Film capacitor, motor controller and vehicle

Abstract

The utility model provides a film capacitor, a motor controller and a vehicle, and the film capacitor comprises a housing, a plurality of first capacitor cores, an aluminum conductive busbar, a copper input terminal, and a copper output terminal. Wherein the plurality of first capacitor cores are arranged in the shell, the aluminum conductive busbar comprises a core connecting part and a terminal connecting part, the core connecting part covers the plurality of first capacitor cores, a plurality of connecting ends are arranged at positions corresponding to the plurality of first capacitor cores, and the first capacitor cores are electrically connected to the core connecting part through the connecting ends; and the core connecting part and the terminal connecting part are respectively provided with a welding area for the aluminum conductive busbar to be in laser welding connection with the output terminal and the input terminal. According to the utility model, the problems of overhigh cost and heavy weight of the existing film capacitor are solved.

Description

Technical Field

[0001] The utility model belongs to the technical field of vehicle accessories, and in particular relates to a film capacitor, a motor controller and a vehicle. Background Art

[0002] In the structural design of the vehicle's electric drive system, the role of the film capacitor in the entire circuit system is to filter out the ripple voltage or current on the DC bus side and provide a clean voltage source for the power module. In the production of film capacitors, copper is usually used as the conductive busbar design, and the welded winding core package and copper busbar are encapsulated inside the plastic shell with epoxy resin to form an electrical connection. Due to the structural design requirements inside the capacitor, copper often accounts for 30% or more of the entire capacitor's internal cost, which leads to excessively high costs for film capacitors, and due to the high density of copper, the weight of the film capacitor is too large. Utility Model Content

[0003] The utility model provides a film capacitor, a motor controller and a vehicle, so as to solve the problems of high cost and heavy weight of the existing film capacitor.

[0004] In order to solve or improve the above technical problems to a certain extent, a thin film capacitor is provided according to an embodiment of the utility model, characterized in that it includes: a housing, a plurality of first capacitor cores, an aluminum conductive busbar, and a copper input terminal and an output terminal;

[0005] Wherein, a plurality of the first capacitor cores are arranged in the housing, the aluminum conductive busbar comprises a core connection portion and a terminal connection portion, the core connection portion covers the plurality of the first capacitor cores, and a plurality of connection ends are provided at positions corresponding to the plurality of the first capacitor cores, and the first capacitor core is electrically connected to the core connection portion through the connection ends;

[0006] The core connection portion and the terminal connection portion are respectively provided with welding areas for laser welding connection between the aluminum conductive busbar and the output terminal and the input terminal.

[0007] In some embodiments, the film capacitor further includes a plurality of Y capacitors, the plurality of Y capacitors are disposed between the first capacitor core and the input terminal, and the Y capacitors are electrically connected to the input terminal through the terminal connection portion.

[0008] In some implementations, a plurality of the Y capacitors are arranged in parallel with each other.

[0009] In some embodiments, the film capacitor further includes a magnetic core inductor, which is disposed between the Y capacitor and the input terminal and is electrically connected to the input terminal through the terminal connecting portion.

[0010] In some embodiments, the core connecting portion and the terminal connecting portion are integrally formed.

[0011] In some embodiments, the film capacitor also includes a relay terminal for connecting a relay and a second capacitor core, the second capacitor core is arranged in the shell and separated from the first capacitor core, the second capacitor core is set on one side of the relay terminal and is electrically connected to the relay terminal through the terminal connecting part.

[0012] In some embodiments, the relay terminal is a copper terminal, and the connection between the terminal connecting portion and the relay terminal is configured as a welding area for laser welding the aluminum conductive busbar and the relay terminal.

[0013] In some embodiments, the plurality of first capacitor cores are arranged in multiple rows, the plurality of connection ends are arranged in multiple rows, and the number of the connection ends in each row decreases sequentially in a direction toward the output terminal.

[0014] According to another embodiment of the present invention, a motor controller is provided, which includes the film capacitor described in any of the above embodiments.

[0015] According to another embodiment of the present invention, a vehicle is provided, which includes the motor controller described in the above embodiment.

[0016] The thin film capacitor of the utility model adopts an aluminum conductive busbar, which can reduce the overall weight of the thin film capacitor, reduce the cost of the thin film capacitor, and reduce the cost of the thin film capacitor. The connection between the aluminum conductive busbar and the external terminals (input terminals, output terminals, relay terminals, etc.) is set as a laser welding area, so that the aluminum conductive busbar and the copper external terminals can be laser welded, while ensuring the firmness of the connection, effectively solving the electrochemical corrosion problem caused by the electrical connection of dissimilar materials, and ensuring the effectiveness and current carrying capacity of the connection, so as to improve the stability of the thin film capacitor.

[0017] The above description is only an overview of the technical solution of the utility model. In order to more clearly understand the technical means of the utility model, it can be implemented in accordance with the contents of the specification. In order to make the above and other purposes, features and advantages of the utility model more obvious and easy to understand, the following preferred embodiments are specifically cited and described in detail with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 A schematic diagram of the structure of a film capacitor according to an embodiment of the utility model;

[0019] Figure 2FIG. 1 is a schematic structural diagram of a film capacitor according to another embodiment of the utility model.

[0020]

Explanation of symbols

[0021] 10. Shell

[0022] 20. The first capacitor core

[0023] 30. Aluminum conductive busbar

[0024] 300, core connection part

[0025] 301. Terminal connection part

[0026] 302. Welding area

[0027] 303, Connection terminal

[0028] 40. Input terminal

[0029] 50. Output terminal

[0030] 60. Y capacitor

[0031] 70. Magnetic core inductor

[0032] 80. Relay terminals

[0033] 90. Second capacitor core DETAILED DESCRIPTION

[0034] In order to further explain the technical means and effects adopted by the present invention to achieve the predetermined purpose of the present invention, the following is a detailed description of the specific implementation and effects of a film capacitor, a motor controller and a vehicle proposed according to the present invention in combination with the accompanying drawings and preferred embodiments.

[0035] See also Figure 1 and Figure 2 As shown, according to an embodiment of the present utility model, a film capacitor is provided, comprising: a housing 10 , a plurality of first capacitor cores 20 , an aluminum conductive busbar 30 , a copper input terminal 40 and an output terminal 50 .

[0036] The first capacitor core 20 is formed by winding a film, and a plurality of first capacitor cores 20 are arranged in the housing 10. The plurality of first capacitor cores 20 can be arranged in a line, in multiple rows, or in a staggered arrangement. The utility model is not limited to the arrangement of the first capacitor core 20.

[0037] The material of the aluminum conductive busbar 30 is aluminum. By using aluminum to prepare the conductive busbar, the weight of the conductive busbar can be reduced by two thirds compared to using copper to prepare the conductive busbar, and the preparation cost of the conductive busbar can be reduced.

[0038] The aluminum conductive busbar 30 includes a core connection portion 300 and a terminal connection portion 301 , wherein the core connection portion 300 is used to connect a plurality of first capacitor cores 20 , and the terminal connection portion 301 is used to connect external terminals, such as an input terminal 40 , an output terminal 50 , and the like.

[0039] Optionally, the core connection part 300 and the terminal connection part 301 can be integrally formed by a process such as stamping. The integrally formed core connection part 300 and the terminal connection part 301 can ensure the connection strength of the core connection part 300 and the terminal connection part 301 and the flow capacity between the core connection part 300 and the terminal connection part 301.

[0040] Of course, the core connection part 300 and the terminal connection part 301 can also be connected by welding, crimping, etc.

[0041] The core connection part 300 is provided with a welding area 302, and the core connection part 300 and the output terminal 50 are connected by laser welding in the welding area 302. The terminal connection part 301 is also provided with a welding area 302, and the terminal connection part 301 and the input terminal 40 are connected by laser welding in the welding area 302.

[0042] In the utility model, the connection of dissimilar materials between the aluminum conductive busbar 30 and the copper external terminal is achieved through a laser welding process, which can not only effectively solve the electrochemical corrosion problem caused by the electrical connection of dissimilar materials, but also ensure the effectiveness and current carrying capacity of the connection to improve the stability of the film capacitor.

[0043] Optionally, the thickness of the welding area 302 is greater than the thickness of other areas of the aluminum conductive busbar 30 .

[0044] like Figure 1 and 2 As shown, the core connection part 300 of the aluminum conductive busbar 30 covers a plurality of first capacitor cores 20, and the core connection part 300 is covered at both ends of the first capacitor core 20. The core connection part 300 is provided with a plurality of connection ends 303 at positions corresponding to the plurality of first capacitor cores 20, and the core connection part 300 is electrically connected to the first capacitor core 20 through the connection ends 303.

[0045] Optionally, the connection end 303 is connected to the first capacitor core 20 by soldering. Of course, the connection end 303 and the first capacitor core 20 can also be connected by other methods, and the present invention is not limited to a specific connection method.

[0046] like Figure 1 and 2As shown, the core connection part 300 forms a plurality of hollow areas at positions corresponding to the first capacitor core 20, and a connection end 303 is formed in the hollow area to connect with the first capacitor core 20. The hollow area is provided to facilitate the connection between the core connection part 300 and the first capacitor core 20, and to achieve heat dissipation of the first capacitor core 20.

[0047] In one embodiment, the plurality of first capacitor cores 20 are arranged in a plurality of rows in the housing 10, and the corresponding connection terminals 303 formed on the core connection portion 300 are also arranged in pairs. The number of the connection terminals 303 in each row decreases in the direction toward the output terminal 50, that is, the closer to the output terminal 50, the fewer the number of the connection terminals 303 in each row.

[0048] In this embodiment, by arranging the number of connection terminals 303 in each row to be smaller as they are closer to the output terminal 50, current balancing can be achieved so that the amount of current transmitted from the first capacitor core 20 at any position to the aluminum conductive busbar 30 remains consistent, ultimately reducing the internal heat generation of the entire film capacitor and improving the overall reliability and service life of the film capacitor.

[0049] In a specific embodiment, Figure 2 As shown, the connection ends 303 on the core connection part 300 are arranged in two rows, wherein the connection ends 303 in a row away from the output terminal 50 are divided into three groups, each with three ends, and the connection ends 303 in a row close to the output terminal 50 are divided into three groups, each with two ends.

[0050] In one embodiment, if Figure 1 and 2 As shown, the film capacitor further includes a plurality of Y capacitors 60, which are disposed between the first capacitor core 20 and the input terminal 40 and are electrically connected to the input terminal 40 through the terminal connection portion 301. The arrangement of the Y capacitors 60 can filter out differential mode interference and common mode interference of the signal input through the input terminal 40.

[0051] Optionally, multiple Y capacitors 60 are arranged side by side and in parallel with each other, which facilitates the grounding of the Y capacitors 60 and enables the Y capacitors 60 to better filter out differential mode interference and common mode interference.

[0052] In one embodiment, if Figure 1 and 2As shown, the film capacitor further includes a core inductor 70, which is disposed between the Y capacitor 60 and the input terminal 40, that is, the core inductor 70 is closer to the input terminal 40 than the Y capacitor 60, and the core inductor 70 is electrically connected to the input terminal 40 through the terminal connection portion 301. By arranging the core inductor 70 at a position closer to the input terminal 40, the core inductor 70 can better filter out high-frequency noise, stabilize voltage and spread the spectrum, so that the back end can obtain a stable and pure power signal.

[0053] In one embodiment, if Figure 2 As shown, the film capacitor further includes a relay terminal 80 and a second capacitor core 90. The second capacitor core 90 is disposed on one side of the relay terminal 80 and is electrically connected to the relay terminal 80 through a terminal connection portion 301. The relay terminal 80 is used to connect an external relay.

[0054] In this embodiment, the second capacitor core 90 is disposed on one side of the relay terminal 80 so that the second capacitor core 90 is closer to the relay, which is beneficial for the second capacitor core 90 to work in conjunction with the relay to realize its voltage boosting function.

[0055] Optionally, the relay terminal 80 is a copper terminal, and a welding area 302 is provided at the connection between the terminal connection part 301 and the relay terminal 80, so that the terminal connection part 301 and the relay terminal 80 are connected by laser welding in the welding area (not shown in the figure).

[0056] The second capacitor core 90 is disposed in the housing 10 and is arranged separately from the plurality of first capacitor cores 20. By arranging the second capacitor core 90 separately from the first capacitor core 20, their functions can be distinguished and subsequent fault repair is facilitated.

[0057] Optionally, the second capacitor core 90 is a Boost capacitor core.

[0058] Another embodiment of the present invention provides a motor controller, which includes the film capacitor of any one of the above embodiments.

[0059] Another embodiment of the present invention provides a vehicle, which includes the motor controller of the above embodiment.

[0060] The thin film capacitor of the utility model adopts an aluminum conductive busbar, which can reduce the overall weight of the thin film capacitor, reduce the cost of the thin film capacitor, and reduce the cost of the thin film capacitor. The connection between the aluminum conductive busbar and the external terminals (input terminals, output terminals, relay terminals, etc.) is set as a laser welding area, so that the aluminum conductive busbar and the copper external terminals can be laser welded, while ensuring the firmness of the connection, effectively solving the electrochemical corrosion problem caused by the electrical connection of dissimilar materials, and ensuring the effectiveness and current carrying capacity of the connection, so as to improve the stability of the thin film capacitor.

[0061] The above are only preferred embodiments of the present invention, and are not intended to limit the present invention in any form. Although the present invention has been disclosed as a preferred embodiment, it is not intended to limit the present invention. Any technician familiar with the profession can make some changes or modifications to equivalent embodiments of equivalent changes using the technical contents disclosed above without departing from the scope of the technical solution of the present invention. However, any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. A film capacitor, characterized in that: include: A housing, a plurality of first capacitor cores, an aluminum conductive busbar, and copper input terminals and output terminals; Wherein, a plurality of the first capacitor cores are arranged in the housing, the aluminum conductive busbar comprises a core connection portion and a terminal connection portion, the core connection portion covers the plurality of the first capacitor cores, and a plurality of connection ends are provided at positions corresponding to the plurality of the first capacitor cores, and the first capacitor core is electrically connected to the core connection portion through the connection ends; The core connection portion and the terminal connection portion are respectively provided with welding areas for laser welding connection between the aluminum conductive busbar and the output terminal and the input terminal.

2. The film capacitor according to claim 1, characterized in that: The film capacitor further includes a plurality of Y capacitors, which are arranged between the first capacitor core and the input terminal, and the Y capacitors are electrically connected to the input terminal through the terminal connection portion.

3. The film capacitor according to claim 2, characterized in that: The multiple Y capacitors are arranged in parallel with each other.

4. The film capacitor according to claim 2 or 3, characterized in that: The film capacitor further includes a magnetic core inductor, which is disposed between the Y capacitor and the input terminal and is electrically connected to the input terminal through the terminal connection portion.

5. The film capacitor according to claim 1, characterized in that: The core connecting portion and the terminal connecting portion are integrally formed.

6. The film capacitor according to claim 1, characterized in that: The film capacitor also includes a relay terminal for connecting a relay and a second capacitor core, the second capacitor core is arranged in the shell and separated from the first capacitor core, the second capacitor core is set on one side of the relay terminal, and is electrically connected to the relay terminal through the terminal connecting part.

7. The film capacitor according to claim 6, characterized in that: The relay terminal is a copper terminal, and the connection between the terminal connecting portion and the relay terminal is configured as a welding area for laser welding of the aluminum conductive busbar and the relay terminal.

8. The film capacitor according to claim 6, characterized in that: The plurality of first capacitor cores are arranged in a plurality of rows, the plurality of connection terminals are arranged in a plurality of rows, and the number of the connection terminals in each row decreases in sequence in a direction toward the output terminal.

9. A motor controller, characterized in that: A film capacitor comprising the film capacitor according to any one of claims 1 to 8.

10. A vehicle, characterized in that: Includes the motor controller as described in claim 9.

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