Shell, motor controller and power assembly

Abstract

The utility model discloses a shell, a motor controller and a power assembly, and relates to the technical field of new energy automobiles, the shell is at least one of an upper cover of the motor controller, a shell of the motor controller and a shell of the power assembly, and the shell comprises a plastic base body and an electromagnetic shielding body; the electromagnetic shielding body is arranged on the plastic base body and used for achieving electromagnetic shielding. According to the technical scheme provided by the utility model, the shell capable of realizing weight reduction and noise reduction effects is provided.

Description

Technical Field

[0001] The utility model relates to the technical field of new energy vehicles, and in particular to a housing, a motor controller and a power assembly. Background Art

[0002] In the power system of new energy vehicles, the shell material is mostly aluminum alloy to achieve electromagnetic shielding, protection, sealing and other functions. Since the density of aluminum alloy is 2.716kg / m 3 , its heavy weight and high material damping factor result in high noise during application. Utility Model Content

[0003] The main purpose of the utility model is to provide a housing, a motor controller and a power assembly, aiming to provide a housing that can achieve weight reduction and noise reduction effects.

[0004] To achieve the above object, the utility model provides a housing, which is at least one of an upper cover of a motor controller, a housing of a motor controller, and an outer shell of a powertrain, and the housing includes:

[0005] Plastic substrate;

[0006] An electromagnetic shielding body is arranged on the plastic substrate to achieve electromagnetic shielding.

[0007] In one embodiment, the electromagnetic shielding body comprises a metal shielding layer, and the metal shielding layer is disposed on the surface of the plastic substrate.

[0008] In one embodiment, the electromagnetic shielding body further includes an anti-corrosion layer, and the anti-corrosion layer is disposed on the surface of the metal shielding layer.

[0009] In one embodiment, the electromagnetic shielding body comprises carbon fiber cloth, and the plastic matrix is ​​filled in the carbon fiber cloth to form a carbon fiber plastic composite layer.

[0010] In one embodiment, the electromagnetic shielding body further comprises a metal mesh, and the metal mesh and the carbon fiber plastic composite layer are stacked.

[0011] In one embodiment, at least one carbon fiber plastic composite layer is disposed on opposite sides of the metal mesh.

[0012] In one embodiment, the electromagnetic shielding body and the plastic base are an integrally injection-molded structure.

[0013] In one embodiment, the electromagnetic shielding body includes metal fibers and / or carbon fibers.

[0014] In one embodiment, the housing comprises:

[0015] A bottom shell, the bottom shell comprising the plastic base and the electromagnetic shielding body;

[0016] An upper cover is disposed on the bottom shell, and the upper cover includes the plastic substrate and the electromagnetic shielding body.

[0017] The utility model further proposes a motor controller, comprising a controller body and a motor controller housing, wherein the motor controller housing comprises a motor controller upper cover and a motor controller housing, wherein the motor controller upper cover and / or the motor controller housing are the housings as described above, and the controller body is arranged in the motor controller housing; wherein the housing comprises:

[0018] Plastic substrate;

[0019] An electromagnetic shielding body is arranged on the plastic substrate to achieve electromagnetic shielding.

[0020] The utility model also provides a power assembly, comprising a power assembly housing, a motor and the motor controller as described above, wherein the motor controller is used to drive the motor to work, and the motor and the motor controller are both arranged in the power assembly housing;

[0021] The powertrain housing is the housing described above.

[0022] The technical solution of the utility model adopts a plastic substrate as the substrate of the shell, and uses an electromagnetic shielding body arranged on the plastic substrate, so that the shell can achieve the effect of electromagnetic shielding, thereby replacing the use of aluminum alloy as the shell. Among them, since the density of plastic is about 1.8kg / m 3 , which is much smaller than the density of aluminum alloy. Therefore, under the same volume, the weight of the shell formed by the plastic matrix and the electromagnetic shielding body is smaller, and its material damping factor is lower, so the noise is also smaller during the application process, thereby achieving the effect of weight reduction and noise reduction. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the embodiments of the utility model or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the utility model. For ordinary technicians in this field, other drawings can be obtained based on the structures shown in these drawings without paying creative work.

[0024] Figure 1 A schematic structural diagram of an embodiment of a housing provided by the utility model;

[0025] Figure 2 A cross-sectional view of an embodiment of a housing provided by the utility model;

[0026] Figure 3 This is an exploded view of another embodiment of the housing provided by the utility model.

[0027] Description of Figure Numbers:

[0028] 100. Shell; 10. Plastic substrate; 11. Inner surface; 12. Outer surface; 20. Electromagnetic shielding body; 21. Metal shielding layer; 22. Anti-corrosion layer; 23. Carbon fiber cloth; 24. Carbon fiber plastic composite layer; 25. Metal mesh.

[0029] The realization of the purpose, functional features and advantages of the utility model will be further explained in conjunction with embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0030] The following will be combined with the drawings in the embodiments of the utility model to clearly and completely describe the technical solutions in the embodiments of the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, not all of the embodiments. Based on the embodiments of the utility model, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the utility model.

[0031] It should be noted that if the embodiments of the present invention involve directional indications (such as up, down, left, right, front, back...), the directional indications are only used to explain the relative position relationship, movement status, etc. between the components in a certain specific posture. If the specific posture changes, the directional indications will also change accordingly.

[0032] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the utility model, the descriptions of "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Therefore, the features limited to "first" and "second" may explicitly or implicitly include at least one of the features. In addition, if "and / or" or "and / or" appears in the full text, its meaning includes three parallel solutions. Taking "A and / or B" as an example, it includes solution A, solution B, or solutions that satisfy both A and B. In addition, the technical solutions between the various embodiments can be combined with each other, but it must be based on the ability of ordinary technicians in this field to implement. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such combination of technical solutions does not exist and is not within the scope of protection required by the utility model.

[0033] In the power system of new energy vehicles, the shell material is mostly aluminum alloy to achieve electromagnetic shielding, protection, sealing and other functions. Since the density of aluminum alloy is 2.716kg / m3 , its heavy weight and high material damping factor result in high noise during application.

[0034] Based on the above problems, the utility model proposes a housing, aiming to provide a housing that can achieve weight reduction and noise reduction effects. Optionally, the housing can be a housing of a motor controller (including an upper cover of the motor controller and a housing of the motor controller), or a housing of a powertrain, etc.

[0035] See also Figures 1 to 3 In one embodiment of the present utility model, the housing 100 includes a plastic substrate 10 and an electromagnetic shielding body 20; the electromagnetic shielding body 20 is disposed on the plastic substrate 10 to achieve electromagnetic shielding.

[0036] The technical solution of the utility model adopts a plastic substrate 10 as the substrate of the housing 100, and uses an electromagnetic shielding body 20 disposed on the plastic substrate 10, so that the housing 100 can achieve the electromagnetic shielding effect, thereby replacing the use of aluminum alloy as the housing 100. Among them, since the density of plastic is about 1.8kg / m 3 , which is much smaller than the density of aluminum alloy. Therefore, under the same volume, the weight of the shell 100 formed by the plastic matrix 10 and the electromagnetic shielding body 20 is smaller, and its material damping factor is lower, so the noise is also smaller during the application process, thereby achieving the effect of weight reduction and noise reduction.

[0037] It should be noted that, compared with an aluminum alloy housing, the housing 100 formed by the plastic substrate 10 and the electromagnetic shielding body 20 can reduce weight by 30% to 60%, while reducing noise by 5dB to 10dB and having the advantage of low carbon emissions.

[0038] Moreover, compared with an aluminum alloy housing, the housing 100 formed by the plastic substrate 10 and the electromagnetic shielding body 20 also has a good corrosion resistance function, for example, it is more resistant to salt spray corrosion and coolant corrosion.

[0039] As some exemplary examples, the plastic substrate 10 may be engineering plastics, such as ABS, nylon, polysulfone, and the like.

[0040] In actual application, the electromagnetic shielding body 20 can be made of conductive and magnetic materials such as metal and carbon fiber, as long as it can achieve the electromagnetic shielding effect.

[0041] In actual application, the electromagnetic shielding body 20 can be set on the surface of the plastic substrate 10, or the electromagnetic shielding body 20 can be filled inside the plastic substrate 10, or the plastic substrate 10 can be filled inside the electromagnetic shielding body 20, as long as the formed shell 100 can reduce weight through the plastic substrate 10 and have an electromagnetic shielding effect.

[0042] See also Figure 1 and Figure 2 In one embodiment of the present invention, the electromagnetic shielding body 20 includes a metal shielding layer 21 , and the metal shielding layer 21 is disposed on the surface of the plastic substrate 10 .

[0043] In this way, by directly arranging the metal shielding layer 21 on the surface of the plastic substrate 10 , a good electromagnetic shielding effect can be achieved through the metal shielding layer 21 , and the preparation process is relatively simple and quick.

[0044] In actual application, the metal shielding layer 21 can be a copper layer, a silver layer or other conductive and magnetic metal materials, as long as it can achieve the electromagnetic shielding effect.

[0045] As some examples, in order to make the metal shielding layer 21 have a better electromagnetic shielding effect while reducing the cost investment, the metal shielding layer 21 can be made into a copper layer.

[0046] In actual application, the metal shielding layer 21 can be fixed on the surface of the plastic substrate by bonding, spraying, electroplating, etc.

[0047] As some exemplary examples, in order to ensure the connection reliability between the metal shielding layer 21 and the plastic substrate 10 , the metal shielding layer 21 may be electroplated on the surface of the plastic substrate 10 .

[0048] As some examples, in order to ensure that the housing 100 has a strong electromagnetic shielding effect, a metal shielding layer 21 may be provided on both the inner surface 11 and the outer surface of the plastic substrate 10. Figure 2 shown.

[0049] See also Figure 1 and Figure 2 In one embodiment of the present utility model, the electromagnetic shielding body 20 further includes an anti-corrosion layer 22 , and the anti-corrosion layer 22 is disposed on the surface of the metal shielding layer 21 .

[0050] In this configuration, since the metal shielding layer 21 has poor corrosion resistance, an anti-corrosion layer 22 is provided on the surface of the metal shielding layer 21 to prevent the metal shielding layer 21 from being exposed to the environment, thereby improving the corrosion resistance of the shell 100 and extending the service life of the shell 100.

[0051] As some examples, the anti-corrosion layer 22 may be a nickel layer, which has good anti-corrosion effect and low cost.

[0052] In actual application, the anti-corrosion layer 22 can be fixed on the surface of the metal shielding layer 21 by bonding, spraying, electroplating, etc.

[0053] As some exemplary examples, in order to ensure the connection reliability between the anti-corrosion layer 22 and the metal shielding layer 21 , the anti-corrosion layer 22 may be sprayed onto the surface of the metal shielding layer 21 .

[0054] In some embodiments, by setting a copper layer and a nickel layer on the surface of the plastic substrate 10, for a single cover of the shell 100, the weight of a single cover can be about 561g, which can reduce the weight by 41.3% compared to the aluminum alloy cover plate, and the noise can be reduced by 5dB to 10dB.

[0055] See also Figure 3 In another embodiment of the present invention, the electromagnetic shielding body 20 includes a carbon fiber cloth 23 , and the plastic matrix 10 is filled in the carbon fiber cloth 23 to form a carbon fiber plastic composite layer 24 .

[0056] In this way, by directly immersing the carbon fiber cloth 23 in the molten plastic so that the molten plastic can fully penetrate into the interior of the carbon fiber cloth 23, the carbon fiber cloth 23 is taken out and cooled, and then the plastic matrix 10 can be filled in the carbon fiber cloth 23 to form a carbon fiber plastic composite layer 24. In this way, the carbon fiber cloth 23 can achieve a good electromagnetic shielding effect, and the preparation process is also relatively simple and quick.

[0057] Optionally, see Figure 3 In another embodiment of the present invention, the electromagnetic shielding body 20 further includes a metal mesh 25 , and the metal mesh 25 and the carbon fiber plastic composite layer 24 are stacked.

[0058] In this way, the metal mesh 25 and the carbon fiber plastic composite layer 24 are stacked to form the shell 100, so that not only the carbon fiber cloth 23 but also the metal mesh 25 can achieve electromagnetic shielding effect, thereby improving the electromagnetic shielding efficiency of the powertrain shell.

[0059] In this embodiment, the preparation process can be as follows: first, directly immerse the carbon fiber cloth 23 in the molten plastic; second, take out the carbon fiber cloth 23 and cool it to obtain a carbon fiber plastic composite layer 24; third, stack the carbon fiber plastic composite layer 24 and the metal mesh 25; fourth, cut it to a suitable size and put it into a fixed mold; fifth, heat and pressurize the mold for automatic molding, and demold it after cooling to obtain the shell 100 product.

[0060] In some embodiments, a carbon fiber plastic composite layer 24 is formed by filling a plastic matrix 10 in a carbon fiber cloth 23, and is stacked with a metal mesh 25 to form a shell 100. For a single cover of the shell 100, the weight of a single cover can be about 372.6 g, which can reduce the weight by 60.9% compared to an aluminum alloy cover, and the noise can be reduced by 5dB to 10dB.

[0061] In actual application, the number of metal mesh 25 used can be one layer or at least two layers, which can be determined according to the actual electromagnetic shielding effect required, and is not specifically limited here. In addition, the number of carbon fiber plastic composite layer 24 used can also be one layer or at least two layers, which can be determined according to the actual strength required, and is not specifically limited here.

[0062] Optionally, see Figure 3 In another embodiment of the present invention, at least one carbon fiber plastic composite layer 24 is disposed on opposite sides of the metal mesh 25 .

[0063] In this configuration, since the metal mesh 25 has poor corrosion resistance, at least one layer of carbon fiber plastic composite layer 24 is provided on both opposite sides of the metal mesh 25 to prevent the metal mesh 25 from being exposed to the environment, thereby improving the corrosion resistance of the shell 100 and extending the service life of the shell 100.

[0064] In actual application, the number of carbon fiber plastic composite layers 24 disposed on two opposite sides of the metal mesh 25 may be the same or different.

[0065] In another embodiment of the present invention, the electromagnetic shielding body 20 and the plastic base 10 are an integral injection-molded structure.

[0066] In this way, the electromagnetic shielding body 20 and the plastic matrix 10 are mixed together and then melt-mixed and integrally injection-molded into the housing 100 . This not only simplifies the preparation process, but also effectively ensures the connection reliability between the electromagnetic shielding body 20 and the plastic matrix 10 .

[0067] In actual application, the electromagnetic shielding body 20 can be made of conductive and magnetic materials such as metal, metal fiber, carbon fiber, etc.

[0068] Optionally, in yet another embodiment of the present invention, the electromagnetic shielding body 20 includes metal fibers and / or carbon fibers.

[0069] In this way, the housing 100 is formed by integrally injection molding metal fibers and / or carbon fibers with the plastic matrix 10 , which not only has good electrical conductivity, thermal conductivity, magnetic conductivity and high temperature resistance, but also has a simple manufacturing method and low cost.

[0070] See also Figure 1 In one embodiment of the utility model, the housing 100 includes a bottom shell and an upper cover; the bottom shell includes a plastic base 10 and an electromagnetic shielding body 20; the upper cover is disposed on the bottom shell, and the upper cover includes a plastic base 10 and an electromagnetic shielding body 20.

[0071] In this way, the shell 100 is formed by using an upper cover and a bottom shell to cover each other, which makes it easy to install other components inside the shell 100. Moreover, since both the bottom shell and the upper cover include a plastic body and an electromagnetic shielding body 20, the bottom shell and the upper cover can achieve the effects of weight reduction and noise reduction.

[0072] In actual application, the bottom shell and the upper cover may be connected by bolts, buckles or other connectors to ensure installation reliability between the bottom shell and the upper cover.

[0073] As some examples, in order to ensure the conductivity between the bottom shell and the upper cover, a metal connector can be used to achieve the connection between the bottom shell and the upper cover. Optionally, mounting holes can be provided on both the bottom shell and the upper cover, and the metal connector can be used to penetrate the mounting holes of the bottom shell and the upper cover respectively, so as to achieve locking between the bottom shell and the upper cover.

[0074] The utility model also proposes a motor controller, which includes a controller body and a motor controller housing, the motor controller housing includes a motor controller upper cover and a motor controller shell, the motor controller upper cover and / or the motor controller shell is a shell 100, the specific structure of the shell 100 refers to the above embodiment, since the motor controller adopts all the technical solutions of all the above embodiments, it at least has all the beneficial effects brought by the technical solutions of the above embodiments, which will not be repeated here. Among them, the controller body is arranged in the motor controller shell.

[0075] The utility model also proposes a powertrain, which includes a powertrain housing, a motor and a motor controller. The specific structure of the motor controller refers to the above-mentioned embodiment. Since the motor controller adopts all the technical solutions of all the above-mentioned embodiments, it has at least all the beneficial effects brought by the technical solutions of the above-mentioned embodiments, which will not be described one by one here.

[0076] Among them, the motor controller is used to drive the motor to work, and the motor and the motor controller are both arranged in the powertrain housing; the powertrain housing is the above-mentioned shell, and the specific structure of the shell 100 refers to the above-mentioned embodiment. Since the motor controller adopts all the technical solutions of all the above-mentioned embodiments, it has at least all the beneficial effects brought by the technical solutions of the above-mentioned embodiments, which will not be repeated here one by one.

[0077] In actual application, the powertrain can be applied to electrical equipment such as vehicles and looms, and no specific limitation is made here.

[0078] The above description is only an exemplary embodiment of the present invention, and does not limit the patent scope of the present invention. All equivalent structural changes made by using the contents of the present invention specification and drawings under the technical concept of the present invention, or directly / indirectly applied in other related technical fields are included in the patent protection scope of the present invention.

Claims

1. A housing, the housing being at least one of an upper cover of a motor controller, a housing of a motor controller, and an outer shell of a powertrain, characterized in that: The housing comprises: Plastic substrate; An electromagnetic shielding body is arranged on the plastic substrate to achieve electromagnetic shielding.

2. The housing according to claim 1, characterized in that The electromagnetic shielding body comprises a metal shielding layer, and the metal shielding layer is arranged on the surface of the plastic substrate.

3. The housing according to claim 2, characterized in that The electromagnetic shielding body further comprises an anti-corrosion layer, and the anti-corrosion layer is arranged on the surface of the metal shielding layer.

4. The housing according to claim 1, characterized in that The electromagnetic shielding body comprises carbon fiber cloth, and the plastic matrix is ​​filled in the carbon fiber cloth to form a carbon fiber plastic composite layer.

5. The housing according to claim 4, characterized in that The electromagnetic shielding body further comprises a metal mesh, and the metal mesh and the carbon fiber plastic composite layer are stacked.

6. The housing according to claim 5, characterized in that At least one carbon fiber plastic composite layer is provided on opposite sides of the metal mesh.

7. The housing according to claim 1, wherein: The electromagnetic shielding body and the plastic base are integrally injection-molded.

8. The housing according to claim 7, characterized in that The electromagnetic shielding body comprises metal fibers and / or carbon fibers.

9. The housing according to any one of claims 1 to 8, characterized in that The housing comprises: A bottom shell, the bottom shell comprising the plastic base and the electromagnetic shielding body; An upper cover is disposed on the bottom shell, and the upper cover includes the plastic substrate and the electromagnetic shielding body.

10. A motor controller, characterized in that: It includes a controller body and a motor controller housing, the motor controller housing includes a motor controller upper cover and a motor controller shell, the motor controller upper cover and / or the motor controller shell is a shell as described in any one of claims 1 to 9, and the controller body is arranged in the motor controller shell.

11. A powertrain, characterized in that: It comprises a powertrain housing, a motor and a motor controller as claimed in claim 10, wherein the motor controller is used to drive the motor to work, and the motor and the motor controller are both arranged in the powertrain housing; The powertrain housing is a housing according to any one of claims 1 to 9.

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