar according to an embodiment of the utility model;

[0045] Figure 8 is a block diagram of an electronic device according to an embodiment of the utility model;

[0046] Fig. 9 is a block diagram of a vehicle according to an embodiment of the present utility model.

[0047] Reference numerals:

[0048] Vehicle 100;

[0049] Electronic device 110;

[0050] Power module 111;

[0051] AC busbar 1; plastic-sealed outer frame 2; metal-clad ceramic substrate 3; IGBT chip 4; FRD chip 5; temperature sensor 6; drive control signal pin 7; heat dissipation base plate 10;

[0052] Limiting groove 21; second elastic buckle 22; second clamping groove 23;

[0053] AC terminal 11; current sensor 12; plastic package housing 13;

[0054] The substrate 121 , the detection chip 122 , the signal lead-out terminal 123 , the step 131 , the protruding portion 132 , the first slot 133 , the first elastic buckle 134 , and the extension portion 135 . DETAILED DESCRIPTION

[0055] The embodiments of the present utility model are described in detail below. The embodiments described with reference to the accompanying drawings are exemplary. The embodiments of the present utility model are described in detail below.

[0056] Reference below Figure 1-Figure 3 An AC busbar according to an embodiment of the utility model is described.

[0057] Figure 1 is a front view of an AC busbar according to an embodiment of the utility model. Figure 2 is a schematic diagram of the back side of an AC busbar according to an embodiment of the utility model, such as Figure 1 and Figure 2 As shown, the AC busbar 1 includes: an AC terminal 11 , a current sensor 12 and a plastic package housing 13 .

[0058] Among them, the AC terminal 11 can be an interface for connecting a drive motor or other electrical equipment in a circuit, and the main function of the AC terminal 11 can be to provide an electrical connection interface. The input and output ends of the AC terminal 11 both extend out of the plastic housing 13. This design enables the AC busbar 1 to be easily connected to other electrical systems and equipment, thereby realizing the input or output of current, improving the connectivity and operability of the entire system. This also helps maintenance personnel to perform maintenance, overhaul or replacement work more conveniently, thereby improving the maintainability of the system.

[0059] In some embodiments, the current sensor 12 may be a device for detecting the current flowing through the AC terminal 11, which can convert the current into a signal that can be measured or read. The current sensor 12 may include various types of sensors, such as a Hall sensor, a magnetoresistive sensor, etc. The current sensor 12 may be a vertical insertion type integrated structure, which has the advantages of simple structure, easy installation, stability and reliability. The current sensor 12 may be configured to generate a signal by responding to the magnetic field generated by the current flowing in the AC busbar 1, and the magnitude of the signal is proportional to the amount of current flowing in the AC busbar 1. Such a design makes current detection more accurate. In the AC busbar 1, the current sensor 12 plays the role of real-time monitoring of current and providing current information, providing important data for the operation and control of the system.

[0060] In some embodiments, the plastic package housing 13 may be an external packaging structure, which is used to wrap the AC terminal 11 and the current sensor 12, and protect and isolate the internal components, thereby preventing the AC terminal 11 and the current sensor 12 from being damaged by the external environment, such as moisture, dust, touch, etc. In addition, the plastic package housing 13 also helps to fix the relative positions of the internal components and maintain the stability of the electrical connection.

[0061] In some embodiments, the plastic housing 13 may be made of materials with high insulation properties such as plastic, rubber, polymer materials (such as polypropylene, polyurethane), or materials with special properties such as high temperature resistance and flame retardancy to ensure a safe and reliable working environment.

[0062] Taking the motor controller as an example, the power module is an important component of the motor controller, in which the AC busbar 1 can be used as the motor input terminal, and the current sensor 12 is used to monitor the current. The plastic shell 13 wraps the AC terminal 11 and the current sensor 12 together, and uses a highly insulating polymer material to ensure safety.

[0063] According to the AC busbar 1 of the embodiment of the utility model, the AC terminal 11 and the current sensor 12 are wrapped with a plastic shell 13, wherein the input end and the output end of the AC terminal 11 both extend out of the plastic shell 13. This design enables the current sensor 12 and the AC terminal 11 to be separately plastic-sealed first in the process of manufacturing the power module 111, forming a compact overall structure, effectively reducing the overall occupied space, and having a high degree of integration. Moreover, this separate packaging design enables the position of the current sensor 12 relative to the AC busbar 1 to be fixed, avoiding relative position changes that may occur during use. This relative position fixity helps to reduce measurement errors and improve the accuracy and stability of current detection. During the calibration process, due to the independent plastic sealing of the current sensor 12, other components are effectively isolated, reducing the risk of chip burning.

[0064] According to the AC busbar 1 of the embodiment of the utility model, a plastic-encapsulated shell 13 is used to wrap the AC terminal 11 and the current sensor 12, wherein the input end and the output end of the AC terminal 11 both extend out of the plastic-encapsulated shell 13, that is, the current sensor 12 and the AC terminal 11 are separately plastic-encapsulated to form a compact overall structure, which can reduce the space occupied inside the power module and has a high degree of integration. In addition, this separate packaging design makes the current sensor 12 easier to install, reduces assembly errors, and further reduces measurement errors, thereby improving the accuracy and stability of current detection. When calibrating the current sensor 12, due to the independent plastic packaging of the current sensor 12, other components in the power module are effectively isolated, reducing the risk of burning the power chip.

[0065] In some embodiments, Figure 3 As shown, the AC terminal 11 is configured with a first through hole along the thickness direction, and the function of the through hole can be to provide a channel for inserting the current sensor 12, so that the current sensor 12 can be connected to the AC terminal 11. The design of the first through hole can be optimized, for example, a special shape or structure can be adopted to improve the stability of sensor insertion and fixation.

[0066] In some embodiments, the current sensor 12 is inserted into the first perforation of the AC terminal 11, which means that the current sensor 12 can be easily inserted into the AC terminal 11 through the perforation to achieve electrical connection between the two. This feature enables the current sensor 12 to be compactly embedded in the AC busbar 1, which contributes to the compactness and integration of the overall structure. The current sensor 12 is insulated from the AC terminal 11 to ensure that no electrical short circuit occurs when they are inserted and connected. This insulation setting can be achieved by using a plastic package housing 13, thereby ensuring that there is electrical insulation isolation between the current sensor 12 and the AC terminal 11.

[0067] like Figure 1 As shown, the plastic housing 13 is structured with a limiting portion. The limiting portion is suitable for limiting the AC busbar 1 at the installation position. This means that during the assembly process, the limiting portion plays a role in positioning and fixing the position, ensuring that the AC busbar 1 is correctly installed in the power module or other equipment. Such a design helps prevent movement or shaking during use, ensuring the stability and reliability of the system.

[0068] In some embodiments, the design of the stopper can adopt a special shape or structure, such as a protrusion, a groove or other structure, and its shape and size match the installation position to ensure coordination with other components in the overall assembly, which can prevent errors in the assembly of the AC busbar 1 and ensure that it is safely and stably installed in the required position. In addition, the material selection of the stopper can also take into account its strength, wear resistance and other characteristics to ensure that it maintains good performance during long-term use.

[0069] In some embodiments, Figure 1 As shown, the limiting portion includes a accommodating cavity with openings at both ends along the length direction of the AC terminal 11. The shape and size of this cavity are adapted to the appearance of the AC terminal 11, so that the AC terminal 11 can pass through the accommodating cavity. In this way, the limiting portion and the AC terminal 11 form an integrated structure. This design is not only conducive to the fixation of the AC terminal 11, but also ensures that the AC terminal 11 can pass through the inside of the limiting portion, which provides convenience for connecting other devices or systems. In addition, the input end and the output end of the AC terminal 11 extend out of the accommodating cavity through the openings at both ends respectively. This design not only allows the AC terminal 11 to be connected to other electrical equipment, but also ensures that the opening of the accommodating cavity limits the AC terminal 11 well.

[0070] In some embodiments, the opening of the accommodating cavity may adopt a special shape, such as a gradual opening or an expanding opening, to ensure a more accurate match between the accommodating cavity and the AC terminal 11. The material of the accommodating cavity may have a certain toughness and wear resistance to ensure that the AC terminal 11 is not easily damaged during the process of passing through and extending.

[0071] In some embodiments, a protrusion 132 is configured at the exit of the corresponding AC terminal 11 of the accommodating cavity. The main function of the protrusion 132 can be to provide a stable support point for fixing the AC terminal 11 to prevent the AC terminal 11 from changing its position inside the AC busbar 1. This is crucial for maintaining the relative position of the current sensor 12 and other components, and helps maintain the stability of the entire system. The shape and size of the protrusion 132 can be adjusted according to the needs of the design to ensure that the AC terminal 11 can be firmly fixed. The protrusion 132 is usually made of a strong and durable material to ensure that it has sufficient strength and durability. This can be plastic, metal or other suitable material.

[0072] In some embodiments, along the thickness direction of the AC terminal 11, a second perforation is constructed on the upper cavity wall of the accommodating cavity at a position corresponding to the first perforation, and this position corresponds to the first perforation. This design helps a portion of the current sensor 12 to extend through the second perforation and connect to the AC terminal 11. This portion can be a measuring element of the current sensor 12 or other portion that requires external contact or observation. The shape and size of the second perforation can be optimized to ensure that a portion of the current sensor 12 can pass through smoothly, while providing sufficient support to ensure the firmness of the connection. Through the second perforation, the connection of the current sensor 12 can not only maintain relative fixity, but also be adjusted to a certain extent when necessary, thereby improving the flexibility and adaptability of the connection.

[0073] like Figure 3As shown, the current sensor 12 includes a substrate 121 , a detection chip 122 and a signal lead-out terminal 123 .

[0074] The substrate 121 is the main structure of the current sensor 12, which is usually a flat plate or sheet made of conductive material, and plays the role of supporting and carrying other key components. The detection chip 122 and the signal lead terminal 123 can be welded on the substrate 121. Moreover, it is inserted into the first through hole of the AC terminal 11 in the vertical direction, ensuring the close connection between the current sensor 12 and the AC terminal 11, which helps to improve the accuracy of the detection.

[0075] In some embodiments, the detection chip 122 is a sensor element in the current sensor 12, and generally includes a sensing device related to current changes, such as a Hall chip. The detection chip 122 includes a first detection chip and a second detection chip. In the thickness direction of the AC terminal 11, the first detection chip and the second detection chip are symmetrically arranged with respect to the center line of the AC terminal 11 to sense the current flowing through the AC terminal 11. They are responsible for converting current changes into electrical signals, thereby realizing accurate detection and measurement of current.

[0076] In some embodiments, the Hall chip can be an electronic component based on the Hall effect. The Hall effect means that when current passes through a conductor, if a magnetic field is applied to the conductor perpendicular to the current direction, a voltage difference will be generated on both sides of the conductor. This voltage difference is called the Hall voltage. The Hall chip uses this effect to detect current, magnetic field or position by measuring the Hall voltage. In the application in the AC busbar 1, the Hall chip can be used to detect the current flowing through the AC terminal 11. When the current passes through the busbar, the magnetic field generated affects the Hall chip, resulting in a change in the Hall voltage, thereby realizing the detection of the current.

[0077] In some embodiments, the signal lead-out terminal 123 is perpendicular to the substrate 121, and the signal lead-out terminal 123 can be an interface connecting the current sensor 12 with an external system, such as a signal lead-out pin, which is used to lead out the signal measured by the current sensor 12 for connection to other devices or systems. These pins are usually made of metal materials and have specific shapes and sizes so as to be inserted or connected to corresponding connectors or sockets. One end of the substrate 121 and the signal lead-out terminal 123 extend out of the accommodating cavity through the second perforation, and the signal lead-out terminal 123 is used to be electrically connected to an external drive control board, thereby realizing current detection on the AC busbar 1, and converting it into an electrical signal output to the external motor drive control board for further processing and control. This connection method helps to realize the timely transmission of current detection information and its integration into the entire system.

[0078] In some embodiments, the gap between the current sensor 12 and the AC terminal 11 located in the accommodating cavity is filled with part of the plastic shell 13 to ensure good insulation and packaging effects, prevent moisture, dust or other harmful substances in the external environment from invading, thereby protecting the current sensor 12 and the AC terminal 11 from damage.

[0079] Therefore, the design of the plastic package housing 13 should ensure that the filling part can completely cover and fill the gap between the current sensor 12 and the AC terminal 11, ensuring the uniformity and integrity of the filling. By filling the gap, the plastic package housing 13 not only provides physical protection, but also improves the electrical insulation performance. This is crucial to ensure the reliability of the insulation between the current sensor 12 and the AC terminal 11.

[0080] In some embodiments, at least one corner of the accommodating cavity is configured with a step 131. The presence of the step 131 strengthens the structure of the accommodating cavity at the corner, making it more solid. This helps to reduce the risk of deformation of the structure when it is subjected to external impact or vibration during use. The step 131 can also provide better support and positioning, ensuring that the relative position of internal components (such as the AC terminal 11 and the current sensor 12) is more stable, thereby reducing position changes caused by vibration or other factors during operation.

[0081] In some embodiments, the design of the step 131 structure has certain processing and manufacturing advantages during the manufacturing process. For example, the construction of the step 131 can be easily achieved by methods such as injection molding or mold casting. The shape and size of the step 131 can be adjusted according to specific needs to adapt to different design and process requirements. For example, it can be designed to be rectangular, trapezoidal, wedge-shaped or serrated, which is determined by the shape and structure of the accommodating cavity. This design helps to provide more flexible options in different application scenarios.

[0082] In some embodiments, the limiting portion includes not only a receiving cavity opened along the length direction of the AC terminal 11, but also an extension portion 135. Such a design introduces an additional extension portion 135 into the structure of the AC busbar 1, and the extension portion 135 is connected to the receiving cavity and is located on one side of the receiving cavity along the width direction of the AC terminal 11. The existence of the extension portion 135 can provide a certain support effect, which helps the limiting portion to maintain the stability of shape and position during installation and use. The addition of the extension portion 135 can also be optimized in structure, making the entire AC busbar 1 more uniform in appearance and more stable in structure. In addition, the shape of the extension portion 135 can be designed according to different requirements, and different geometric shapes can be selected, such as rectangle, cone, etc.

[0083] Therefore, by introducing the extension portion 135 into the limiting portion, the structural stability, directionality and overall appearance of the AC busbar 1 can be adjusted to make it more suitable for different application scenarios, which helps to improve the performance and reliability of the AC busbar 1.

[0084] In some embodiments, the extension 135 has specific dimensions and positional relationships in the thickness direction and length direction of the AC terminal 11. In the thickness direction of the AC terminal 11, the upper surface of the extension 135 is flush with the upper surface of the accommodating cavity, and the thickness of the extension 135 is less than the thickness of the accommodating cavity. This design is intended to ensure the limiting effect of the limiting portion in the thickness direction while avoiding excessive increase in the overall height. In the length direction of the AC terminal 11, the width of the extension 135 is less than the width of the accommodating cavity, ensuring that the extension 135 does not interfere with adjacent components or structures during connection and limiting, and making the AC busbar 1 easier to integrate in a limited space. Therefore, by adjusting the size and positional relationship of the extension 135 in the thickness and length directions, a more compact and stable limiting effect can be achieved in a limited space. This helps to improve the overall performance and applicability of the AC busbar 1.

[0085] In some embodiments, the plastic housing is further configured with a first fixing portion, which is disposed on the limiting portion. The purpose of such a design is to make full use of the structure of the limiting portion to achieve dual functions in the same area, including both limiting and fixing functions. The existence of the first fixing portion provides support and positioning for the fixing of the AC busbar 1 and the power module 111. By cooperating with the corresponding structure on the power module, a reliable fixing effect is achieved, ensuring a stable connection between the AC busbar 1 and the power module.

[0086] In addition, the provision of the first fixing portion not only helps prevent the relative movement of the AC busbar 1 during use, but also helps enhance the stability of the overall structure. This is essential for reliable operation under vibration, impact and other environments. By reasonably designing the shape, size and position of the first fixing portion, its role in fixing and supporting can be fully utilized to ensure that the requirements for a firm connection between the AC busbar 1 and the power module can be met under different working conditions.

[0087] like Figure 1 and Figure 2 As shown, the first fixing portion includes a first slot 133 and a first elastic buckle 134. The first slot 133 can be an open slot design, which cooperates with the protrusions or buckles of other components to ensure a safe and reliable connection. The first slot 133 is arranged on the outer surface of the upper cavity wall of the accommodating cavity, which means that the first slot 133 is located above the accommodating cavity, which helps to prevent the components in the accommodating cavity from relative displacement. In the width direction of the AC terminal 11, the first slot 133 is located on the side of the second perforation away from the extension portion 135.

[0088] Therefore, the provision of the first slot 133 helps to position and fix the AC busbar 1, ensuring that it maintains the correct position and a firmly connected state during the installation process. The position arrangement of the first slot 133 relative to the second perforation and the extension 135 may be coordinated with the layout and connection requirements of other components to ensure the coordinated operation of the overall system. In addition, the presence of the first slot 133 makes the installation and disassembly of the AC busbar 1 more convenient, which helps to maintain and replace components. In an embodiment, the shape and size of the first slot 133 can be designed and optimized to ensure that it can effectively work with other fixed structures to improve the overall performance of the system.

[0089] In some embodiments, the first elastic buckle 134 can be made of an elastic material, such as elastic plastic, to ensure a certain degree of deformation and elasticity during connection. The first elastic buckle 134 is located on the bottom surface of the extension portion 135. By being arranged on the bottom surface, the first elastic buckle 134 provides a certain elastic damping when in contact with other structures, forming an elastic locking effect to ensure the firmness of the fixation. The presence of the first elastic buckle 134 enhances the fixation of the AC busbar 1 and the power module. By providing an elastic connection method, it can provide a certain resistance during fixation to ensure a firm connection. At the same time, its elastic characteristics also make it relatively easy for the AC busbar 1 to be installed in or removed from the power module, thereby improving the convenience of maintenance and replacement of components.

[0090] In some embodiments, Figure 2 As shown, the portion of the first elastic buckle 134 extending out of the plastic package shell 13 can be four evenly distributed elastic hook structures. Such a design helps to balance the force of the connection point and provide a more stable fixing effect. The evenly distributed hook structure can evenly apply force during connection, reduce the pressure on a single connection point, and improve the firmness of the connection. In addition, the elastic hook structure can be a structure that can be deformed within a certain range, providing a certain pressure or resistance through elastic deformation. This structure can generate a certain elastic force during connection, making the connection tighter and helping to prevent accidental falling off.

[0091] In some embodiments, in the thickness direction of the AC terminal 11, the input end of the AC terminal 11 is bent toward the bottom surface of the plastic package shell, which can achieve a more compact overall design. This helps to reduce the occupied space of the device and improve the integration. In addition, the bent structure of the input end of the AC terminal 11 can also provide a certain stability, help maintain the relative position of the input end, and reduce the relative position change that may occur during use.

[0092] Reference below Figure 4 A power module according to an embodiment of the present invention is described.

[0093] Figure 4 is a schematic diagram of the structure of a power module according to an embodiment of the utility model, such as Figure 4 As shown, the power module 111 includes: the AC busbar 1 and the plastic package frame 2 described in the above embodiment.

[0094] Among them, the AC busbar 1 may include components such as the AC terminal 11, the current sensor 12 and the plastic shell 13 described in the above embodiment. The AC terminal 11 is used for electrical connection, the current sensor 12 is used to detect the current flowing through the AC terminal 11, and the plastic shell 13 wraps the AC terminal 11 and the current sensor 12 to provide protection and isolation functions.

[0095] In some embodiments, the plastic outer frame 2 can be the outer frame of the power module 111 body, which is used to protect and fix the internal components. The plastic outer frame 2 is constructed with a mounting structure at the mounting position corresponding to the AC busbar 1. This structural design is intended to ensure the assembly and fixation of the AC busbar 1 and ensure its correct position in the power module 111. The design of the plastic outer frame 2 can match the AC busbar 1 to form a compact overall structure, which helps to reduce the occupied space of the power module 111 and improve the integration. The design of the mounting structure can make it easier to install the AC busbar 1 into the power module 111 during the manufacturing process, thereby improving the convenience of assembly.

[0096] In some embodiments, the mounting structure of the plastic outer frame 2 can be in various forms, such as a slot or other appropriate structure, to ensure accurate positioning and firm connection of the AC busbar 1 in the module. By embedding the AC busbar 1 in the mounting structure, the plastic outer frame 2 is assembled with the AC busbar 1, ensuring a firm connection between them. This contributes to the stability and reliability of the entire power module 111, and provides a simple and effective way to make the AC busbar 1 work in coordination with other components of the power module 111.

[0097] In some embodiments, the plastic housing 13 of the AC busbar 1 is configured to have a limiting portion, which is designed to limit the AC busbar 1 at the installation position of the power module 111 by cooperating with the installation structure.

[0098] Figure 5 Schematic diagram of a power module before AC busbar and current sensor are installed according to an embodiment of the utility model. Figure 5As shown, the installation structure includes a limiting groove 21, which is designed to match the limiting portion on the plastic housing 13 of the AC busbar 1. The shape and size of the limiting groove 21 should be adapted to the limiting portion to ensure accurate position matching and limiting during the installation process. This matching arrangement enables the AC busbar 1 to be firmly embedded in the power module 111 and stably fixed in the installation position. By matching the limiting portion with the limiting groove 21, the power module 111 achieves effective limiting of the AC busbar 1, ensuring that it maintains the correct position inside the module. This helps to improve the mechanical stability and reliability of the entire power module 111.

[0099] In some embodiments, the plastic housing 13 of the AC busbar 1 is configured with a first fixing portion for fixing the AC busbar 1 and the power module 111. The first fixing portion may include a first slot 133 and a first elastic buckle 134, which are used to cooperate with the mounting structure of the power module 111 to achieve a firm connection.

[0100] In some embodiments, the mounting structure includes a second fixing portion, the second fixing portion is matched with the first fixing portion, and the first fixing portion and the second fixing portion are properly matched to ensure that the AC busbar 1 and the power module 111 are tightly fixed together. By matching the first fixing portion with the second fixing portion, the power module 111 effectively fixes the AC busbar 1. This helps to ensure that the AC busbar 1 maintains a stable relative position during use and operation, improves the mechanical stability and reliability of the power module 111, and ensures easy installation and maintenance. In practical applications, the shape and size of the first fixing portion and the second fixing portion can be optimized according to specific needs and design requirements.

[0101] In some embodiments, the second fixing portion includes a second elastic buckle 22 and a second slot 23. The second elastic buckle 22 can be an elastic structure extending in the transverse direction, such as a raised portion with a certain elasticity. This structure can be bent when connected, and then return to its original shape by elastic force. The material of the second elastic buckle 22 has a certain strength and toughness, and can undergo elastic deformation, such as elastic plastic. The second elastic buckle 22 is located on one side of the limiting slot 21, and the second elastic buckle 22 is matched and connected with the first slot 133.

[0102] Specifically, Figure 5-Figure 7As shown, during the assembly process, the second elastic buckle 22 can undergo elastic deformation, allowing it to enter the first slot 133 on the plastic housing 13. Once assembled in place, the second elastic buckle 22 returns to its original shape and engages with the first slot 133, thereby achieving the snap-fit ​​fixation between the plastic housing frame 2 of the power module 111 and the plastic housing 13 of the AC busbar 1. This structure ensures the firmness and stability of the package. With such a design, the assembly process of the power module 111 becomes simpler, and the elastic deformation and recovery of the second elastic buckle 22 ensure the snap-fit ​​fixation effect after the assembly is completed. This is crucial to ensure the stability and reliability of the entire power module 111 packaging structure.

[0103] Therefore, by matching the first card slot 133 with the second elastic card buckle 22, a connection method similar to a socket is formed. This design feature makes the installation and removal process more convenient, while ensuring the firm connection of the power module 111. This card buckle design has good reliability and stability, and is suitable for power modules 111 in various environments and use conditions. In practical applications, the shape and size of the card buckle can be optimized according to specific needs and design requirements.

[0104] In some embodiments, the second slot 23 is a part of the second fixing portion, which is usually arranged in the structure of the power module 111, and corresponds to the first elastic buckle 134. The shape and size of the second slot 23 can match the shape of the first elastic buckle 134 to ensure matching during connection. Therefore, the role of the second slot 23 can be to provide a position to cooperate with the mounting structure of the power module 111 to achieve effective fixation.

[0105] Specifically, Figure 5-Figure 7 As shown, a first elastic buckle 134 is provided on the plastic-encapsulated shell 13. The buckle is engaged with the inner side of the second slot 23 on the plastic-encapsulated outer frame 2 of the power module 111. The first elastic buckle 134 includes four evenly distributed elastic hook structures. During the assembly process, the first elastic buckle 134 can produce elastic deformation so that it enters the second slot 23. Once assembled in place, the first elastic buckle 134 returns to its original shape and engages with the inner side of the second slot 23. This engaging method improves the connection strength by engaging the elastic buckle with the slot, ensuring that the assembly between the plastic-encapsulated outer frame 2 of the power module 111 and the plastic-encapsulated shell 13 of the AC busbar 1 has high stability and strength. Through such a design, looseness is not easy to occur after the assembly is completed, and the engaging method of the elastic buckle with the slot improves the stability and efficiency of the assembly. This is very important for ensuring the reliability and stability of the entire system during operation.

[0106] In some embodiments, Figure 4As shown, the power module 111 also includes a metal-clad ceramic substrate 3. The metal-clad ceramic substrate 3 can be a ceramic substrate 121 with a metal covering layer. This substrate 121 structure generally includes a ceramic substrate, the surface of which is coated with a metal layer. The metal layer provides good thermal conductivity and electrical conductivity in the metal-clad ceramic substrate 3, and the ceramic substrate provides mechanical support for the metal-clad ceramic substrate 3. The metal layer can protect the substrate 121 from the influence of the external environment to a certain extent, for example, prevent moisture and chemicals from corroding the ceramic substrate. Therefore, the metal-clad ceramic substrate 3 is generally used as a packaging substrate 121 in the manufacture of electronic devices. The metal covering layer can provide additional protection and also facilitate assembly.

[0107] In some embodiments, the conductive layer of the metal-clad ceramic substrate 3 is provided with a plurality of conductive areas, which are generally used to connect different components in the power module 111, such as an IGBT (Insulated Gate Bipolar Transistor) chip 4, an FRD (Fast Recovery Diode) chip 5, a temperature sensor 6, etc. Moreover, the IGBT chip 4, the FRD chip 5, the temperature sensor 6 and the corresponding conductive areas of the metal-clad ceramic substrate 3 can be electrically connected by bonding with aluminum wires or copper wires. These bonding operations ensure the reliability of the transmission and connection of electrical signals.

[0108] In some embodiments, the IGBT chip 4, the FRD chip 5, the temperature sensor 6 and the drive control signal pin 7 can be soldered on the metal-clad ceramic substrate 3 by soldering. The material used for soldering can be SnSb (tin-antimony alloy), SnAg (tin-silver alloy), PbSnAg (lead-tin-silver alloy), SnAgCu (tin-silver-copper alloy) and other solders to ensure a firm electrical connection.

[0109] In some implementations, the IGBT chip 4 and the FRD chip 5 are common power semiconductor components in the power module 111, which are used to control current and voltage to achieve power regulation and conversion. These chips are respectively connected to specific conductive areas on the metal-clad ceramic substrate 3 for electrical connection and control. The temperature sensor 6 is used to monitor the temperature of the power module 111. The temperature sensor 6 is connected to a conductive area on the metal-clad ceramic substrate 3 to measure the temperature in real time and provide corresponding temperature feedback.

[0110] In some embodiments, the drive control signal pins 7 may be pins for transmitting drive and control signals, connected to specific conductive areas on the metal-clad ceramic substrate 3. These signal pins are responsible for transmitting control signals to various components of the power module 111 to ensure normal operation and coordinated operation.

[0111] In general, through the design of the conductive area, each power element and sensor can be conveniently connected to the metal-clad ceramic substrate 3 to form an integrated circuit structure. The power module 111 realizes the integration and connection of core components, enabling it to work efficiently and stably. The design and connection method of the conductive area ensures the electrical connection and signal transmission between different components, enabling the power module 111 to operate reliably in high-power applications.

[0112] In some embodiments, the DC positive electrode 8, the DC negative electrode 9 and the AC busbar 1 can be ultrasonically welded on the metal-clad ceramic substrate 3. This connection method can improve the vibration resistance of the entire module, increase the firmness of the connection, and help maintain the reliability of the connection in a vibration environment.

[0113] In some embodiments, the gaps between the IGBT chip 4, the FRD chip 5, the drive control signal pin 7, the DC positive electrode 8, the DC negative electrode 9, the AC busbar 1 and the temperature sensor 6 on the metal-clad ceramic substrate 3 can be electrically isolated by covering with silica gel. The electrical isolation method using silica gel can effectively prevent interference from external factors and improve the anti-interference ability of the module. This design helps to increase the service life of the module and ensure its stable and reliable operation in various working environments.

[0114] like Figure 4 As shown, the power module 111 also includes a heat dissipation base plate 10. The metal-clad ceramic substrate 3 is located on the heat dissipation base plate 10, and the heat dissipation base plate 10 and the metal-clad ceramic substrate 3 can be soldered. The good thermal conductivity of the metal-clad ceramic substrate 121 helps to quickly transfer the heat inside the power module 111 to the heat dissipation base plate 10. The heat dissipation base plate 10 can effectively conduct and disperse the heat generated by the power module 111, thereby improving the heat dissipation performance. In an embodiment, the heat dissipation base plate 10 can be made of a material with good thermal conductivity, such as aluminum alloy or copper, to increase the heat dissipation effect.

[0115] In some embodiments, the plastic outer frame 2 surrounds the heat dissipation base plate 10 to protect and encapsulate the heat dissipation base plate 10. The plastic outer frame 2 can be made of high temperature resistant plastic or other suitable materials to ensure that the external environment does not have an adverse effect on the normal operation of the power module 111. In addition, the plastic outer frame 2 can also improve the mechanical strength and durability of the power module 111.

[0116] Reference below Figure 8 An electronic device according to an embodiment of the present invention is described.

[0117] Figure 8 is a block diagram of an electronic device according to an embodiment of the present utility model, such as Figure 8As shown, the electronic device 110 includes at least one power module 111 as described in the above embodiment. For example, it may include one power module 111, or it may include two or more. In an embodiment, the electronic device 110 may include but is not limited to a computer, a drive motor controller, an inverter, a frequency converter, etc. These electronic devices 110 can be used to process high-power electrical signals and achieve effective power conversion. By integrating the power module 111, the electronic device 110 can achieve efficient and reliable power circuit control and heat dissipation management to meet the requirements of various application fields.

[0118] According to the electronic device 110 of the embodiment of the utility model, by adopting the power module 111 described in the above embodiment, the power module 111 is first separately sealed with the current sensor 12 and the AC terminal 11 before assembly, forming a compact overall structure, effectively reducing the overall occupied space, and having a high degree of integration. In addition, this separate packaging design allows the position of the current sensor 12 relative to the AC busbar 1 to be fixed, avoiding relative position changes that may occur during use. This relative position fixity helps to reduce measurement errors and improve the accuracy and stability of current detection. During the calibration process, due to the independent plastic sealing of the current sensor 12, other components are effectively isolated, reducing the risk of chip burning.

[0119] Reference below Fig. 9 A vehicle according to an embodiment of the present invention is described.

[0120] Fig. 9 is a block diagram of a vehicle according to an embodiment of the present utility model, such as Fig. 9 As shown, the vehicle 100 includes at least one power module 111 as described in the above embodiment, for example, one power module 111, or two or more. In the embodiment, the vehicle 100 may include but is not limited to an electric vehicle, a hybrid vehicle, and the like.

[0121] According to the vehicle 100 of the embodiment of the utility model, by adopting the power module 111 described in the above embodiment, the power module 111 is first separately sealed with the current sensor 12 and the AC terminal 11 before assembly, forming a compact overall structure, effectively reducing the overall occupied space, and having a high degree of integration. In addition, this separate packaging design allows the position of the current sensor 12 relative to the AC busbar 1 to be fixed, avoiding relative position changes that may occur during use. This relative position fixity helps to reduce measurement errors and improve the accuracy and stability of current detection. During the calibration process, due to the independent plastic sealing of the current sensor 12, other components are effectively isolated, reducing the risk of chip burning, thereby improving the overall performance of the vehicle 100.

[0122] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "illustrative embodiments", "examples", "specific examples", or "some examples" means that the specific features, structures, materials, or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the utility model. In this specification, the schematic expressions of the above terms do not necessarily refer to the same embodiment or example.

[0123] Although the embodiments of the present invention have been shown and described, those skilled in the art will appreciate that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the claims and their equivalents.

Claims

1. An AC busbar, characterized in that: include: AC terminal; A current sensor, used to detect the current flowing through the AC terminal; A plastic-encapsulated shell encapsulates the AC terminal and the current sensor, and an input end and an output end of the AC terminal both extend out of the plastic-encapsulated shell.

2. The AC busbar according to claim 1, characterized in that: The AC terminal is configured with a first through hole along the thickness direction; The current sensor is inserted into the first through hole, and the current sensor is insulated from the AC terminal.

3. The AC busbar according to claim 2, characterized in that: The plastic package shell is constructed as follows: A limiting portion, wherein the limiting portion is suitable for limiting the AC busbar at an installation position.

4. The AC busbar according to claim 3, characterized in that: The limiting portion includes a receiving cavity with openings at both ends along the length direction of the AC terminal; The AC terminal passes through the accommodating cavity, and the input end and the output end of the AC terminal extend out of the accommodating cavity through the openings at both ends respectively.

5. The AC busbar according to claim 4, characterized in that: A protrusion is configured at the exit of the accommodating cavity corresponding to the exit side of the AC terminal, for fixing the AC terminal.

6. The AC busbar according to claim 4, characterized in that: Along the thickness direction of the AC terminal, a second through hole is formed on the upper cavity wall of the accommodating cavity at a position corresponding to the first through hole, and a portion of the current sensor extends out of the accommodating cavity through the second through hole.

7. The AC busbar according to claim 6, characterized in that: The current sensor comprises a substrate, a detection chip and a signal lead-out terminal, wherein the detection chip and the signal lead-out terminal are both located on the substrate; The substrate is vertically inserted into the first through hole; The detection chip comprises a first detection chip and a second detection chip, and in the thickness direction of the AC terminal, the first detection chip and the second detection chip are symmetrically arranged with respect to the center line of the AC terminal to sense the current flowing through the AC terminal; One end of the substrate and the signal lead-out terminal extend out of the accommodating cavity through the second through hole, and the signal lead-out terminal is used to be electrically connected to an external drive control board.

8. The AC busbar according to claim 7, characterized in that: The gap between the current sensor and the AC terminal in the accommodating cavity is filled with the plastic package shell.

9. The AC busbar according to claim 4, characterized in that: At least one corner of the accommodating cavity is configured with a step.

10. The AC busbar according to claim 6, characterized in that: The limiting portion also includes: An extension portion is connected to the accommodating cavity, and along the width direction of the AC terminal, the extension portion is located at one side of the accommodating cavity.

11. The AC busbar according to claim 10, characterized in that: In the thickness direction of the AC terminal, the upper surface of the extension portion is flush with the upper surface of the accommodating cavity, and the thickness of the extension portion is less than the thickness of the accommodating cavity; In the length direction of the AC terminal, the width of the extension portion is smaller than the width of the accommodating cavity.

12. The AC busbar according to claim 10, characterized in that: The plastic package housing is also constructed with: A first fixing portion, wherein the first fixing portion is located on the limiting portion and is used to fix the AC busbar and the power module.

13. The AC busbar according to claim 12, characterized in that: The first fixing portion comprises: The first card slot is arranged on the outer surface of the upper cavity wall of the accommodating cavity, and in the width direction of the AC terminal, the first card slot is located on a side of the second through hole away from the extension portion.

14. The AC busbar according to claim 12, characterized in that: The first fixing portion comprises: A first elastic buckle is located on the bottom surface of the extending portion.

15. The AC busbar according to claim 14, characterized in that: The first elastic buckle includes four evenly distributed hook structures.

16. The AC busbar according to any one of claims 1 to 15, characterized in that: In the thickness direction of the AC terminal, the input end of the AC terminal is bent toward the bottom surface of the plastic package shell.

17. A power module, characterized in that: include: The AC busbar according to any one of claims 1 to 16; A plastic-sealed outer frame is provided with an installation structure at an installation position corresponding to the AC busbar, so as to assemble the AC busbar.

18. The power module according to claim 17, characterized in that: The plastic-sealed shell of the AC busbar is configured with a limiting portion for limiting the AC busbar at the installation position; The mounting structure comprises a limiting groove, and the limiting groove is matched with the limiting portion.

19. The power module according to claim 18, characterized in that: The plastic-encapsulated shell of the AC busbar is configured with a first fixing portion for fixing the AC busbar and the power module; The mounting structure includes a second fixing portion, and the second fixing portion is matched with the first fixing portion.

20. The power module according to claim 19, characterized in that: The first fixing portion includes a first card slot; The second fixing portion includes a second elastic buckle, the second elastic buckle is located at one side of the limiting groove, and the second elastic buckle is matched and connected with the first buckle groove.

21. The power module according to claim 20, characterized in that: The first fixing portion includes a first elastic buckle; The second fixing portion includes a second clamping slot, the second clamping slot is arranged opposite to the second elastic buckle, and the second clamping slot is matched and connected with the first elastic buckle.

22. The power module according to any one of claims 17 to 21, characterized in that: The power module further comprises: A metal-clad ceramic substrate, wherein the conductive layer of the metal-clad ceramic substrate is provided with a plurality of conductive areas; The IGBT chip, the FRD chip, the temperature sensor and the drive control signal pins are all arranged on the metal-clad ceramic substrate, and the IGBT chip, the FRD chip and the temperature sensor are respectively connected to corresponding conductive areas.

23. The power module according to claim 22, characterized in that: The power module further comprises: The heat dissipation bottom plate is located on the metal-clad ceramic substrate, and the plastic sealing outer frame surrounds the heat dissipation bottom plate.

24. An electronic device, characterized in that: Comprising at least one power module according to any one of claims 17-23.

25. A vehicle, characterized in that: Comprising at least one power module according to any one of claims 17-23.

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