Film capacitor without plastic shell

Abstract

The utility model discloses a film capacitor without a plastic shell, which belongs to the technical field of new energy automobiles and comprises a controller casing, a film capacitor core and a film capacitor core mounting shell, the controller casing is integrally connected with the film capacitor core and the film capacitor core mounting shell in a die-casting manner, and the film capacitor core mounting shell is provided with a mounting cavity with an opening on one side. A thin-film capacitor assembly matched with the mounting cavity in shape is detachably arranged in the mounting cavity; the controller shell is provided with a first mounting side and a second mounting side, the thin-film capacitor core mounting shell is arranged on the first mounting side, and the opening of the mounting cavity is positioned on one side, far away from the controller shell, of the thin-film capacitor core mounting shell, so that a redundant mounting structure between the controller shell and the thin-film capacitor core mounting shell is not needed, the mounting steps can be greatly simplified, and the mounting efficiency is improved. The production cost is reduced; and a traditional installation plastic shell structure is not needed, the whole structure reduces heat conduction paths in heat dissipation, the heat dissipation efficiency is improved, and the service life of equipment can be further prolonged.

Description

Technical Field

[0001] The utility model relates to the technical field of new energy vehicles, in particular to a plastic-free film capacitor. Background Art

[0002] As one of the three major components of new energy vehicles, the motor controller, which is the energy conversion center of new energy vehicles, plays an irreplaceable role. The long service life, low cost, and high cost performance of the motor controller have become important parameters for measuring the performance of the motor controller. Among them, the film capacitor is one of the important components of the motor controller. The existing film capacitor is protected by an outer plastic shell, and the film capacitor is connected to the motor controller housing through fixing bolts. A heat-conducting silicone grease is provided between the film capacitor and the motor controller. The heat dissipation of the film capacitor is from the capacitor core to the potting compound inside the film capacitor, and then conducted to the plastic shell of the film capacitor. Finally, the plastic shell of the film capacitor conducts heat to the motor controller housing through the heat-conducting silicone grease for heat dissipation. The whole structure is relatively cumbersome and the heat dissipation efficiency is low, which may lead to a reduction in the service life of the motor controller. Summary of the Utility Model

[0003] To overcome the deficiencies, the technical problem to be solved by the utility model is: how to simplify the structure of the film capacitor and improve the heat dissipation efficiency.

[0004] The technical solution adopted by the utility model to solve its technical problems is:

[0005] A plastic-free film capacitor includes a controller housing and a film capacitor core mounting shell. The controller housing is integrally die-cast and connected to the film capacitor core mounting shell. The film capacitor core mounting shell is provided with an installation cavity with a single-sided opening, and a film capacitor assembly adapted to the shape of the installation cavity is detachably arranged in the installation cavity. The controller housing is provided with a first installation side and a second installation side. The film capacitor core mounting shell is arranged on the first installation side, and the opening of the installation cavity is located on the side of the film capacitor core mounting shell away from the controller housing. The integral setting of the film capacitor core mounting shell and the controller housing can directly install the film capacitor in the installation cavity without redundant installation structures between the film capacitor and the controller housing, which can greatly simplify the installation steps and reduce the production cost. Moreover, without the traditional plastic shell installation structure, the whole structure reduces the heat conduction path in heat dissipation, improves the heat dissipation efficiency, and can thus improve the service life of the equipment.

[0006] Further, a potting compound layer for insulation is provided between the installation cavity and the film capacitor assembly to ensure good insulation effect.

[0007] Further, the potting compound layer completely covers the outer wall of the film capacitor assembly.

[0008] Further, the above-mentioned thin-film capacitor assembly includes a thin-film capacitor core and a copper bar that are connected to each other, specifically defining the structure of the thin-film capacitor assembly.

[0009] Further, the above-mentioned thin-film capacitor assembly is provided with insulating paper for insulating contact with the mounting shell of the above-mentioned thin-film capacitor core.

[0010] Further, both the above-mentioned controller housing and the mounting shell of the above-mentioned thin-film capacitor core are aluminum die-castings. Aluminum die-castings are convenient for processing and the integrated molding process has a lower cost.

[0011] Further, a current output component, a filter magnetic ring, and a motor control drive board are also provided on the above-mentioned first mounting side, and a low-voltage connector and a control board are provided on the above-mentioned second mounting side. The thin-film capacitor assembly, the current output component, the filter magnetic ring, and the motor control drive board are on the same side, ensuring the wiring of the electronic circuit and the design of the heat dissipation structure.

[0012] The beneficial effects of the present utility model are as follows:

[0013] By integrally setting the mounting shell of the thin-film capacitor core and the controller housing, the thin-film capacitor assembly can be directly mounted in the mounting cavity without an extra mounting structure between the thin-film capacitor assembly and the controller housing, which can greatly simplify the mounting steps and reduce the production cost. Moreover, without the traditional mounting plastic shell structure, the entire structure reduces the heat conduction path in heat dissipation, improves the heat dissipation efficiency, and thus can improve the service life of the device. Description of the Drawings

[0014] Figure 1 is a schematic diagram of the unmounted structure of the thin-film capacitor assembly of the present utility model;

[0015] Figure 2 is a schematic diagram of the mounted structure of the thin-film capacitor assembly of the present utility model;

[0016] Figure 3 is a cross-sectional view of the mounted structure of the present utility model;

[0017] In the figure, the labels are: 1 - controller housing, 2 - mounting shell of the thin-film capacitor core, 3 - mounting cavity, 4 - thin-film capacitor assembly, 5 - potting glue layer, 6 - first mounting side, 7 - second mounting side, 41 - thin-film capacitor core, 42 - copper bar, 43 - insulating paper. Detailed Embodiment

[0018] The present utility model will be further described below with reference to the drawings.

[0019] As Figures 1 - 3As shown in the figure, an embodiment of the present application provides a plastic-free film capacitor, which includes a controller housing 1 and a film capacitor core mounting shell 2. The above-mentioned controller housing 1 and the above-mentioned film capacitor core mounting shell 2 are integrally die-cast and connected. The above-mentioned film capacitor core mounting shell 2 is provided with an installation cavity 3 with a single-sided opening. A film capacitor assembly 4 adapted to the shape of the above-mentioned installation cavity 3 is detachably arranged in the above-mentioned installation cavity 3; the above-mentioned controller housing 1 is provided with a first installation side 6 and a second installation side 7. The above-mentioned film capacitor core mounting shell 2 is arranged on the above-mentioned first installation side 7, and the opening of the above-mentioned installation cavity 3 is located on the side of the above-mentioned film capacitor core mounting shell 2 away from the above-mentioned controller housing 1.

[0020] It should be noted that the integral setting of the film capacitor core mounting shell 2 and the controller housing 1 can directly install the film capacitor in the installation cavity 3 without redundant installation structures between the controller housing 1, which can greatly simplify the installation steps and reduce the production cost; moreover, there is no need for a traditional plastic shell structure for installation. The entire structure reduces the heat conduction path in heat dissipation, improves the heat dissipation efficiency, and thus can extend the service life of the equipment.

[0021] Moreover, an encapsulating glue layer 5 for insulation is provided between the above-mentioned installation cavity 3 and the above-mentioned film capacitor assembly 4 to ensure good insulation and protection effects.

[0022] It is worth noting that the above-mentioned first installation side 6 is the installation direction towards the motor or the electric drive axle, so that the film capacitor assembly 4 is installed between the connection part of the motor or the electric drive axle and the controller housing 1 to ensure the sealing performance after installation. Moreover, the installation cavity 3 is integrally die-cast by the motor controller housing 1 and the film capacitor core mounting shell 2, and the processing process is simple and the cost is low. Moreover, both the above-mentioned controller housing 1 and the above-mentioned film capacitor core mounting shell 2 are aluminum die-castings, ensuring the high efficiency of the entire production and processing process.

[0023] The above-mentioned film capacitor assembly 4 includes a film capacitor core 41 and a copper row 42 connected to each other. Generally, after the film capacitor core 41 and the copper row 42 are integrally welded and fixed, the installation cavity 3 is filled with the encapsulating glue layer 5 to complete the complete insulation of the inner wall of the installation cavity 3. Then, the complete welded and fixed body is placed into the installation cavity 3, and then the encapsulating colloid is filled and sealed. That is to say, through two filling and encapsulation processes of the encapsulating colloid, the above-mentioned encapsulating glue layer 5 completely covers the outer wall of the Sohu film capacitor assembly 4, ensuring that the film capacitor assembly 4 is completely encapsulated in the film capacitor core mounting shell 2, and improving the encapsulation protection and insulation effects.

[0024] Moreover, the film capacitor assembly 4 is provided with an insulating paper 43 that is in insulating contact with the edge of the housing of the above-mentioned film capacitor core mounting shell 2. Specifically, after the insulating paper 43 is pressed against the copper row 42, the insulating function between the copper row 42 and the film capacitor core mounting shell 2 is realized.

[0025] In addition, a current output component, a filter magnetic ring, and a motor control drive board are further provided on the first installation side 6, and a low-voltage connector and a control board are provided on the second installation side 7, so as to realize the reasonable and orderly arrangement and placement of each component on the controller housing 1.

[0026] In the embodiment of the present application, by canceling the plastic shell of the traditional thin-film capacitor, the cavity for placing the thin-film capacitor core 41 generated inside the motor controller is reduced, reducing materials such as the plastic shell of the thin-film capacitor, the installation screws between the thin-film capacitor and the motor controller, and the heat-dissipating silicone grease coated between the thin-film capacitor and the motor controller housing 1. The steps of coating silicone grease on the thin-film capacitor and the step of locking the thin-film capacitor to the motor controller housing are reduced, simplifying the assembly process and reducing the production cost of the motor controller; moreover, the heat conduction path of the thin-film capacitor is reduced, the temperature of the thin-film capacitor is lowered, and the service life of the thin-film capacitor is improved.

[0027] Among them, the heat conduction path of the traditional thin-film capacitor is as follows: the thin-film capacitor core 41 conducts the heat generated after the operation of the motor controller passes through the thin-film capacitor filtering to the potting compound through the potting compound, and then the potting compound conducts the heat to the plastic shell of the thin-film capacitor, and the plastic shell of the thin-film capacitor conducts the heat to the motor controller housing 1 through the thermal conductive silicone grease. The heat conduction path of the thin-film capacitor assembly 4 in this embodiment is: the thin-film capacitor core 41 conducts to the potting compound, and the potting compound conducts the temperature to the motor controller housing 1. Compared with the heat conduction path of the traditional thin-film capacitor, the structure in this embodiment can effectively reduce the heat conduction path of the thin-film capacitor, lower the temperature of the thin-film capacitor, and improve the service life of the thin-film capacitor.

[0028] In summary, the present application proposes a plastic-shell-free thin-film capacitor, including a controller housing 1 and a thin-film capacitor core thin-film capacitor core mounting shell 2. The controller housing 1 is integrally die-cast and connected to the thin-film capacitor core thin-film capacitor core mounting shell 2. The thin-film capacitor core mounting shell 2 is provided with an installation cavity 3 with a single-side opening. A thin-film capacitor assembly 4 adapted to the shape of the installation cavity 3 is detachably arranged in the installation cavity 3. The controller housing 1 is provided with a first installation side 6 and a second installation side 7. The thin-film capacitor core mounting shell 2 is arranged on the first installation side 6, and the opening of the installation cavity 3 is located on the side of the thin-film capacitor core mounting shell 2 away from the controller housing 1. By integrally setting the thin-film capacitor core mounting shell 2 and the controller housing 1, the thin-film capacitor can be directly installed in the installation cavity 3 without an extra installation structure between the thin-film capacitor and the controller housing 1, which can greatly simplify the installation steps and reduce the production cost; moreover, without the traditional plastic-shell installation structure, the entire structure reduces the heat conduction path in heat dissipation, improves the heat dissipation efficiency, and further can improve the service life of the device.

Claims

1. A plastic-free film capacitor, characterized in that, It includes a controller housing (1) and a film capacitor core mounting housing (2). The controller housing (1) is integrally die-cast and connected to the film capacitor core mounting housing (2). The film capacitor core mounting housing (2) is provided with an installation cavity (3) with a single-side opening. A film capacitor assembly (4) adapted to the shape of the installation cavity (3) is detachably arranged in the installation cavity (3). The controller housing (1) is provided with a first installation side (6) and a second installation side (7). The film capacitor core mounting housing (2) is arranged on the first installation side (6), and the opening of the installation cavity (3) is located on the side of the film capacitor core mounting housing (2) away from the controller housing (1).

2. The plastic-free film capacitor according to claim 1, characterized in that, An encapsulant layer (5) for insulation is provided in the installation cavity (3) and on the film capacitor assembly (4).

3. The plastic-free film capacitor according to claim 2, wherein The encapsulant layer (5) completely covers the outer wall of the film capacitor assembly (4).

4. A plastic-free film capacitor according to claim 1, characterized in that, The film capacitor assembly (4) includes a film capacitor core (41) and a copper bar (42) connected to each other.

5. A plastic-free film capacitor according to claim 1, characterized in that, The film capacitor assembly (4) is provided with insulating paper (43) for insulating cooperation with the film capacitor core mounting housing (2).

6. The plastic-free film capacitor according to claim 1, wherein, Both the controller housing (1) and the film capacitor core mounting housing (2) are aluminum die-castings.

7. A plastic-free film capacitor according to claim 1, wherein, A current output component, a filter magnetic ring, and a motor control drive board are further arranged on the first installation side (6), and a low-voltage connector and a control board are arranged on the second installation side (7).

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