Capacitor assembly, motor controller and vehicle

Abstract

The utility model relates to a capacitor assembly, a motor controller and a vehicle, and the capacitor assembly comprises a housing which is provided with an accommodation space and an opening communicated with the accommodation space; the capacitor is at least partially arranged in the accommodating space; the first busbar body is suitable for enabling the first electrode of the capacitor to be connected with a power switch of a motor controller; wherein the first busbar body comprises a part which is arranged in the accommodating space to be connected with the capacitor and the other part which is arranged at the opening to be connected with a power switch of the motor controller. The capacitor assembly, the motor controller and the vehicle have the advantages of being flexible in structure and good in universality.

Description

Technical Field

[0001] The present application relates to the technical field of electronic devices, and in particular, to a capacitor assembly, a motor controller, and a vehicle. Background Art

[0002] The capacitor assembly is one of the core components of some electronic control devices, including a bus capacitor and a bus bar, etc. The bus capacitor is electrically connected to external devices through the bus bar. For example, in a motor controller, the bus capacitor is connected to each phase of the IGBT (Insulated Gate Bipolar Transistor) power tube through the bus bar.

[0003] In some application scenarios, when the capacitor assembly matches external devices with different specifications or distances, it is necessary to replace the bus bar or the bus capacitor, etc. to meet the adaptation requirements. However, the capacitor assembly in the prior art has problems such as poor structural flexibility and versatility, resulting in inconvenient replacement. Summary of the Utility Model

[0004] An embodiment of the present application provides a capacitor assembly to improve the structural flexibility and versatility of the bus bar, so as to at least partially solve the above technical problems.

[0005] To achieve the above object, according to the first aspect of the present application, a capacitor assembly is provided, including:

[0006] A housing having an accommodation space and an opening communicating with the accommodation space;

[0007] A capacitor, at least partially disposed in the accommodation space;

[0008] A first bus bar body adapted to connect the first electrode of the capacitor to a power switch of a motor controller;

[0009] Wherein, the first bus bar body includes a part disposed in the accommodation space to connect the capacitor and another part disposed at the opening to connect the power switch of the motor controller.

[0010] Optionally, the capacitor assembly further includes: a first insulator, at least disposed in the accommodation space to fill between the capacitor, the first bus bar body, and / or the housing; the first insulator has a first surface disposed at the opening; a part of the first bus bar body disposed at the opening extends out of the first surface.

[0011] Optionally, a first external terminal is connected between the first bus bar body and the power switch.

[0012] The first busbar body includes: a first busbar joint portion, the first busbar joint portion having: a first busbar extension surface extending at least along a first direction; a first busbar contact surface extending at least along a third direction;

[0013] The first external terminal includes: a first terminal joint portion connected to the first busbar joint portion; a first terminal connection portion connected between the first terminal joint portion and a power switch of the motor controller; wherein, the first terminal joint portion has a first terminal contact surface, and the first busbar contact surface and the first terminal contact surface are arranged in a fitting manner.

[0014] Optionally, in a second direction, a plurality of the first terminal connection portions are arranged at intervals.

[0015] Optionally, in a third direction, a plurality of the first terminal connection portions are arranged in alignment.

[0016] Optionally, the first terminal connection portion is bent relative to the first terminal joint portion.

[0017] Optionally, the capacitor assembly further includes: a second busbar body adapted to connect the second electrode of the capacitor to a power switch of the motor controller; wherein, the second busbar body includes a part arranged in the accommodation space to connect a part of the capacitor and another part arranged at the opening to connect the power switch of the motor controller.

[0018] Optionally, the capacitor assembly further includes: a first external terminal connected between the first busbar body and the power switch; a second external terminal connected between the second busbar body and the power switch;

[0019] Wherein, the first external terminal includes: a first terminal joint portion connected to the first busbar body; a first terminal connection portion connected between the first terminal joint portion and a power switch of the motor controller;

[0020] The second external terminal includes: a second terminal joint portion connected to the second busbar body; a second terminal connection portion connected between the second terminal joint portion and a power switch of the motor controller.

[0021] Optionally, the first busbar body includes: a first busbar joint portion, the first busbar joint portion is connected to the first terminal joint portion; the second busbar body includes: a second busbar joint portion, the second busbar joint portion is connected to the second terminal joint portion; at least part of the first busbar joint portion is arranged between the first terminal joint portion and the second busbar joint portion, and at least part of the second busbar joint portion is arranged between the second terminal joint portion and the first busbar joint portion.

[0022] Optionally, the capacitor assembly further includes: an insulating layer disposed at least partially between the first busbar body and the second busbar body to insulate the first busbar body and the second busbar body from each other, and the insulating layer is insulating glue filling and / or insulating paper.

[0023] Optionally, at least two layers of the insulating paper are provided between the first busbar joint and the second busbar joint.

[0024] Optionally, the first busbar joint has: a first extending structure extending at least along a first direction; a first contacting structure extending at least along a third direction; and the insulating paper extends at least from the first extending structure to the first contacting structure;

[0025] The second busbar joint has: a second extending structure extending at least along a first direction; a second contacting structure extending at least along a third direction; and the insulating paper extends at least from the second extending structure to the second contacting structure.

[0026] Optionally, the insulating paper is bent to cover at least a part of the first terminal joint and / or the first busbar joint.

[0027] Optionally, the insulating paper is bent to cover at least a part of the second terminal joint and / or the second busbar joint.

[0028] According to a second aspect of the present application, a motor controller is provided, including the capacitor assembly and a power switch as described above.

[0029] According to a third aspect of the present application, a vehicle is further provided, including the motor controller as described above.

[0030] The beneficial effects of the present application are as follows: a capacitor assembly, a motor controller and a vehicle with flexible structure and good versatility are provided.

[0031] More specifically, some embodiments of the present application may produce the following specific beneficial effects:

[0032] Since a part of the first busbar body is disposed in the accommodation space and another part is disposed at the opening to connect the power switch of the motor controller, that is, the first busbar body is not completely disposed in the accommodation space, the first busbar body can be connected to external devices through externally connected different conductors such as terminals and wires. Thus, the first busbar body can be flexibly matched with the power switch, improving the structural flexibility of the capacitor assembly, and by replacing the externally connected conductors, it can be adapted to power switches of various specifications or distances, with good versatility.

[0033] Other features and advantages of the present application will be described in detail in the subsequent specific implementation part. Brief Description of the Drawings

[0034] To more clearly illustrate the technical solutions in the embodiments of the present application, the following will briefly introduce the drawings required for the description of the embodiments. Obviously, the drawings in the following description are only some embodiments of the present application. For those skilled in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0035] To more fully understand the present application and its beneficial effects, the following will be described in conjunction with the drawings, where the same reference numerals represent the same parts in the following description.

[0036] Figure 1 is a schematic diagram of the overall structure of the capacitor assembly provided in the exemplary embodiment of the present application;

[0037] Figure 2 is a top view of a partial structure of the capacitor assembly provided in the exemplary embodiment of the present application;

[0038] Figure 3 is an electrical topology diagram of the capacitor assembly provided in the exemplary embodiment of the present application;

[0039] Figure 4 is a schematic diagram of the structure of the bus capacitor and the safety capacitor in the capacitor assembly provided in the exemplary embodiment of the present application;

[0040] Figure 5 is a connection relationship diagram of the first busbar body and the second busbar body in the capacitor assembly provided in the exemplary embodiment of the present application with external terminals, power terminals, and sampling terminals;

[0041] Figure 6 is Figure 5 an enlarged schematic diagram of a part of

[0042] Figure 7 is Figure 5 an exploded view of the connection relationship of the first busbar body and the second busbar body shown in with switch terminals, power terminals, and sampling terminals;

[0043] Figure 8 is a cross-sectional view of the capacitor assembly provided in the exemplary embodiment of the present application in an unencapsulated state;

[0044] Figure 9 is a cross-sectional view of the capacitor assembly provided in the exemplary embodiment of the present application in an encapsulated state;

[0045] Figure 10 is Figure 9 an enlarged schematic diagram of a part of

[0046] Figure 11 It is another cross-sectional view of the capacitor assembly provided in the exemplary embodiment of the present application;

[0047] Figure 12 It is a schematic diagram of the overall structure of the vehicle provided in the exemplary embodiment of the present application.

[0048] Description of reference numerals:

[0049] 1. Vehicle;

[0050] 10. Capacitor assembly;

[0051] 110. First busbar body; 111. First welding terminal; 112. First busbar connection part; 113. First busbar joint part; 113a. First extension structure; 113b. First contact structure; 113c. First busbar contact surface; 113d. First busbar extension surface; 114. First bridging part;

[0052] 120. Second busbar body; 121. Second welding terminal; 122. Second busbar connection part; 123. Second busbar joint part; 123a. Second extension structure; 123b. Second contact structure; 123c. Second busbar contact surface; 123d. Second busbar extension surface; 124. Second bridging part;

[0053] 100a. Installation space; 100b. Insulation space;

[0054] 210. Capacitor; 211. Busbar capacitor; 212. Safety capacitor;

[0055] 220. First external terminal; 220a. A-phase positive terminal connection part; 220b. B-phase positive terminal connection part; 220c. C-phase positive terminal connection part; 221. First terminal joint part; 221a. First terminal contact surface; 222. First terminal connection part;

[0056] 230. Second external terminal; 230a. A-phase negative terminal connection part; 230b. B-phase negative terminal connection part; 230c. C-phase negative terminal connection part; 231. Second terminal joint part; 231a. Second terminal contact surface; 232. Second terminal connection part;

[0057] 241. First power terminal; 242. Second power terminal;

[0058] 251. First sampling terminal; 252. Second sampling terminal;

[0059] 260. Housing; 260a. Accommodating space; 260b. Open end;

[0060] 271. First insulator; 271a. First surface; 272. Second insulator; 272a. Second surface; 273. Insulating layer; 274. First insulating paper; 274a. First main body portion; 274b. First branch portion; 275. Second insulating paper; 275a. Second main body portion; 275b. Second branch portion; 275c. Third branch portion;

[0061] 280. Partition member; 280a. Protection space; 290. Grounding terminal;

[0062] X. First direction; Y. Second direction; Z. Third direction;

[0063] D1. First spacing; D2. Second spacing. Detailed implementation manner

[0064] Next, the technical solutions in the embodiments of the present application will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative efforts belong to the protection scope of the present application.

[0065] According to the first aspect of the present application, with reference to Figure 1 , Figure 2 , Figures 4 to 8 , the present application provides a capacitor assembly 10, including a capacitor 210, a housing 260, a first busbar body 110, and a second busbar body 120.

[0066] The housing 260 has an accommodation space 260a and an opening 260b communicating with the accommodation space 260a. The capacitor 210 is disposed in the accommodation space 260a; at least a part of the capacitor 210 is disposed in the accommodation space 260a; the first busbar body 110 is adapted to connect the first electrode of the capacitor 210 to a power switch (not shown) of the motor controller; the second busbar body 120 is adapted to connect the second electrode of the capacitor 210 to the power switch of the motor controller. Specifically, the power switch includes an IGTB (Insulated Gate Bipolar Transistor) module.

[0067] In some embodiments, the first busbar body 110 includes a part disposed in the accommodation space 260a to connect the capacitor 210 and another part disposed at the opening 260b to connect the power switch of the motor controller.

[0068] Since a part of the first busbar body 110 is disposed within the accommodation space 260a and another part is disposed at the opening 260b to connect to the power switch of the motor controller, that is, the first busbar body 110 is not entirely disposed within the accommodation space 260a. Thus, the first busbar body 110 can be connected to external devices by externally connecting different conductors such as terminals and wires. Thereby, the first busbar body 110 can be flexibly matched with the power switch, improving the structural flexibility of the capacitor assembly 10, and by replacing the externally connected conductors, it can be adapted to power switches of various specifications or distances, with good versatility.

[0069] In some embodiments, referring to Figures 4 to 8 , the second busbar body 120 includes a part disposed within the accommodation space 260a to connect to the capacitor 210 and another part disposed at the opening 260b to connect to the power switch of the motor controller.

[0070] It can be understood that in this application, it can be selected to dispose a part of either the first busbar body 110 or the second busbar body 120 at the opening 260b to connect to the power switch of the motor controller, or both the first busbar body 110 and the second busbar body 120 have a part disposed at the opening 260b to connect to the power switch of the motor controller, and this is not limited. Additionally, a part of the first busbar body 110 and the second busbar body 120 is connected to the capacitor 210 and another part is connected to the power switch, which does not limit that the first busbar body 110 and the second busbar body 120 of this application only include these two parts, and may also include other functional parts, such as a part for connecting to a power source or a part for connecting to a sampling module, etc.

[0071] In some embodiments, referring to Figures 4 to 7 , the capacitor assembly 10 further includes a first external terminal 220 and a second external terminal 230.

[0072] The first busbar body 110 is connected to the power switch of the motor controller through the first external terminal 220, and the second busbar body 120 is connected to the power switch of the motor controller through the second external terminal 230. The first external terminal 220 has a first terminal joint portion 221, and the second external terminal 230 has a second terminal joint portion 231.

[0073] The first busbar body 110 has a first busbar connection portion 112 and a first busbar joint portion 113. The first busbar connection portion 112 is connected to the first electrode of the capacitor 210, and the first terminal joint portion 221 is joined to the first busbar joint portion 113 so that the first external terminal 220 and the first busbar body 110 form an electrical connection. The "joining" in this application can be understood as a detachable connection, a fixed connection, a surface contact, etc., which are ways that can achieve an electrical connection.

[0074] The second busbar body 120 has a second busbar connection portion 122 and a second busbar joint portion 123. The second busbar connection portion 122 is connected to the second electrode of the capacitor 210, and the second terminal joint portion 231 is joined to the second busbar joint portion 123 so that the second external terminal 230 and the second busbar body 120 are electrically connected.

[0075] The first busbar joint portion 113 and the second busbar joint portion 123 are stacked, and at least a part of the stacked portions is disposed in the accommodation space 260a of the housing 260. It can be understood that at least a part of the stacked first busbar joint portion 113 and the second busbar joint portion 123 extends from the inside of the accommodation space 260a of the housing 260 to outside the accommodation space 260a, or the first busbar joint portion 113 and the second busbar joint portion 123 can also be completely disposed in the accommodation space 260a to replace the extension length of the external terminal in the accommodation space 260a.

[0076] By stacking the first busbar joint portion 113 and the second busbar joint portion 123, and at least a part of the stacked portions is disposed in the accommodation space 260a of the housing 260, a part of the length of the external terminal is replaced by the stacked portion and extends outward, thereby reducing the length of the external terminal, effectively reducing the stray inductance, and reducing the risk of damage to the power switch.

[0077] In some embodiments, referring to Figure 1 、 Figure 2 、 Figure 5 and Figure 7 , the capacitor assembly 10 further includes a first power terminal 241 and a second power terminal 242.

[0078] The first power terminal 241 and the second power terminal 242 are respectively used to electrically connect the capacitor 210 to a power source. Specifically, the power source includes a battery pack (not shown). The first busbar body 110 is used to connect the first external terminal 220 and the first power terminal 241 to the first electrode of the capacitor 210 respectively; the second busbar body 120 is used to connect the second external terminal 230 and the second power terminal 242 to the second electrode of the capacitor 210 respectively. The current output by the power source enters the capacitor assembly 10 through the power terminals and is output from the first external terminal 220 and the second external terminal 230.

[0079] Exemplarily, referring to Figures 2 to 5 , the first busbar body 110 can be a positive busbar, and the second busbar body 120 can be a negative busbar. Correspondingly, the first power terminal 241 can be a positive power terminal, and the second power terminal 242 can be a negative power terminal.

[0080] The bus capacitor 211 is formed by connecting multiple winding cores in parallel. The first busbar body 110 is provided with a plurality of first welding terminals 111 evenly distributed thereon, and the second busbar body 120 is provided with a plurality of second welding terminals 121 evenly distributed thereon. The number of the first welding terminals 111 and the second welding terminals 121 is the same as the number of the winding cores. The upper and lower ends of the winding cores are respectively welded to the first welding terminals 111 and the second welding terminals 121.

[0081] In some embodiments, referring to Figure 2 , Figures 8 to 11 , the capacitor assembly 10 further includes: a first insulator 271.

[0082] The first insulator 271 is at least disposed in the accommodation space 260a, and is at least used for potting the accommodation space 260a of the housing 260, so that the first busbar body 110, the second busbar body 120, and the capacitor 210 are insulated in the accommodation space 260a, or filled between the capacitor 210, the first busbar body 110, the second busbar body 120, or the housing 260 to achieve insulation.

[0083] Optionally, the first insulator 271 is an insulating filler, and specifically, epoxy resin or silicone rubber can be selected.

[0084] The first insulator 271 has a first surface 271a disposed at the opening 260b, and at least a part of the first busbar joint portion 113 and / or the second busbar joint portion 123 disposed at the opening 260b protrudes from the first surface 271a.

[0085] It can be understood that at least a part of one of the first busbar joint portion 113 and the second busbar joint portion 123 may protrude from the first surface 271a, or at least a part of both the first busbar joint portion 113 and the second busbar joint portion 123 protrudes from the first surface 271a.

[0086] By disposing the first insulator 271 in the accommodation space 260a, the insulation performance of the first busbar body 110 and the second busbar body 120 is improved. And since one side of the housing 260 has an opening 260b, it is beneficial to fill the first insulator 271 into the accommodation space 260a.

[0087] In some embodiments, the first busbar body 110 and / or the second busbar body 120 has a multi-segment bending structure so that there are at least different first spacing D1 and second spacing D2 between the overlapping parts of the first busbar body 110 and the second busbar body 120.

[0088] The lamination in the present application can be understood as: the projections of the first busbar body 110 and / or the second busbar body 120 in any direction have overlapping parts, and the spacing between the two in the lamination direction is not specifically limited.

[0089] It can be understood that the first busbar body 110 and / or the second busbar body 120 having a multi-segment bending structure means that at least one of the first busbar body 110 and the second busbar body 120 has a multi-segment bending structure, so that the distance between the overlapping parts of the first busbar body 110 and the second busbar body 120 can change with the bending. Exemplarily, the first distance D1 can be used to meet the requirement of connecting the busbar capacitor 211. The second distance D2 is less than the first distance D1 and can match the input terminal structure of the power switch.

[0090] It can be understood that the first distance D1 is at least formed between the first busbar connection part 112 and the second busbar connection part 122, and the second distance D2 is at least formed between the first busbar joint part 113 and the second busbar joint part 123.

[0091] Through the above technical solution, by the first busbar body 110 and / or the second busbar body 120 having a multi-segment bending structure, so that there are at least different first distance D1 and second distance D2 between the overlapping parts of the first busbar body 110 and the second busbar body 120. By adjusting the different distance combinations between the overlapping parts of the first busbar body 110 and the second busbar body 120, while using the first distance D1 to meet the requirement of connecting the busbar capacitor 211, the overlapping part with the second distance D2 is used to match the input terminal structure of the power switch, reducing the length and bending times of the external terminal in the stacking direction.

[0092] It should be noted that the indication of the third direction Z in the present application indicating the up and down direction is only for the convenience of introducing the specific embodiments of the present application. There is no absolute corresponding relationship between the third direction Z and the up and down direction. Similarly, there is no absolute corresponding relationship between the first direction X and the front and back direction, and the second direction Y and the left and right direction. Moreover, the first direction X, the second direction Y and the third direction Z in the present application are only for expressing the relative position relationship. The first direction X, the second direction Y and the third direction Z can be perpendicular to each other or obliquely intersecting. They only indicate the general orientation, rather than the absolute geometric relationship.

[0093] In some embodiments, referring to Figures 5 to 11 , the first busbar joint part 113 includes: a first extension structure 113a. The second busbar joint part 123 includes: a second extension structure 123a.

[0094] The first extension structure 113a extends at least along the first direction X. The second extension structure 123a extends at least along the first direction X; the first extension structure 113a and the second extension structure 123a are stacked, and at least part of the first extension structure 113a and / or the second extension structure 123a penetrates through the first surface 271a.

[0095] When the distance between the capacitor 210 and the power switch in the motor controller is large, by adjusting the lengths of the first extension structure 113a and the second extension structure 123a in the first direction X, the first busbar joint 113 and the second busbar joint 123 can be made to match the installation distance between the busbar capacitor 211 and the power switch, so that the first busbar body 110 and the second busbar body 120 can be connected to the power switch without increasing the length of the external terminals.

[0096] The lengths of the first extension structure 113a and the second extension structure 123a protruding from the first surface 271a can be flexibly adjusted according to the position of the capacitor assembly 10 inside the motor controller.

[0097] In some embodiments, referring to Figures 5 to 11 , the first extension structure 113a and the second extension structure 123a are stacked. It can be understood that the projection of the second extension structure 123a in the third direction Z and the projection of the first extension structure 113a in the third direction Z at least partially overlap. By overlapping the first extension structure 113a and the second extension structure 123a, the stray inductance at the first extension structure 113a and the second extension structure 123a can be reduced. At the same time, through the abutting cooperation of the first extension structure 113a and the second extension structure 123a, the mutual positioning of the first busbar body 110 and the second busbar body 120 in the third direction Z can be achieved.

[0098] Optionally, the projection of the second extension structure 123a in the third direction Z and the projection of the first extension structure 113a in the third direction Z completely overlap, further reducing the stray inductance at the first extension structure 113a and the second extension structure 123a.

[0099] In some embodiments, referring to Figures 5 to 11 , the first busbar joint 113 further includes: a first contact structure 113b. The second busbar joint 123 further includes: a second contact structure 123b.

[0100] The first contact structure 113b extends at least along the third direction Z; the second contact structure 123b extends at least along the third direction Z; wherein, the third direction Z intersects or is perpendicular to the first direction X obliquely, the first terminal joint 221 is coupled to the first contact structure 113b, and the second terminal joint 231 is coupled to the second contact structure 123b.

[0101] The first terminal joint 221 and the first contact structure 113b are connected by welding; of course, the first terminal joint 221 and the first contact structure 113b can also be connected by other means, such as bolt connection or snap connection, etc., and this is not limited. Similarly, the connection method of the second terminal joint 231 and the second contact structure 123b is not limited either.

[0102] The first contact structure 113b and the second contact structure 123b are stacked to reduce the generation of stray inductance.

[0103] In some embodiments, the first external terminal 220 can be directly connected to the first extension structure 113a, and the second external terminal 230 can be directly connected to the second extension structure 123a, without the need to provide the first contact structure 113b and the second contact structure 123b.

[0104] In some embodiments, referring to Figures 5 to 11 , the projection of the first contact structure 113b in the first direction X and the projection of the first bridging portion 114 in the first direction X at least partially overlap. The projection of the second contact structure 123b in the first direction X and the projection of the first contact structure 113b in the first direction X at least partially overlap.

[0105] By defining the bending directions of the first contact structure 113b and the second contact structure 123b, while ensuring the distance between the first contact structure 113b and the second contact structure 123b, through the abutting cooperation between the first contact structure 113b and the second contact structure 123b, the positioning of the first busbar body 110 and the second busbar body 120 in the first direction X can be achieved. Combining the above abutting cooperation between the first extension structure 113a and the second extension structure 123a in the third direction Z, the positioning of the first busbar body 110 and the second busbar body 120 in the first direction X and the third direction Z is simultaneously achieved, improving the assembly efficiency.

[0106] In some embodiments, referring to Figures 5 to 8 , the first busbar joint portion 113 has: a first busbar extension surface 113d and a first busbar contact surface 113c. The first busbar extension surface 113d extends at least along the first direction X; the first busbar contact surface 113c extends at least along the third direction Z; wherein, the first terminal joint portion 221 has a first terminal contact surface 221a, and the first busbar contact surface 113c and the first terminal contact surface 221a are arranged in a fitting manner; the first direction X and the third direction Z are perpendicular or obliquely intersecting.

[0107] The "arranged in a fitting manner" here means that the first busbar contact surface 113c and the first terminal contact surface 221a extend in substantially the same direction and there is a small and uniform gap between them.

[0108] Through the fitting arrangement between the second busbar joint portion 123 and the second terminal joint portion 231, the stability of the structure is increased, and at the same time, the efficiency of electrical connection is improved, reducing power loss.

[0109] In some embodiments, referring to Figures 5 to 8, the second busbar joint portion 123 has: a second busbar extension surface 123d and a second busbar contact surface 123c. The second busbar extension surface 123d extends at least along the first direction X; the second busbar contact surface 123c extends at least along the third direction Z; the second terminal joint portion 231 has a second terminal contact surface 231a, and the second busbar contact surface 123c and the second terminal contact surface 231a are disposed in a fitting manner. The first direction X and the third direction Z are perpendicular or obliquely intersecting.

[0110] The "fitting arrangement" here means that the second busbar contact surface 123c and the second terminal contact surface 231a extend in substantially the same direction and there is a small and uniform gap between them.

[0111] Through the fitting arrangement between the second busbar joint portion 123 and the second terminal joint portion 231, the stability of the structure is increased, and at the same time, the efficiency of electrical connection is improved and power loss is reduced.

[0112] In some embodiments, referring to Figures 5 to 11 , the first busbar body 110 further has: a first bridging portion 114.

[0113] The first bridging portion 114 extends at least along the third direction Z; in the third direction Z, the first bridging portion 114 is located between the first busbar connection portion 112 and the first busbar joint portion 113. Specifically, the first bridging portion 114 is located between the first busbar connection portion 112 and the first extension structure 113a.

[0114] Through the arrangement of the first bridging portion 114, the first busbar connection portion and the first busbar joint portion 113 are respectively disposed at different positions in the third direction Z.

[0115] In some embodiments, referring to Figures 5 to 11 , the second busbar body 120 further has: a second bridging portion 124.

[0116] The second bridging portion 124 extends at least along the third direction Z; in the third direction Z, the second bridging portion 124 is located between the second busbar connection portion 122 and the second busbar joint portion 123. Specifically, the second bridging portion 124 is located between the second busbar connection portion 122 and the second extension structure 123a.

[0117] Through the arrangement of the second bridging portion 124, the second busbar connection portion 122 and the second busbar joint portion 123 are respectively disposed at different positions in the third direction Z.

[0118] Through the cooperation of the first bridging portion 114 and the second bridging portion 124, while adjusting the distance between the first busbar joint portion 113 and the second busbar joint portion 123, the first busbar joint portion 113 and the second busbar joint portion 123 are arranged at appropriate positions in the third direction Z, facilitating the adaptation of the first external terminal 220 and the second external terminal 230 to the input terminals of the power switch.

[0119] It can be understood that according to the position of the capacitor 210 inside the housing 260 or the installation position of the capacitor assembly 10 inside the motor controller, one or both combinations of the first bridging portion 114 and the second bridging portion 124 can be flexibly selected, and the above effect of adjusting the positions of the first busbar joint portion 113 and the second busbar joint portion 123 in the third direction Z can be achieved.

[0120] In some embodiments, referring to Figure 5 , the first power terminal 241 is connected to the first bridging portion 114, and the second power terminal 242 is connected to the second bridging portion 124.

[0121] In some embodiments, referring to Figure 5 、 Figures 8 to 11 , the first bridging portion 114 and the second bridging portion 124 are respectively arranged at different positions in the first direction X. By defining that the first bridging portion 114 and the second bridging portion 124 are at different positions in the first direction X, the first bridging portion 114 and the second bridging portion 124 are staggered to provide an insulation distance, avoiding short circuit caused by the first power terminal 241 or the second power terminal 242 contacting both bridging portions simultaneously during the extension along the third direction Z.

[0122] In some embodiments, referring to Figures 5 to 11 , the first external terminal 220 further includes: a first terminal connection portion 222.

[0123] The first terminal connection portion 222 is connected between the first terminal joint portion 221 and the power switch of the motor controller.

[0124] By setting the combination of the first terminal connection portion 222 and the first terminal joint portion 221, the welding surface is larger due to the cooperation between the first terminal contact surface 221a and the first busbar contact surface 113c. While increasing the structural stability of the external terminal, the length of the first terminal connection portion 222 can be determined according to the distance between the first busbar body 110 and the power switch. Without changing the structures such as the first busbar body 110 and the bus capacitor 211, different power switches can be matched only by replacing the first external terminal 220, and the structure has strong flexibility.

[0125] The first terminal coupling part 221 and the first terminal connection part 222 are integrally formed, or the first terminal coupling part 221 and the first terminal connection part 222 can be fixed by means such as welding or bolt connection, and no limitation is made thereto.

[0126] The second external terminal 230 further includes: a second terminal connection part 232.

[0127] The second terminal connection part 232 is connected between the second terminal coupling part 231 and the power switch of the motor controller.

[0128] Similarly, the combination of the second terminal connection part 232 and the second terminal coupling part 231 can achieve the same above effects, and the connection manner between the second terminal connection part 232 and the second terminal coupling part 231 is not limited and will not be elaborated herein.

[0129] In some embodiments, referring to Figures 1 to 3 、 Figure 5 and Figure 7 , in the second direction Y, a plurality of first terminal connection parts 222 are arranged at intervals.

[0130] It can be understood that the first external terminal 220 includes an A-phase positive terminal connection part 220a, a B-phase positive terminal connection part 220b, and a C-phase positive terminal connection part 220c. The A-phase positive terminal connection part 220a, the B-phase positive terminal connection part 220b, and the C-phase positive terminal connection part 220c are arranged at intervals in the second direction Y and are respectively electrically connected to the first busbar body 110, so that the first busbar body 110 can be respectively connected to multiple input ends of the power switch. At the same time, the distance between the A-phase positive terminal connection part 220a, the B-phase positive terminal connection part 220b, and the C-phase positive terminal connection part 220c can leave space for the arrangement of the first terminal connection part 222.

[0131] In the second direction Y, a plurality of second terminal connection parts 232 are arranged at intervals.

[0132] It can be understood that the second external terminal 230 includes an A-phase negative terminal connection part 230a, a B-phase negative terminal connection part 230b, and a C-phase negative terminal connection part 230c. The A-phase negative terminal connection part 230a, the B-phase negative terminal connection part 230b, and the C-phase negative terminal connection part 230c are arranged at intervals in the second direction Y and are respectively electrically connected to the second busbar body 120, so that the second busbar body 120 can be respectively connected to multiple input ends of the power switch. At the same time, the distance between the A-phase negative terminal connection part 230a, the B-phase negative terminal connection part 230b, and the C-phase negative terminal connection part 230c can leave space for the arrangement of the second terminal connection part 232.

[0133] In some embodiments, referring to Figure 1 、Figure 2 And Figure 5 in the third direction Z, a plurality of first terminal connection portions 222 are arranged in alignment. By arranging the plurality of first terminal connection portions 222 in alignment, it is convenient to connect with the power switch.

[0134] In some embodiments, referring to Figure 7 , the first terminal connection portion 222 is bent relative to the first terminal bonding portion 221. By bending the first terminal connection portion 222 relative to the first terminal bonding portion 221, while ensuring the connection strength between the first external terminal 220 and the first busbar body 110, the overall length of the first external terminal 220 in the first direction X is avoided from being too long.

[0135] The second terminal connection portion 232 is bent relative to the second terminal bonding portion 231. By bending the second terminal connection portion 232 relative to the second terminal bonding portion 231, while ensuring the connection strength between the second external terminal 230 and the second busbar body 120, the overall length of the second external terminal 230 in the first direction X is avoided from being too long.

[0136] In some embodiments, referring to Figures 8 to 11 , at least a part of the first busbar bonding portion 113 is arranged between the first terminal bonding portion 221 and the second busbar bonding portion 123; at least a part of the second busbar bonding portion 123 is arranged between the second terminal bonding portion 231 and the first busbar bonding portion 113. Adopting such a scheme enables the first terminal bonding portion 221 and the second terminal bonding portion 231 to be as close as possible, with a compact structure.

[0137] In some embodiments, referring to Figures 8 to 11 , the capacitor assembly 10 further includes: an insulating layer 273.

[0138] The insulating layer 273 is at least partially disposed between the first busbar body 110 and the second busbar body 120 to insulate the first busbar body 110 and the second busbar body 120 from each other, and the insulating layer 273 is insulating filler and / or insulating paper.

[0139] It can be understood that the insulating layer 273 can achieve insulation only by using insulating paper, or by using insulating filler. The insulating layer can also be a combination of insulating filler and insulating paper, which can protect the insulating paper from moisture while achieving the insulation effect.

[0140] Optionally, the insulating filler can be selected from epoxy resin, silicone, etc. The insulating paper can be selected from PT insulating paper, PI film, etc.

[0141] The insulating paper is at least partially disposed between the first busbar bonding portion 113 and the second busbar bonding portion 123. The insulating paper is in surface contact with both the first busbar bonding portion 113 and the second busbar bonding portion 123.

[0142] Through the arrangement of the insulating paper, insulation between the first busbar joint portion 113 and the second busbar joint portion 123 is achieved. At the same time, it can avoid the situation that the insulating sealant cannot be completely filled due to the limitation of the gap size between the first busbar joint portion 113 and the second busbar joint portion 123, ensuring the insulation effect.

[0143] In some embodiments, referring to Figures 8 to 11 , there are at least two layers of insulating paper between the first busbar joint portion 113 and the second busbar joint portion 123. By arranging multiple layers of insulating paper, the insulation effect is further improved.

[0144] In some embodiments, referring to Figures 8 to 11 , between the first busbar joint portion 113 and the second busbar joint portion 123, a first layer of insulating paper 274 and a second layer of insulating paper 275 can be arranged.

[0145] The first layer of insulating paper 274 extends from the first extension structure 113a to the first contact structure 113b. By designing the shape of the first layer of insulating paper 274 to fit the first extension structure 113a and the first contact structure 113b, the adhesion to the first busbar joint portion 113 is improved, and the insulation effect is enhanced.

[0146] The second layer of insulating paper 275 extends from the second extension structure 123a to the second contact structure 123b. By designing the shape of the second layer of insulating paper 275 to fit the second extension structure 123a and the second contact structure 123b, the adhesion to the second busbar joint portion 123 is improved, and the insulation effect is enhanced.

[0147] In some embodiments, referring to Figures 8 to 11 , the insulating paper is bent to cover at least a part of the first terminal joint portion 221 and / or the first busbar joint portion 113.

[0148] In one example, the first layer of insulating paper 274 includes a first main body portion 274a and a first branch portion 274b. The first main body portion 274a is arranged between the first busbar joint portion 113 and the second busbar joint portion 123. The first branch portion 274b bends towards the first terminal joint portion 221 at a position where the first contact structure 113b is far from the first extension structure 113a, so that the first branch portion 274b can cover a part of the first terminal joint portion 221, realizing the isolation between the first terminal joint portion 221 and the first bridging portion 114.

[0149] Adopting such a solution can improve the insulation isolation of the first terminal joint portion 221 while ensuring the insulation between the first busbar joint portion 113 and the second busbar joint portion 123, thereby improving the reliability of the capacitor assembly 10.

[0150] In some embodiments, referring to Figures 8 to 11 , the insulating paper is bent so as to cover at least a part of the second terminal joint 231 and / or the second busbar joint 123.

[0151] In one example, the second insulating paper 275 includes a second main body portion 275a, a second branch portion 275b, and a third branch portion 275c. The second main body portion 275a is disposed between the first busbar joint 113 and the second busbar joint 123. The second branch portion 275b is bent toward the second terminal joint 231 at a position away from the second extension structure 123a of the second contact structure 123b, so that the second branch portion 275b can cover a part of the second terminal joint 231. Since the second branch portion 275b is located outside the whole formed by the second busbar joint 123 and the second terminal joint 231, the second branch portion 275b can cover a part of the second terminal joint 231, and it is possible to prevent the second busbar joint 123 and the second terminal joint 231 from being exposed and causing a short circuit. The third branch portion 275c is bent toward the second bridging portion 124 at a position away from the second contact structure 123b of the second extension structure 123a, covering at least a part of the second bridging portion 124, thereby better isolating the first busbar body 110 and the second busbar body 120 to prevent a short circuit.

[0152] Adopting such a solution can improve the reliability of the capacitor assembly 10 while ensuring the insulation between the first busbar body 110 and the second busbar body 120.

[0153] In some embodiments, referring to Figure 1 , Figures 8 to 11 , the capacitor assembly 10 further includes: a partition member 280.

[0154] The partition member 280 has a protection space 280a extending in the first direction X; at least a part of the partition member 280 protrudes from the first surface 271a, and at least a part of the first busbar joint 113 and / or the second busbar joint 123 is located in the protection space 280a. It can be understood that the portions of the first busbar joint 113 combined with the first terminal connection portion 222 and the portions of the second busbar joint 123 combined with the second terminal connection portion 232 extend into the protection space 280a.

[0155] By providing the partition member 280, the first busbar joint 113 and the second busbar joint 123 protruding from the first surface 271a can be protected.

[0156] In some embodiments, referring to Figures 9 to 11 , the capacitor assembly 10 further includes: a second insulator 272.

[0157] The second insulator 272 fills at least a part of the protection space 280a. The second insulator 272 further has a second surface 272a disposed at the protection space 280a, and at least a part of the first external terminal 220 and / or the second external terminal 230 protrudes from the second surface 272a.

[0158] Optionally, the second insulator 272 is an insulating potting compound, and specifically, epoxy resin or silica gel can be selected, etc.

[0159] By filling the second insulator 272 into the protection space 280a, at least the laminated portions of the first busbar joint portion 113 and the second busbar joint portion 123 are wrapped, increasing the insulation performance between the first busbar joint portion 113 and the second busbar joint portion 123 and the insulation performance between multiple groups of external terminals. At the same time, it prevents the moisture absorption of the insulating paper or being damaged by other devices inside the motor controller, improving the safety performance of the capacitor assembly 10.

[0160] Since it is considered that the filling thickness of the second insulator 272 in the protection space 280a affects the overall size of the capacitor assembly 10 in the first direction, the distance from the second surface 272a to the second terminal joint portion 231 and the second busbar joint portion 123 is limited, and there is an easy short - circuit risk after the second surface 272a is damaged.

[0161] Based on the above considerations, through the arrangement of the second branch portion 275b, even if the second surface 272a is damaged, it can still insulate and isolate the second terminal joint portion 231 and the second busbar joint portion 123, avoiding the short - circuit problem caused by exposure.

[0162] In some embodiments, referring to Figures 9 to 11 , the projected profile of the partition member 280 in the first direction X is smaller than the projected profile of the housing 260 in the first direction X.

[0163] It can be understood that the cross - sectional area of the partition member 280 is smaller than the cross - sectional area of the housing 260, so that while meeting the insulation requirements, the partition member 280 reduces the potting amount of the second insulator 272, the weight of the capacitor assembly 10, and the occupied space of the capacitor assembly 10.

[0164] In the capacitor assembly 10 of the present application, the second insulator 272 adopts a multi - time potting method:

[0165] First, perform the first potting on the housing 260. The first surface 271a of the first potting reaches the bottom of the partition member 280. The first surface 271a can be flush with the opening 260b of the housing 260 or cover a part of the partition member 280. After the second insulator 272 is cured, a new cavity is formed between the first surface 271a and the partition member 280. Subsequently, perform the second potting to fill the partition member 280 to form the second surface 272a, covering the first busbar joint 113, the second busbar joint 123, and part of the external terminals.

[0166] In some embodiments, the partition member 280 is further provided with a snap structure (not shown) for snap - connecting to the first busbar body 110 or the second busbar body 120 to achieve the positioning of the partition member 280 and ensure that the partition member 280 does not shift during the potting process.

[0167] In some embodiments, referring to Figures 1 to 5 , the capacitor 210 includes: a bus capacitor 211 and a safety capacitor 212.

[0168] The bus capacitor 211 is disposed in the accommodation space 260a; the first electrode of the bus capacitor 211 is connected to the first busbar connection portion 112, and the second electrode of the bus capacitor 211 is connected to the second busbar connection portion 122. The bus capacitor 211 is used for energy storage and voltage stabilization.

[0169] The safety capacitor 212 is disposed in the accommodation space 260a and is located between the first busbar connection portion 112 and the second busbar connection portion 122. Specifically, the safety capacitor 212 is a Y - capacitor. The first electrode of the safety capacitor 212 is electrically connected to the first busbar connection portion 112, the second electrode of the safety capacitor 212 is electrically connected to the second busbar connection portion 122, and the middle terminal of the safety capacitor 212 is electrically connected to the ground terminal 290 to reduce the common - mode interference of the motor controller circuit. The ground terminal 290 is fixedly connected to the housing 260.

[0170] By integrating the safety capacitor 212 and the bus capacitor 211 into the housing 260, the installation process of the motor controller is reduced, the processing difficulty is lowered, and the process quality is improved.

[0171] The safety capacitor 212 and the bus capacitor 211 are adjacent to each other in the second direction Y. This enables the safety capacitor 212 to be as close as possible to the power switch, reducing the noise loop area of the motor controller, thereby reducing noise and facilitating the motor controller to suppress common - mode interference.

[0172] In some embodiments, referring to Figure 1 、 Figure 5 、 Figures 7 to 9, a part of the first power terminal 241 and / or a part of the second power terminal 242 are bent from inside the accommodation space 260a to outside the accommodation space 260a onto the housing 260, and the power terminal is connected to the DC bus bar by a fixing bolt.

[0173] The projection of the power terminal in the third direction Z and the projection of the safety capacitor 212 in the third direction Z at least partially overlap, so as to make full use of the space above the housing 260.

[0174] In some embodiments, the fixing bolts of the first power terminal 241 and the second power terminal 242 are at least partially located inside the accommodation space 260a and above the safety capacitor 212, making full use of the space inside the housing 260, avoiding occupying additional space inside the motor controller outside the capacitor assembly 10, and making the overall structure more compact.

[0175] In some embodiments, refer to Figure 1 , Figure 3 , Figure 5 and Figure 7 , the capacitor assembly 10 further includes a first sampling terminal 251 and a second sampling terminal 252. The motor controller can sample the voltages of the first bus bar body 110 and the second bus bar body 120 through the first sampling terminal 251 and the second sampling terminal 252.

[0176] Exemplarily, the first sampling terminal 251 is welded to the first bus bar body 110, and the second sampling terminal 252 is welded to the second bus bar body 120. More specifically, the first sampling terminal 251 is welded to the first bridging portion 114, and the second sampling terminal 252 is welded to the second bridging portion 124.

[0177] According to the second aspect of the present application, there is provided a motor controller, which includes the above-mentioned capacitor assembly and power switch, and the capacitor assembly is connected to the power switch through an external terminal. This motor controller has all the beneficial effects of the above-mentioned motor controller, and the present application will not elaborate herein.

[0178] According to the third aspect of the present application, refer to Figure 12 , there is provided a vehicle 1, which includes the above-mentioned motor controller, and this vehicle 1 has all the beneficial effects of the motor controller, and the present application will not elaborate herein.

[0179] This vehicle 1 can be a fuel vehicle, a plug-in hybrid vehicle or a new energy vehicle, etc., and the present application does not make specific limitations thereto.

[0180] In the description of the present application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more features. In the description of the present application, "a plurality of" means two or more, unless otherwise specifically defined.

[0181] In the above embodiments, the descriptions of the respective embodiments have their own emphases. For parts not elaborated in a certain embodiment, reference may be made to the relevant descriptions of other embodiments.

[0182] Among the embodiments, implementation manners and related technical features of the present application, they can be combined and replaced with each other without conflict.

[0183] The above are only the preferred embodiments of the present application and do not impose any formal restrictions on the present application. However, any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present application without departing from the content of the technical solution of the present application still fall within the scope of the technical solution of the present application.

Claims

1. A capacitor component, characterized in that: include: A housing having a receiving space and an opening communicating with the receiving space; A capacitor, at least partially disposed in the accommodation space; A first busbar body, adapted to connect the first electrode of the capacitor to a power switch of a motor controller; The first busbar body includes a portion disposed in the accommodation space to connect to the capacitor and another portion disposed at the opening to connect to a power switch of a motor controller.

2. The capacitor assembly according to claim 1, characterized in that: The capacitor assembly also includes: A first insulator is at least arranged in the accommodation space to fill between the capacitor, the first busbar body and / or the housing; The first insulator has a first surface disposed at the opening; a portion of the first busbar body disposed at the opening protrudes from the first surface.

3. The capacitor assembly according to claim 1, characterized in that: The capacitor assembly also includes: The first external terminal is connected between the first busbar body and the power switch.

4. The capacitor assembly according to claim 3, characterized in that: The first busbar body comprises: a first busbar joint portion, wherein the first busbar joint portion has: A first busbar extension surface extending at least along a first direction; The first busbar contact surface extends at least along a third direction; The first external terminal comprises: A first terminal joint portion, connected to the first busbar joint portion; A first terminal connecting portion connected between the first terminal combining portion and a power switch of the motor controller; The first terminal combining portion has a first terminal contact surface, and the first busbar contact surface and the first terminal contact surface are arranged in close contact.

5. The capacitor assembly according to claim 4, characterized in that: In the second direction, a plurality of the first terminal connection portions are arranged at intervals.

6. The capacitor assembly according to claim 4, characterized in that: In the third direction, a plurality of the first terminal connection portions are aligned.

7. The capacitor assembly according to claim 4, characterized in that: The first terminal connecting portion is bent relative to the first terminal combining portion.

8. The capacitor assembly according to claim 1, characterized in that: The capacitor assembly also includes: A second busbar body, adapted to connect the second electrode of the capacitor to a power switch of the motor controller; The second busbar body includes a portion disposed in the accommodation space to connect to the capacitor and another portion disposed at the opening to connect to a power switch of a motor controller.

9. The capacitor assembly according to claim 8, characterized in that: The capacitor assembly also includes: A first external terminal connected between the first busbar body and the power switch; A second external terminal connected between the second busbar body and the power switch; Wherein, the first external terminal comprises: A first terminal joint portion, connected to the first busbar body; A first terminal connecting portion connected between the first terminal combining portion and a power switch of the motor controller; The second external terminal comprises: A second terminal joint portion is connected to the second busbar body; The second terminal connecting portion is connected between the second terminal combining portion and the power switch of the motor controller.

10. The capacitor assembly according to claim 9, characterized in that: The first busbar body comprises: a first busbar coupling portion, the first busbar coupling portion being connected to the first terminal coupling portion; The second busbar body comprises: a second busbar coupling portion, the second busbar coupling portion being connected to the second terminal coupling portion; At least a portion of the first busbar coupling portion is disposed between the first terminal coupling portion and the second busbar coupling portion, and at least a portion of the second busbar coupling portion is disposed between the second terminal coupling portion and the first busbar coupling portion.

11. The capacitor assembly according to claim 10, characterized in that: The capacitor assembly also includes: An insulating layer, wherein the insulating layer is at least partially disposed between the first busbar body and the second busbar body to insulate the first busbar body from the second busbar body, and the insulating layer is insulating filler and / or insulating paper.

12. The capacitor assembly according to claim 11, characterized in that: At least two layers of the insulating paper are provided between the first busbar joint portion and the second busbar joint portion.

13. The capacitor assembly according to claim 12, characterized in that: The first busbar joint has: A first extending structure extending at least along a first direction; A first contact structure extending at least along a third direction; The insulating paper at least extends from the first extending structure to the first contact structure; The second busbar joint has: A second extension structure extending at least along the first direction; A second contact structure extending at least along a third direction; The insulating paper at least extends from the second extending structure to the second contact structure.

14. The capacitor assembly according to claim 12, characterized in that: The insulating paper is bent so as to cover at least a portion of the first terminal joint and / or the first busbar joint.

15. The capacitor assembly according to claim 12, characterized in that: The insulating paper is bent so as to cover at least a portion of the second terminal joint and / or the second busbar joint.

16. A motor controller, characterized in that: It comprises the capacitor assembly and the power switch as described in any one of claims 1 to 15.

17. A vehicle, characterized in that: Includes the motor controller as described in claim 16.

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