Copper bar assembly for motor controller, motor controller and vehicle

Abstract

The utility model discloses a copper bar assembly used for a motor controller, the motor controller and a vehicle, the copper bar assembly comprises a copper bar body on which a plurality of connecting bars are formed; the injection molding shell wraps at least part of the periphery of the copper bar body, at least part of the injection molding shell is arranged between the two adjacent connecting bars, and a mounting position is formed on the injection molding shell; the connecting piece is connected to the mounting position, and the connecting piece is suitable for connecting the injection molding shell with the power module; and the fastener is suitable for being connected with the injection molding shell so as to limit the movement of the connecting piece relative to the injection molding shell in the thickness direction. According to the copper bar assembly, the injection molding shell wraps the periphery of the copper bar body and is filled between the two adjacent connecting bars, and the connecting pieces are fixed on the injection molding shell through the fasteners, so that the integration level of the copper bar assembly is improved, the copper bar assembly is connected with the power module without adding an additional mounting seat, and the cost is reduced. And the reliability of connection between the copper bar assembly and the power module is improved.

Description

Technical Field

[0001] The utility model relates to the technical field of motor controllers, in particular to a copper bar assembly for a motor controller, a motor controller and a vehicle. Background Art

[0002] In the related art, the integration degree of the traditional copper bar assembly is not high, it occupies a large space, and an additional mounting seat needs to be added when the copper bar assembly is connected to the power module, the installation steps are complex, and the risk of unreliable connection between the copper bar assembly and the power module is increased. Summary of the Utility Model

[0003] The utility model aims to solve at least one of the technical problems existing in the prior art. For this reason, an object of the utility model is to provide a copper bar assembly for a motor controller. According to the copper bar assembly of the utility model, the injection molding housing wraps around the outer periphery of the copper bar body and fills the space between two adjacent connecting bars, and the connecting member is fixed to the injection molding housing by a fastener, which improves the integration degree of the copper bar assembly. When the copper bar assembly is connected to the power module, no additional mounting seat is required, and the reliability of the connection between the copper bar assembly and the power module is improved.

[0004] The utility model also provides a motor controller with the above copper bar assembly.

[0005] The utility model also provides a vehicle with the above motor controller.

[0006] The copper bar assembly for a motor controller according to the utility model includes: a copper bar body, on which a plurality of connecting bars are formed; an injection molding housing, which wraps around at least part of the outer periphery of the copper bar body, and at least part of the injection molding housing is arranged between two adjacent connecting bars, and an installation position is formed on the injection molding housing; a connecting member, which is arranged at the installation position, and the connecting member is adapted to connect the injection molding housing to the power module; a fastener, which is arranged on the side of the connecting member away from the installation position, and the fastener is adapted to be connected to the injection molding housing to limit the movement of the connecting member relative to the injection molding housing in the thickness direction.

[0007] According to the copper busbar assembly of the present utility model, an injection molded housing is coated on at least a part of the outer periphery of the copper busbar body. When injection molding, the injection molded housing can fill the gap between two adjacent connection bars, thereby improving the current transmission performance of the copper busbar assembly. The connecting member is arranged at the installation position, and the fastening member is arranged on the side of the connecting member away from the installation position. The fastening member is adapted to be connected to the injection molded housing by a rivet, so as to fix the connecting member between the fastening member and the injection molded housing. The copper busbar assembly can be connected to the power module through the connecting member. The connection between the copper busbar assembly and the power module does not require an additional mounting seat, which improves the reliability of the connection between the copper busbar assembly and the power module, and also improves the integration of the copper busbar assembly.

[0008] According to some embodiments of the present utility model, the copper busbar body includes: a first copper busbar portion, the first copper busbar portion is connected to a plurality of the connection bars, and the first copper busbar portion extends along a first direction; a second copper busbar portion, the second copper busbar portion is connected to the first copper busbar portion, and the second copper busbar portion extends along a second direction, wherein the first direction is orthogonal to the second direction.

[0009] According to some embodiments of the present utility model, a support portion protruding along the first direction is formed on the second copper busbar portion. The support portion is arranged on the side of the installation position away from the connecting member. The support portion cooperates with the connecting member to limit the movement of the copper busbar body relative to the power module.

[0010] According to some embodiments of the present utility model, the support portions are configured to be multiple and are arranged at intervals on the second copper busbar portion. The connecting member and the fastening member are configured to be multiple and arranged in one-to-one correspondence with the support portions.

[0011] According to some embodiments of the present utility model, the injection molded housing includes: a first coating portion, the first coating portion coats at least a part of the outer periphery of the first copper busbar portion; a second coating portion, the second coating portion is connected to the first coating portion, and the second coating portion coats the outer periphery of the second copper busbar portion. A protrusion protruding toward the first direction and fitting with the support portion is formed on the second coating portion. An installation position is provided on the protrusion, and the bottom of the protrusion is configured as an installation surface. The connecting member is spaced from the installation surface.

[0012] According to some embodiments of the present utility model, the injection molded housing further includes: a third coating portion, the third coating portion is disposed around at least a part of the outer periphery of the first coating portion and is located at the connection bar. A sealing surface that abuts against the motor controller housing is formed on the top surface of the third coating portion, and a sealing groove is formed on the sealing surface; the copper busbar assembly further includes: a sealing member, the sealing member is disposed in the sealing groove to seal the connection between the motor controller housing and the injection molded housing.

[0013] According to some embodiments of the present utility model, the injection molded housing is configured as a plastic part.

[0014] According to some embodiments of the present utility model, the copper busbar assembly further includes: an adhesive layer, which is disposed between the first covering portion and the connecting busbar.

[0015] The motor controller according to the present utility model will be briefly described below.

[0016] The motor controller according to the present utility model is provided with the copper busbar assembly described in any one of the above embodiments. Since the motor controller according to the present utility model is provided with the copper busbar assembly described in any one of the above embodiments, the copper busbar assembly of the motor controller according to the present application has good insulation performance, sealing performance, and stable current transmission performance, improving the stability and reliability during the operation of the motor controller.

[0017] The vehicle according to the present utility model will be briefly described below.

[0018] The vehicle according to the present utility model is provided with the motor controller described in any one of the above embodiments. Since the vehicle according to the present utility model is provided with the motor controller described in any one of the above embodiments, the vehicle according to the present application has higher stability, better safety, and stronger reliability during operation.

[0019] The additional aspects and advantages of the present utility model will be partially given in the following description, partially become apparent from the following description, or be understood through the practice of the present utility model. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The above and / or additional aspects and advantages of the present utility model will become apparent and be readily understood from the description of the embodiments in conjunction with the following drawings, wherein:

[0021] Figure 1 is a schematic structural diagram of a copper busbar assembly according to an embodiment of the present utility model;

[0022] Figure 2 is a schematic structural diagram of a copper busbar body according to an embodiment of the present utility model;

[0023] Figure 3 is a top view of a copper busbar body according to an embodiment of the present utility model;

[0024] Figure 4 is a schematic connection diagram of a copper busbar assembly and a motor controller housing according to an embodiment of the present utility model.

[0025] Reference numerals:

[0026] 100, copper busbar assembly; 200, motor controller housing;

[0027] 11. First covering part; 12. Second covering part; 13. Third covering part; 14. Seal; 15. Protrusion

[0028] 21. First copper bar part; 22. Second copper bar part; 23. Connecting bar; 24. Support part

[0029] 31. Connector; 32. Fastener Detailed implementation manners

[0030] The embodiments of the present utility model will be described in detail below. Examples of the embodiments are shown in the accompanying drawings, where the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below by referring to the accompanying drawings are exemplary and are only used to explain the present utility model and should not be construed as a limitation to the present utility model.

[0031] In the related art, the integration degree of the traditional copper bar assembly is not high enough, occupying a relatively large space. Moreover, when the copper bar assembly is connected to the power module, an additional mounting seat needs to be added. The integration degree is not high enough, and the installation steps are complex, increasing the risk of unreliable connection between the copper bar assembly and the power module.

[0032] The following refers to Figures 1 - 4 Describe a copper bar assembly for a motor controller according to an embodiment of the present utility model.

[0033] The copper bar assembly 100 for a motor controller according to the present utility model includes: a copper bar body, an injection molded housing, a connector 31, and a fastener 32. A plurality of connecting bars 23 are formed on the copper bar body; the injection molded housing covers at least a part of the outer periphery of the copper bar body, and at least a part of the injection molded housing is disposed between two adjacent connecting bars 23. An installation position is formed on the injection molded housing; the connector 31 is disposed on the installation position, and the connector 31 is adapted to connect the injection molded housing to the power module; the fastener 32 is disposed on a side of the connector 31 away from the installation position, and the fastener 32 is adapted to be connected to the injection molded housing to limit the movement of the connector 31 relative to the injection molded housing in the thickness direction.

[0034] In some specific embodiments, the copper busbar assembly 100 is composed of a copper busbar body, an injection-molded housing, a connecting member 31, and a fastening member 32. A plurality of juxtaposed and spaced connecting bars 23 are provided on the copper busbar body. The plurality of connecting bars 23 are injection-molded with an injection-molded material in a juxtaposed state, so that an injection-molded housing is coated on at least a part of the outer periphery of the copper busbar body. When injection-molding, the injection-molded housing can fill the gap between two adjacent connecting bars 23, thereby improving the current transmission performance of the copper busbar assembly 100. An installation position is provided on the injection-molded housing. The connecting member 31 is disposed on the installation position. The fastening member 32 is disposed on a side of the connecting member 31 away from the installation position. The fastening member 32 is adapted to be connected to the injection-molded housing by a rivet, so as to fix the connecting member 31 between the fastening member 32 and the injection-molded housing, restricting the movement of the connecting member 31 relative to the injection-molded housing in the thickness direction. The copper busbar assembly 100 can be connected to the power module through the connecting member 31. The connection between the copper busbar assembly 100 and the power module does not require an additional mounting seat, improving the reliability of the connection between the copper busbar assembly 100 and the power module, and at the same time improving the integration of the copper busbar assembly 100.

[0035] According to the copper busbar assembly of the present invention, an injection-molded housing is coated on at least a part of the outer periphery of the copper busbar body. When injection-molding, the injection-molded housing can fill the gap between two adjacent connecting bars 23, thereby improving the current transmission performance of the copper busbar assembly 100. The connecting member 31 is disposed on the installation position. The fastening member 32 is disposed on a side of the connecting member 31 away from the installation position. The fastening member 32 is adapted to be connected to the injection-molded housing by a rivet, so as to fix the connecting member 31 between the fastening member 32 and the injection-molded housing. The copper busbar assembly 100 can be connected to the power module through the connecting member 31. The connection between the copper busbar assembly 100 and the power module does not require an additional mounting seat, improving the reliability of the connection between the copper busbar assembly 100 and the power module, and at the same time improving the integration of the copper busbar assembly 100.

[0036] According to some embodiments of the present invention, the copper busbar body includes: a first copper busbar portion 21 and a second copper busbar portion 22. The first copper busbar portion 21 extends in a first direction. The first copper busbar portion 21 can serve as a main current-carrying path. The first copper busbar portion 21 is connected to a plurality of connecting bars 23, and the current can be evenly distributed to each connecting bar 23 to improve the efficiency and safety of current transmission. The second copper busbar portion 22 is connected to the first copper busbar portion 21. The second copper busbar portion 22 extends in a second direction, wherein the first direction is orthogonal to the second direction, reducing the length of the copper busbar assembly 100 in the first direction or the second direction. Compared with the copper busbar assembly 100 arranged only in one direction, this arrangement can reduce the volume of the copper busbar assembly 100 in a certain direction, making the copper busbar assembly 100 more compact in structure and occupying less space.

[0037] According to some embodiments of the present utility model, a support portion 24 protruding along the first direction is formed on the second copper row portion 22. The support portion 24 is disposed on the side of the installation position away from the connecting member 31. The support portion 24 cooperates with the connecting member 31 to limit the movement of the copper row body relative to the power module.

[0038] In some specific embodiments, a support portion 24 is formed on the second copper row. The support portion 24 extends in the first direction. A first mounting hole is formed on the support portion 24, and a second mounting hole is formed on the connecting member 31. The first connection hole and the second connection hole can be connected by bolts, thereby fixing the power module to the copper row assembly 100 and realizing the connection between the power module and the copper row assembly 100.

[0039] According to some embodiments of the present utility model, the support portions 24 are configured to be multiple and are arranged at intervals on the second copper row portion 22. The connecting members 31 and the fastening members 32 are configured to be multiple and are arranged in one-to-one correspondence with the support portions 24. During the assembly process of the support portion 24 and the connecting member 31, each support portion 24 and its corresponding connecting member 31 can be independently installed and adjusted, which is convenient for precise alignment and fastening, reducing the assembly complexity of the copper row body and the power module. At the same time, when maintaining the equipment or replacing faulty components, the connecting member 31 and the support portion 24 with a connection failure can be dealt with specifically without affecting the normal connection of other connecting members 31 and support portions 24. In addition, the design of multiple support portions 24 and multiple connecting members 31 can increase the connection points between the copper row body and the power module, improving the stability and reliability of the connection between the copper row body and the power module.

[0040] According to some embodiments of the present utility model, the injection-molded housing includes: a first covering portion 11 and a second covering portion 12. The first covering portion 11 covers at least a part of the outer periphery of the first copper busbar portion 21, and the first covering portion 11 also covers at least a part of the outer periphery of the connection busbar 23 and fills the gap between two adjacent connection busbars 23 to improve the current transmission performance of the copper busbar assembly 100. The second covering portion 12 is connected to the first covering portion 11, and the second covering portion 12 covers the outer periphery of the second copper busbar portion 22. A protrusion 15 protruding in the first direction and fitting with the support portion 24 is formed on the second covering portion 12. An installation position is provided on the protrusion 15, and the bottom of the protrusion 15 is configured as an installation surface. The connecting member 31 is received in the installation position, and the fastening member 32 is provided at one end of the connecting member 31 away from the installation surface. The fastening member 32 is connected to the installation surface to fix the connecting member 31 between the fastening member 32 and the installation surface. The connecting members 31 are spaced from the installation surface, so that there is a certain gap between at least some of the connecting members 31 and the surface, and at least some of the connecting members 31 can move a certain distance in the thickness direction and the horizontal direction within the installation position, reducing the matching difficulty among the connecting member 31, the support portion 24, and the power module, reducing the assembly difficulty between the connecting member 31 and the power module, and improving the connection accuracy and assembly efficiency between the power module and the copper busbar assembly 100.

[0041] According to some embodiments of the present utility model, the injection-molded housing is connected to the motor controller by bolts. The injection-molded housing is further provided with a third covering portion 13. The third covering portion 13 is disposed around at least a part of the outer periphery of the first covering portion 11 and is located at the connection busbar 23. A sealing surface is formed on the top surface of the third covering portion 13. One end surface of the motor controller housing 200 in the axial direction is attached to the sealing surface to prevent moisture, dust, or other contaminants in the external environment from entering the interior of the motor controller housing 200. A sealing groove disposed in a surrounding manner may be formed on the sealing surface. A sealing member is further provided in the copper busbar assembly 100. The sealing member is embedded in the sealing groove. The sealing member can usually be made of an elastic material, such as rubber or silica gel, and can fill any tiny gaps in a compressed state to provide a continuous sealing barrier to further enhance the sealing performance between the injection-molded housing and the motor controller housing 200.

[0042] According to some embodiments of the present utility model, the injection-molded housing is configured as a plastic part. The injection-molded housing can be made of polyphenylene sulfide material. Since polyphenylene sulfide has good insulation properties, using it as the manufacturing material of the injection-molded housing can ensure the insulation performance between the injection-molded housing and the connection busbar 23, improve the safety of the motor controller during operation, and at the same time, there is no need to separately treat the surface of the connection busbar 23, which can reduce the production process of the copper busbar body and lower the manufacturing cost.

[0043] According to some embodiments of the present utility model, the copper busbar assembly 100 further includes: an adhesive layer, which is disposed between the first covering portion 11 and the connecting busbar 23. The adhesive layer can fill the tiny gap between the first covering portion 11 and the connecting busbar 23, thereby forming a tight sealing layer between the connecting busbar 23 and the first covering portion 11, preventing external environmental factors such as moisture and dust from invading, improving the sealing performance between the connecting busbar 23 and the first covering portion 11. At the same time, the adhesive layer also has good insulation performance and can provide additional electrical insulation for the connecting layer and the first covering portion 11.

[0044] The motor controller according to the present utility model will be briefly described below.

[0045] The motor controller according to the present utility model is provided with the copper busbar assembly 100 described in any one of the above embodiments. Since the motor controller according to the present utility model is provided with the copper busbar assembly 100 described in any one of the above embodiments, the copper busbar assembly 100 of the motor controller according to the present application has good insulation performance, sealing performance, and stable current transmission performance, improving the stability and reliability during the operation of the motor controller.

[0046] The vehicle according to the present utility model will be briefly described below.

[0047] The vehicle according to the present utility model is provided with the motor controller described in any one of the above embodiments. Since the vehicle according to the present utility model is provided with the motor controller described in any one of the above embodiments, the vehicle according to the present application has higher stability, better safety, and stronger reliability during operation. In the description of the present utility model, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc. indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present utility model and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus cannot be construed as a limitation of the present utility model.

[0048] In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be construed as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include one or more of such features. In the description of the present utility model, the meaning of "a plurality" is two or more unless otherwise specifically defined.

[0049] In the present utility model, unless otherwise clearly defined and limited, terms such as "installation", "connection", "coupling", "fixation", etc. shall be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or an integral body; it may be a mechanical connection, an electrical connection, or a communication connection; it may be directly connected, or indirectly connected through an intermediate medium, and it may be the internal communication of two components or the interaction relationship between two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present utility model can be understood according to specific circumstances.

[0050] In the present utility model, unless otherwise clearly defined and limited, the first feature being "on" or "under" the second feature may be that the first and second features are in direct contact, or the first and second features are indirectly in contact through an intermediate medium. Moreover, the first feature being "above", "over" and "on top of" the second feature may be that the first feature is directly above or obliquely above the second feature, or merely indicates that the first feature has a higher horizontal height than the second feature. The first feature being "under", "beneath" and "underneath" the second feature may be that the first feature is directly below or obliquely below the second feature, or merely indicates that the first feature has a lower horizontal height than the second feature.

[0051] In the description of this specification, the description with reference to terms such as "one embodiment", "some embodiments", "example", "specific example", or "some examples", etc. means that the specific features, structures, materials, or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present utility model. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described may be combined in a suitable manner in any one or more embodiments or examples. In addition, without contradiction, those skilled in the art can combine and combine the different embodiments or examples described in this specification and the features of different embodiments or examples.

[0052] Although the embodiments of the present utility model have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present utility model, and the scope of the present utility model is defined by the claims and their equivalents.

Claims

1. A copper busbar assembly for a motor controller, characterized in that: include: A copper busbar body, on which a plurality of connecting bars (23) are formed; An injection-molded shell, the injection-molded shell covering at least a portion of the outer periphery of the copper bar body, and at least a portion of the injection-molded shell being arranged between two adjacent connecting bars (23), and a mounting position being formed on the injection-molded shell; A connecting piece (31), the connecting piece (31) being arranged on the installation position, and the connecting piece (31) being suitable for connecting the injection-molded housing with the power module; A fastener (32), the fastener (32) being arranged on a side of the connecting member (31) away from the mounting position, the fastener (32) being suitable for being connected to the injection-molded shell to limit movement of the connecting member (31) relative to the injection-molded shell in a thickness direction.

2. The copper busbar assembly for a motor controller according to claim 1, characterized in that: The copper busbar body comprises: A first copper bar portion (21), the first copper bar portion (21) being connected to the plurality of connecting bars (23), and the first copper bar portion (21) extending along a first direction; A second copper bar portion (22), the second copper bar portion (22) is connected to the first copper bar portion (21), and the second copper bar portion (22) extends along a second direction, wherein the first direction is orthogonal to the second direction.

3. The copper busbar assembly for a motor controller according to claim 2, characterized in that: A support portion (24) protruding along a first direction is formed on the second copper busbar portion (22); the support portion (24) is arranged on a side of the installation position away from the connecting piece (31); the support portion (24) cooperates with the connecting piece (31) to limit the movement of the copper busbar body relative to the power module.

4. The copper busbar assembly for a motor controller according to claim 3, characterized in that: The supporting parts (24) are constructed in plurality and are arranged at intervals on the second copper bar part (22); the connecting parts (31) and the fastening parts (32) are constructed in plurality and are arranged in one-to-one correspondence with the supporting parts (24).

5. The copper busbar assembly for a motor controller according to claim 3, characterized in that: The injection molded housing comprises: A first covering portion (11), the first covering portion (11) covering at least a portion of the outer circumference of the first copper bar portion (21); A second covering portion (12), the second covering portion (12) is connected to the first covering portion (11), the second covering portion (12) covers the outer periphery of the second copper bar portion (22), a protrusion (15) protruding toward the first direction and fitting with the support portion (24) is formed on the second covering portion (12), a mounting position is arranged on the protrusion (15), the bottom of the protrusion (15) is constructed as a mounting surface, and the connecting member (31) and the mounting surface are arranged at intervals.

6. The copper busbar assembly for a motor controller according to claim 5, characterized in that: The injection molded housing further comprises: a third covering portion (13), the third covering portion (13) being arranged around at least a portion of the outer periphery of the first covering portion (11) and being located at the connecting row (23), the top surface of the third covering portion (13) being formed with a sealing surface abutting against a motor controller housing, the sealing surface being formed with a sealing groove; The copper busbar assembly further includes a sealing member, which is disposed in the sealing groove to seal the connection between the motor controller housing and the injection molding housing.

7. The copper busbar assembly for a motor controller according to claim 1, characterized in that: The injection-molded housing is designed as a plastic part.

8. The copper busbar assembly for a motor controller according to claim 5, characterized in that: Also includes: A glue coating layer, wherein the glue coating layer is arranged between the first covering portion (11) and the connecting row (23).

9. A motor controller, characterized in that: A copper busbar assembly comprising any one of claims 1 to 8.

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

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