Motor controller module, motor controller, power assembly and electric vehicle

Abstract

The utility model provides a motor controller module, a motor controller, a power assembly and an electric vehicle, the motor controller module comprises a bus capacitor and a heat dissipation plate, the heat dissipation plate is laminated on the outer side of a shell, and one side surface of the heat dissipation plate is used for fixing a three-phase bridge arm. The shell comprises a groove, the groove is used for containing the partition plate, one surface of the partition plate is used for forming a liquid cooling cavity with the groove bottom of the groove and one part of the groove peripheral wall of the groove, and the other surface of the partition plate is used for forming another liquid cooling cavity with the other side face of the heat dissipation plate and the other part of the groove peripheral wall of the groove. And the maximum distance between the other surface and the bottom of one groove is smaller than the depth of one groove. According to the motor controller, the double-layer flow channel is formed by the heat dissipation plate, the partition plate and the groove of the shell, the bus capacitor and the three-phase bridge arm are cooled, the cooling efficiency and the integration degree of the motor controller are improved, and miniaturization of the motor controller is facilitated.

Description

Technical Field

[0001] The present application relates to the technical field of electric vehicles, and in particular to a motor controller module, a motor controller, a powertrain, and an electric vehicle. Background Art

[0002] Currently, in the field of electric vehicles, the powertrain includes a motor controller and a motor. The motor controller supplies power to the motor to drive the wheels. The motor controller includes multiple electronic and electrical components such as bus capacitors, three-phase bridge arms, heat sinks and circuit boards. There are many parts and the assembly is complex. The integration of the motor controller is low, which makes the motor controller larger in size. Utility Model Content

[0003] The present application provides a motor controller module, a motor controller, a powertrain, and an electric vehicle.

[0004] In a first aspect, the present application provides a motor controller module, which includes a busbar capacitor and a heat sink. The inner cavity of a housing of the busbar capacitor is used to accommodate a capacitor core package. A heat sink is stacked on the outside of the housing. The heat sink includes two side surfaces along the stacking direction of the heat sink and the housing. One side surface is used to fix a three-phase bridge arm. The three-phase bridge arm is used to receive power from a power battery of an electric vehicle through a capacitor core package and output a three-phase current to drive the motor of the electric vehicle. Among them, a housing includes a groove. Along the stacking direction of the heat sink and the housing, the notch of the groove faces the heat sink. The groove is used to accommodate a partition. The partition includes two surfaces. One surface is used to form a liquid cooling cavity with the bottom of the groove and a portion of the groove wall of the groove. The other surface is used to form another liquid cooling cavity with the other side surface of the heat sink and another portion of the groove wall of the groove. The maximum distance between the other surface and the bottom of the groove is less than the depth of the groove.

[0005] In an embodiment of the present application, the shell includes a groove, and the notch of the groove faces the heat sink along the stacking direction of the heat sink and the shell. The groove is used to accommodate a partition, so that the groove, the heat sink and the partition can be enclosed to form two liquid cooling chambers, one liquid cooling chamber and the other liquid cooling chamber are used to circulate cooling liquid, and one liquid cooling chamber and the other liquid cooling chamber are stacked. The cooling liquid in one liquid cooling chamber is used to cool the bus capacitor, and the cooling liquid in the other liquid cooling chamber is used to cool the three-phase bridge arm, forming a double-layer flow channel to cool the three-phase bridge arm and the bus capacitor, which can improve the heat dissipation efficiency of the motor controller module and make the motor controller module work smoothly.

[0006] In an embodiment of the present application, one surface is used to form a liquid cooling cavity with the bottom of a groove and a portion of the groove wall of a groove, and the other surface is used to form another liquid cooling cavity with the other side of the heat sink and another portion of the groove wall of a groove. The bottom of a groove and a portion of the groove wall formed by the shell are directly used to form a liquid cooling cavity with one surface of the partition, and then the other surface of the partition is used to form another liquid cooling cavity with the other side of the heat sink and another portion of the groove wall of a groove, so that the busbar capacitor and the heat sink in the motor controller module have a higher degree of integration. Directly using a groove of the shell to form two liquid cooling cavities can not only improve the integration of the motor controller module, but also make the motor controller module have a smaller volume along the stacking direction of the heat sink and the shell, which is conducive to the miniaturization of the motor controller module and the miniaturization of the motor controller.

[0007] In an embodiment of the present application, the maximum distance between another surface and the bottom of a groove is less than the depth of a groove, so that a portion of the groove wall of a groove can participate in forming a liquid cooling cavity, and another portion of the groove wall of a groove can participate in forming another liquid cooling cavity. When forming a double-layer flow channel, it will not occupy too much space of the motor controller module along the stacking direction of the heat sink and the shell, which is beneficial for the motor controller module to improve the heat dissipation efficiency while having a smaller volume.

[0008] In one embodiment, along a stacking direction of a heat dissipation plate and a housing, a distance between one surface and a groove bottom of a groove is greater than or equal to a distance between another surface and a groove opening of the groove.

[0009] In an embodiment of the present application, the distance between one surface and the bottom of a groove along the stacking direction of the heat sink and the housing is greater than the distance between the other surface and the opening of the groove. This allows the liquid cooling cavity formed by the one surface and the bottom of the groove to have a larger space, which facilitates the circulation of more coolant within the liquid cooling cavity, thereby improving the heat dissipation effect of the liquid cooling cavity on the bus capacitor, and thus improving the cooling efficiency of the motor controller module. The distance between the other surface and the opening of the groove is smaller, which helps ensure that the partition and the groove do not occupy too much space in the motor controller module along the stacking direction of the heat sink and the housing, and facilitates the miniaturization of the motor controller module.

[0010] In an embodiment of the present application, the distance between one surface and the bottom of a groove along the stacking direction of the heat sink and the shell is equal to the distance between another surface and the groove opening of a groove, so that the other liquid cooling cavity formed by the other surface and another part of the groove wall of a groove and the other side surface of the heat sink can be larger in volume, thereby improving the heat dissipation and cooling effect of the three-phase bridge arm.

[0011] In one embodiment, a housing further includes a plurality of spoiler teeth, each spoiler tooth extending from a groove bottom toward a groove opening along a stacking direction of a heat sink and a housing, and a height of each spoiler tooth is less than a depth of a groove.

[0012] In an embodiment of the present application, each spoiler tooth extends from the bottom of a groove toward the notch of a groove along the stacking direction of the heat sink and the shell, so that the spoiler tooth can stir the coolant in a liquid cooling cavity formed at the bottom of a groove, increase the heat dissipation area of ​​the coolant and the shell, and extend the flow path of the coolant in a liquid cooling cavity, which is beneficial to improving the heat dissipation effect of a liquid cooling cavity on the bus capacitor and improving the cooling efficiency of the motor controller module.

[0013] In the embodiment of the present application, the height of each spoiler tooth is less than the depth of a groove, so that there is space above the spoiler tooth for accommodating a partition and for forming another liquid cooling cavity.

[0014] In one embodiment, a three-phase bridge arm includes multiple power modules, which are spaced apart along the length of the three-phase bridge arm. Each power module includes two sets of copper busbars, which are opposite each other along the width of the three-phase bridge arm. The length of the three-phase bridge arm along its length is greater than its width. A partition includes multiple pairs of through holes, which are used to connect one liquid cooling chamber to another liquid cooling chamber. Multiple pairs of through holes extend through the partition along the stacking direction of a heat sink and a housing, each pair of through holes including two through holes. The multiple pairs of through holes are spaced apart along the length of the three-phase bridge arm, and the two through holes of each pair are spaced apart along the width of the three-phase bridge arm. Each power module is aligned with a pair of through holes along the stacking direction of the heat sink and the housing.

[0015] In an embodiment of the present application, multiple power modules are spaced apart along the length of the three-phase bridge arm, allowing the multiple power modules to operate relatively independently without interfering with each other. Each power module includes two sets of copper busbars, which are arranged opposite each other along the width of the three-phase bridge arm. One of the two sets of copper busbars in the power module receives direct current from the power battery, converts the direct current into alternating current, and outputs it to the motor through the other set of copper busbars. The two sets of copper busbars are arranged opposite each other along the width of the three-phase bridge arm, which facilitates the layout of the circuitry within the motor controller and facilitates smoother operation of the motor driven by the power battery current.

[0016] In the embodiment of the present application, the length of the three-phase bridge arm along its length direction is greater than the length along its width direction, so that the three-phase bridge arm does not occupy too much space of the motor controller module along the width direction of the three-phase bridge arm.

[0017] In an embodiment of the present application, multiple pairs of through holes are used to connect one liquid cooling cavity with another liquid cooling cavity, and multiple pairs of through holes penetrate the partition along the stacking direction of the heat sink and the shell, so that the two liquid cooling cavities in the motor controller module have a higher degree of integration. Multiple pairs of through holes connect one liquid cooling cavity with another liquid cooling cavity so that the coolant flowing into the motor controller module can flow in parallel in one liquid cooling cavity and another liquid cooling cavity, cooling the three-phase bridge arm and the bus capacitor, which is beneficial to improving the cooling efficiency of the motor controller module.

[0018] In an embodiment of the present application, each pair of through holes includes two through holes, and multiple pairs of through holes are spaced apart along the length of the three-phase bridge arm, so that more coolant in one liquid-cooling cavity and another liquid-cooling cavity can flow through the multiple pairs of through holes, which is beneficial to speeding up the exchange of coolant in one liquid-cooling cavity and another liquid-cooling cavity, thereby improving heat dissipation efficiency. Multiple pairs of through holes are spaced apart along the length of the three-phase bridge arm, and the two through holes of each pair of through holes are spaced apart along the width of the three-phase bridge arm, so that coolant in another liquid-cooling cavity can flow through each pair of through holes to achieve parallel flow, which is beneficial to coolant flowing through the other liquid-cooling cavity faster, quickly removing heat from the three-phase bridge arm, and improving the heat dissipation efficiency of the motor controller module.

[0019] In the embodiment of the present application, each power module is aligned with a pair of through-holes along the stacking direction of the heat sink and the housing, and the two through-holes of each pair are spaced apart along the width direction of the three-phase bridge arm. This ensures that each pair of through-holes is aligned in the same direction as the two sets of copper busbars of each power module. This ensures that the direction of coolant flowing between the two through-holes of each pair of through-holes is aligned with the direction of current flow in each power module, which is beneficial for improving heat dissipation efficiency. The alignment of each power module with a pair of through-holes along the stacking direction of the heat sink and the housing also facilitates each power module to have a larger heat dissipation area with the coolant in the other liquid-cooling chamber, which is beneficial for improving heat dissipation efficiency.

[0020] In one embodiment, the length of each through hole along the length direction of the three-phase bridge arm is greater than its width along the width direction of the three-phase bridge arm. The spacing between the two through holes of each pair of through holes along the width direction of the three-phase bridge arm is greater than half the width of a groove along the width direction of the three-phase bridge arm.

[0021] In the embodiment of the present application, the length of each through hole along the length direction of the three-phase bridge arm is greater than its width along the width direction of the three-phase bridge arm, and the width of each through hole along the width direction of the three-phase bridge arm is smaller, so that the coolant flows through a longer path along the width direction of the three-phase bridge arm, thereby allowing the coolant to contact more spoiler teeth in a groove to improve the heat dissipation effect of the busbar capacitor. Each through hole is longer in the length direction of the three-phase bridge arm, which is conducive to each pair of through holes forming a wider parallel flow along the length direction of the three-phase bridge arm in another liquid cooling cavity, which is conducive to more coolant flowing from the through hole to another liquid cooling cavity on the upper layer. The length direction of the through hole is the same as the length direction of the three-phase bridge arm, so that the cooling efficiency of the three-phase bridge arm is more uniform. Therefore, the length of each through hole along the length direction of the three-phase bridge arm is greater than its width along the width direction of the three-phase bridge arm, so that the coolant can take away more heat from the capacitor module without affecting the circulation efficiency of the through hole, thereby facilitating the coolant to take away the heat of the three-phase bridge arm faster, which is conducive to improving the heat dissipation efficiency of the motor controller module.

[0022] In an embodiment of the present application, the spacing between the two through holes of each pair of through holes along the width direction of the three-phase bridge arm is greater than half the width of a groove along the width direction of the three-phase bridge arm, which is beneficial to increase the flow distance of the coolant between the two through holes of each pair of through holes, thereby effectively taking away the heat of the spoiler teeth, so that the coolant in one liquid cooling cavity and the other liquid cooling cavity flows evenly.

[0023] In one embodiment, a housing further includes a plurality of reinforcing ribs, each of which protrudes from the bottom of a groove toward a partition along the stacking direction of a heat sink and a housing. The height of each reinforcing rib along the stacking direction of a heat sink and a housing is less than the depth of a groove. Partial through-holes and partial reinforcing ribs are alternately arranged along the length of the three-phase bridge arm.

[0024] In an embodiment of the present application, the shell also includes a plurality of reinforcing ribs, and each reinforcing rib protrudes from the bottom of a groove toward the partition along the stacking direction of the heat sink and the shell. The reinforcing ribs protruding from the bottom of a groove toward the partition can reinforce the partition to compensate for the structural strength reduced by the formation of through holes in the partition, thereby helping to improve the overall structural strength of the motor controller module.

[0025] In an embodiment of the present application, along the stacking direction of the heat sink and the shell, the height of each reinforcing rib is less than the depth of a groove, so as to avoid the reinforcing rib being too high and causing the partition to be supported at a higher position, so that there is space above the partition to form another liquid cooling cavity.

[0026] In an embodiment of the present application, some through holes and some reinforcing ribs are alternately arranged in sequence along the length direction of the three-phase bridge arm, so that the reinforcing ribs can reinforce the partitions whose structural strength is weakened due to the opening of the through holes, which is beneficial to improving the structural strength of the motor controller module, and some through holes and some reinforcing ribs are alternately arranged in sequence to avoid the reinforcing ribs blocking the through holes and affecting the circulation of the coolant.

[0027] In one embodiment, a housing further includes a protrusion and two inlets and outlets. Along the stacking direction of a heat sink and a housing, a protrusion protrudes from the bottom of a groove toward the notch of a groove. A partition is stacked on the protrusion. The protrusion is used to separate a liquid-cooling cavity into two liquid-cooling sub-cavities and to separate two inlets and outlets. Each liquid-cooling sub-cavity is used to connect to another liquid-cooling cavity and an inlet and outlet. The two inlets and outlets are used to connect to an external flow channel. Along the stacking direction of the heat sink and the housing, the height of the protrusion is less than the depth of the groove. The length of the protrusion is greater than or equal to the length of the groove along the length direction of the three-phase bridge arm.

[0028] In an embodiment of the present application, a protrusion extends from the bottom of one groove toward the notch of another groove along the stacking direction of the heat sink and the housing, and a partition is stacked on the protrusion, so that the protrusion can separate a liquid-cooling cavity into two liquid-cooling sub-cavities. The protrusion is used to separate two inlets and outlets, and each liquid-cooling sub-cavity is used to connect another liquid-cooling cavity and an inlet or to connect another liquid-cooling cavity and another inlet and outlet. The two inlets and outlets are used to connect to external flow channels. The protrusion prevents the coolant in one liquid-cooling cavity from flowing directly only between the two inlets and outlets. The protrusion allows the coolant in one liquid-cooling cavity to communicate with the coolant in the other liquid-cooling cavity through the through hole.

[0029] In an embodiment of the present application, along the stacking direction of the heat sink and the shell, the height of the protrusion is less than the depth of a groove, so that the partition is stacked on the protrusion, and there is still space in a groove above the partition to form another liquid cooling cavity.

[0030] In an embodiment of the present application, the length of the protrusion is greater than or equal to the length of a groove along the length direction of the three-phase bridge arm, so that the protrusion can enhance the structural strength of a groove and effectively separate the two inlets and outlets.

[0031] In one embodiment, a protrusion includes a sealing groove, which is recessed away from a partition along the stacking direction of a heat sink and a housing. The sealing groove is used to accommodate a seal. Another side surface of a heat sink includes a plurality of heat dissipation teeth, which protrude toward a partition along the stacking direction of the heat sink and the housing. A seal is used to seal the gap between the partition and the protrusion and to abut the other surface of the partition against the plurality of heat dissipation teeth. In the stacking direction of the heat sink and the housing, the distance between the plurality of heat dissipation teeth and the bottom of the sealing groove is less than the sum of the free length of the seal and the length of the portion of the partition contacted by the seal.

[0032] In an embodiment of the present application, the sealing groove is recessed away from the partition along the stacking direction of the heat sink and the shell, and the sealing groove is used to accommodate a seal so that the seal can seal the gap between the partition and the protrusion, so that the coolant in the two liquid-cooled sub-cavities can be effectively isolated, so that the coolant in one liquid-cooled sub-cavity needs to flow through the other liquid-cooled sub-cavity and then flow back to the other liquid-cooled sub-cavity.

[0033] In an embodiment of the present application, the other side of the heat sink includes a plurality of heat sink teeth, and the plurality of heat sink teeth protrude toward the partition along the stacking direction of the heat sink and the shell. The plurality of heat sink teeth are located in another liquid cooling cavity, and are used to increase the heat dissipation area in the other liquid cooling cavity, improve the heat dissipation effect of the coolant in the other liquid cooling cavity, and improve the cooling efficiency of the coolant on the three-phase bridge arm, thereby improving the cooling efficiency of the motor controller module.

[0034] In an embodiment of the present application, the seal is used to seal the gap between the partition and the protrusion and to abut the other surface of the partition against multiple heat dissipation teeth, so that the seal can not only relatively seal the two liquid-cooling sub-cavities independently, but also prevent the coolant flowing into the other liquid-cooling cavity from having a gap between the tooth surface of the heat dissipation teeth and the other surface of the partition to generate laminar flow. The laminar flow of coolant has less resistance than the circulation of coolant between the heat dissipation teeth. If laminar flow is generated, the coolant will flow more from the tooth surface of the heat dissipation teeth, without more contact with the heat dissipation teeth, and will not be stirred by the heat dissipation teeth, thereby reducing the cooling effect of the coolant in the other liquid-cooling cavity on the three-phase bridge arm, which is not conducive to improving the cooling efficiency of the motor controller module.

[0035] In an embodiment of the present application, along the stacking direction of the heat sink and the shell, the distance between the multiple heat sink teeth and the bottom of the sealing groove is less than the sum of the free length of the seal and the length of the portion of the partition in contact with the seal, so that the seal in the sealing groove can apply an upward elastic force to the partition along the stacking direction of the heat sink and the shell, so that the other surface of the partition can abut against the multiple heat sink teeth, so that the coolant flowing from the liquid cooling cavity through the through hole into the other liquid cooling cavity will not generate laminar flow on the tooth surface of the heat sink teeth, which is beneficial to increase the contact area between the coolant and the heat sink teeth, thereby improving the cooling effect of the other liquid cooling cavity on the three-phase bridge arm, and further improving the cooling efficiency of the motor controller module.

[0036] In one embodiment, a surface of a partition includes a sealing protrusion, which protrudes toward a sealing groove along the stacking direction of a heat sink and a housing. The sealing groove is configured to accommodate the sealing protrusion, and the sealing protrusion is configured to compress a sealing member. In the stacking direction of the heat sink and the housing, the sum of the length of the sealing protrusion and the free length of the sealing member is greater than the depth of the sealing groove.

[0037] In an embodiment of the present application, the sealing protrusion protrudes toward the sealing groove along the stacking direction of the heat sink and the shell. The sealing groove is used to accommodate the sealing protrusion, and the sealing protrusion is used to squeeze the seal. The sealing protrusion cooperates with the sealing groove and the seal to make the sealing connection between the partition and the protrusion more stable. Not only can a liquid cooling chamber be divided into two liquid cooling sub-chambers, but the seal can also better exert force on the partition, so that the other surface of the partition is in contact with multiple heat dissipation teeth, avoiding the coolant in the other liquid cooling chamber from flowing between the heat dissipation teeth and the partition, so that the coolant flows more between the heat dissipation teeth, thereby improving the cooling effect of the other liquid cooling chamber on the three-phase bridge arm.

[0038] In an embodiment of the present application, along the stacking direction of the heat sink and the shell, the sum of the length of the sealing protrusion and the free length of the seal is greater than the depth of the sealing groove, so that the seal can have an upward elastic force on the partition, so that the other surface of the partition is in contact with multiple heat dissipation teeth, avoiding the coolant in the other liquid cooling cavity from flowing between the heat dissipation teeth and the partition, allowing more coolant to flow between the heat dissipation teeth, thereby improving the cooling effect of the other liquid cooling cavity on the three-phase bridge arm.

[0039] In one embodiment, a protrusion includes a first section, a second section, and a third section connected in sequence. The first section and the second section are arranged on either side of the two inlets along the length of the three-phase bridge arm. The two ends of the second section are arranged on different sides of the two inlets along the width of the three-phase bridge arm.

[0040] In an embodiment of the present application, the first section and the second section are arranged on both sides of the two inlets and outlets along the length direction of the three-phase bridge arm, so that the protrusion can better isolate the two inlets and outlets, and can also improve the problem of reduced strength of the shell due to the opening of two inlets and outlets.

[0041] In an embodiment of the present application, the two ends of the second section along its length direction are arranged on different sides of the two inlets and outlets along the width direction of the three-phase bridge arm, so that the two inlets and outlets can be isolated in two liquid-cooled sub-cavities respectively, so that the coolant flowing into one liquid-cooled cavity will not only flow between the two inlets and outlets but also flow through the other liquid-cooled cavity. The double-layer flow channel enables the three-phase bridge arm and bus capacitor of the motor controller module to be cooled and cooled at the same time, thereby improving the cooling efficiency of the motor controller module.

[0042] In one embodiment, a groove peripheral wall includes a plurality of retaining protrusions for retaining a partition. Along the stacking direction of a heat sink and a housing, the distance between each retaining protrusion and the bottom of the groove is greater than the distance between the other surface of the partition and the bottom of the groove.

[0043] In an embodiment of the present application, the groove wall of a groove includes multiple locking protrusions, which are used to limit the partition. The multiple locking protrusions enable the partition to be fixedly placed on the top of the shell, which is conducive to forming two relatively stable liquid cooling chambers, improving the structural reliability of the motor controller module, and thus improving the structural reliability of the motor controller. The locking protrusion is located on the groove wall of a groove and is used to lock the side plate under the locking protrusion, so that the other part of the groove wall where the locking protrusion is located, the other surface of the partition, and the heat sink enclose to form another liquid cooling chamber, improving the integration and integration between the structures of the motor controller module.

[0044] In an embodiment of the present application, along the stacking direction of the heat sink and the shell, the distance between each locking protrusion and the bottom of a groove is greater than the distance between the other surface of the partition and the bottom of a groove, so that the locking protrusion can be stacked on the partition along the stacking direction of the heat sink and the shell. Along the stacking direction of the heat sink and the shell, the locking protrusion, the partition, and the notch of a groove are arranged in sequence, so that the locking protrusion can limit the partition, fix the partition on a groove, and make the structure of the motor controller module more stable.

[0045] In one embodiment, the other side surface of a heat sink further includes another groove and a plurality of heat dissipation teeth. Along the stacking direction of the heat sink and the housing, the other groove is recessed away from the partition, and the plurality of heat dissipation teeth protrude from the bottom of the other groove toward the partition. The other surface is configured to form another liquid cooling cavity with the other groove on the other side surface of the heat sink and another portion of the peripheral wall of the groove. In the stacking direction of the heat sink and the housing, the depth of the other groove is less than the length of at least a portion of the heat dissipation teeth, the depth of the other groove is less than the maximum distance between the bottom of the groove and the partition, and the length of the plurality of heat dissipation teeth is less than the depth of the groove.

[0046] In the embodiment of the present application, another groove is recessed away from the partition along the stacking direction of the heat sink and the housing, allowing the other groove of the heat sink to form a larger liquid cooling cavity with the partition. This also provides sufficient space for the arrangement of multiple heat sink teeth, allowing more coolant to flow in the other liquid cooling cavity, thereby improving the cooling effect of the coolant on the three-phase bridge arm. Multiple heat sink teeth protrude from the bottom of the other groove toward the partition, allowing the heat sink teeth to be arranged in the other liquid cooling cavity to stir the coolant flowing through the other liquid cooling cavity, thereby improving the cooling efficiency of the motor controller module.

[0047] In an embodiment of the present application, another surface is used to form another liquid cooling cavity with another groove on the other side of the heat sink and another part of the groove wall of a groove. The groove wall of a groove is used not only to form one liquid cooling cavity but also to form another liquid cooling cavity, so that the formation of the two liquid cooling cavities will not occupy too much space of the motor controller module along the stacking direction of the heat sink and the shell, which is conducive to the miniaturized arrangement of the motor controller module and can also improve the integration of the motor controller module.

[0048] In an embodiment of the present application, along the stacking direction of the heat sink and the housing, the depth of another groove is less than the length of at least a portion of the heat sink teeth, allowing at least a portion of the heat sink teeth to abut against the other surface of the partition. This prevents the coolant from laminar flow in the other liquid cooling chamber due to gaps between the tooth surfaces of the heat sink teeth and the other surface of the partition, thereby improving heat dissipation efficiency. The longer heat sink teeth also help increase the contact area between the coolant and the heat sink teeth, thereby improving the cooling effect of the coolant and the cooling efficiency of the motor controller module.

[0049] In an embodiment of the present application, the depth of another groove is less than the maximum distance between the bottom of a groove and a partition, so that after forming a liquid cooling cavity and another liquid cooling cavity, too much space of the motor controller module along the stacking direction of the heat sink and the shell will not be occupied, which is conducive to the miniaturized layout of the motor controller module.

[0050] In an embodiment of the present application, the length of multiple heat dissipation teeth is less than the depth of a groove, so that when the heat dissipation plate uses a groove to form another liquid cooling cavity, the other liquid cooling cavity will not occupy too much space of the motor controller module along the stacking direction of the heat dissipation plate and the shell, which is conducive to the miniaturized layout of the motor controller module.

[0051] In a second aspect, the present application provides a motor controller, which includes a housing and a motor controller module as in the first aspect, wherein the housing is used to accommodate the motor controller module, and the internal flow channel of the housing is used to connect two inlets and outlets of a shell of a bus capacitor in the motor controller module.

[0052] In the motor controller module of the present embodiment, two liquid cooling chambers are formed by utilizing a heat sink, a partition, and a groove in the housing of the busbar capacitor. The two liquid cooling chambers are used to circulate coolant to form a double-layer flow channel, cooling the busbar capacitor and the three-phase bridge arm, thereby improving the cooling efficiency of the motor controller module. Using the groove formed by the housing of the busbar capacitor to form a liquid cooling chamber can also improve the integration of the motor controller module, facilitate the miniaturization of the motor controller module, and thus facilitate the miniaturization of the motor controller.

[0053] In a third aspect, the present application provides a powertrain, which includes a motor and a motor controller as in the second aspect, wherein the motor is used to receive power from a motor controller module of the motor controller.

[0054] The motor controller in the embodiment of the present application includes a motor controller module. The motor controller module forms two liquid cooling chambers by utilizing a heat sink, a partition, and a groove in the housing of the bus capacitor. The two liquid cooling chambers are used to circulate coolant to form a double-layer flow channel, cooling the bus capacitor and the three-phase bridge arm, thereby improving the cooling efficiency of the motor controller module. Using the groove formed by the housing of the bus capacitor to form the liquid cooling chamber can also improve the integration of the motor controller module, facilitate the miniaturization of the motor controller module, and thus facilitate the miniaturization of the motor controller and powertrain.

[0055] In a fourth aspect, the present application provides an electric vehicle, which includes a frame, a power battery and a powertrain as in the third aspect, wherein the frame is used to fix the power battery and the powertrain, and the motor of the powertrain is used to receive power from the power battery through a motor controller to drive the wheels.

[0056] The powertrain in the embodiment of the present application includes a motor controller module. The motor controller module forms two liquid cooling chambers by utilizing a heat sink, a partition, and a groove in the housing of the bus capacitor. The two liquid cooling chambers are used to circulate coolant to form a double-layer flow channel, cooling the bus capacitor and the three-phase bridge arm, thereby improving the cooling efficiency of the motor controller module. Using a groove formed by the housing of the bus capacitor to form a liquid cooling chamber can also improve the integration of the motor controller module, facilitate the miniaturization of the motor controller module, and thus facilitate the miniaturization of the motor controller and powertrain, thereby optimizing the overall vehicle layout. BRIEF DESCRIPTION OF THE DRAWINGS

[0057] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the embodiments of the present application will be described below.

[0058] Figure 1 is a schematic structural diagram of an electric vehicle provided in an embodiment of the present application;

[0059] Figure 2 is a schematic structural diagram of a powertrain provided in an embodiment of the present application;

[0060] Figure 3 Schematic diagram of the structure of the motor controller module provided in the embodiment of the present application;

[0061] Figure 4 is an exploded view of a motor controller module provided in an embodiment of the present application;

[0062] Figure 5 is a cross-sectional view of a motor controller module provided in an embodiment of the present application;

[0063] Figure 6 yes Figure 5 A partial enlarged view of the M1 portion of the motor controller module;

[0064] Figure 7 is a schematic structural diagram of a housing provided in an embodiment of the present application;

[0065] Figure 8 is a cross-sectional view of a housing provided in an embodiment of the present application;

[0066] Figure 9 Schematic diagram of the structure of the partition provided in the embodiment of the present application;

[0067] Figure 10 is a schematic structural diagram of a partition provided in another embodiment of the present application;

[0068] Figure 11 yes Figure 5 A partial enlarged view of the M2 part of the motor controller module;

[0069] Figure 12 is another structural schematic diagram of the partition provided in an embodiment of the present application;

[0070] Figure 13 yes Figure 5 A partial enlarged view of the M1 portion of the motor controller module;

[0071] Figure 14 is another exploded view of the motor controller module provided in an embodiment of the present application;

[0072] Figure 15 This is another structural diagram of the motor controller module provided in an embodiment of the present application. DETAILED DESCRIPTION

[0073] The technical solutions in the embodiments of the present application will be described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments.

[0074] In order to improve the heat dissipation efficiency of the motor controller and miniaturize the layout of the motor controller module, the present application provides a motor controller module, which includes a busbar capacitor and a heat sink. The inner cavity of a housing of the busbar capacitor is used to accommodate a capacitor core pack. The heat sink is stacked on the outside of the housing. The heat sink includes two side surfaces along the stacking direction of the heat sink and the housing. One side surface is used to fix a three-phase bridge arm. The three-phase bridge arm is used to receive power from the power battery of the electric vehicle through the capacitor core pack and output a three-phase current to drive the motor of the electric vehicle. The housing includes a groove. The groove opening faces the heat sink along the stacking direction of the heat sink and the housing. The groove is used to accommodate a partition. The partition includes two surfaces. One surface is used to form a liquid cooling cavity with the bottom of the groove and a portion of the groove wall. The other surface is used to form another liquid cooling cavity with the other side surface of the heat sink and another portion of the groove wall. The maximum distance between the other surface and the bottom of the groove is less than the depth of the groove. By utilizing the heat sink, partitions, and grooves in the busbar capacitor housing to form two liquid cooling chambers, coolant circulates through the two chambers to form a double-layer flow channel, cooling the busbar capacitors and three-phase bridge arms, thereby improving the cooling efficiency of the motor controller module. Using the grooves formed in the busbar capacitor housing to form the liquid cooling chambers also improves the integration of the motor controller module, facilitating the miniaturization of the motor controller module and, consequently, the motor controller.

[0075] The motor controller module provided in the embodiment of the present application is used for a motor controller, the motor controller is applied to a powertrain, and the powertrain is applied to an electric vehicle to improve the overall performance of the electric vehicle.

[0076] Figure 1 This is a schematic diagram of the structure of the electric vehicle 1 provided in an embodiment of the present application. Figure 2 This is a schematic diagram of the structure of the powertrain 10 provided in an embodiment of the present application. Figure 3 This is a structural diagram of the motor controller module 100 provided in an embodiment of the present application.

[0077] In one embodiment, the electric vehicle 1 includes a powertrain 10, a frame 20 and a power battery 30. Figure 1 As shown, the vehicle frame 20 is used to fix the power battery 30 and the powertrain 10. In the embodiment of the present application, the powertrain 10 is used to receive power from the power battery 30 and to drive the wheels 40.

[0078] In the embodiment of the present application, the power battery 30 may also be referred to as a battery pack. In the embodiment of the present application, the electric vehicle 1 refers to a wheeled device driven or towed by a power device.

[0079] In one embodiment, the powertrain 10 includes a motor 11, a reducer 12, and a motor controller 13. Figure 2 As shown, in the embodiment of the present application, the motor 11 includes a motor shaft (not shown), a motor stator (not shown) and a motor rotor (not shown). The motor rotor is fixedly mounted on the motor shaft. After receiving AC power, the motor stator drives the motor rotor to rotate, thereby driving the motor shaft to rotate. The reducer 12 includes a gear assembly (not shown), an input shaft (not shown) and an output shaft (not shown). The motor shaft of the motor 11 is used for transmission connection with the input shaft of the reducer 12. The input shaft receives the power transmitted by the motor shaft of the motor 11 and transmits the power to the output shaft through the gear assembly. The gear assembly can be set as needed and can be a single-speed reduction gear assembly, a two-speed reduction gear assembly or a multi-speed reduction gear assembly.

[0080] In the embodiment of the present application, the motor controller 13 is used to control the motor 11 of the electric vehicle 1 to drive the wheels 40 of the electric vehicle 1. The motor controller 13 is used to receive direct current (DC) power from the power battery 30 and convert the DC power into AC power for transmission to the motor 11. The power battery 30 is connected to the windings of the motor 11 through the motor controller 13 to drive the motor 11.

[0081] In one embodiment, the motor controller 13 is also used to charge and discharge the power battery 30. The motor controller 13 is also used to integrate at least one of an onboard charger, a vehicle controller, and a power distribution device.

[0082] In one embodiment, if Figure 2 and Figure 3As shown, the motor controller 13 includes a housing (not shown) and a motor controller module 100. The housing is used to accommodate the motor controller module 100. The motor 11 is used to receive power from the motor controller module 100 of the motor controller 13. The motor controller module 100 includes a heat sink, a bus capacitor 101, and a three-phase bridge arm 103. The heat sink is used to cool the bus capacitor 101 and the three-phase bridge arm 103.

[0083] In one embodiment, the motor controller 13 further includes components such as a DC filter, a Hall copper busbar assembly, and a circuit board.

[0084] The motor controller of an electric vehicle requires the arrangement of a large number of electronic and electrical components, such as DC filters, bus capacitors, power modules, heat sinks, etc. The large number of parts makes the motor controller larger in size and has a low degree of integration. The bus capacitors and power modules will generate heat and heat up during operation, and the cooling effect of the heat sink on the bus capacitors and power modules needs to be improved.

[0085] In an embodiment of the present application, two liquid cooling chambers are formed by utilizing a heat sink, a partition, and a groove in the housing of the busbar capacitor. The two liquid cooling chambers are used to circulate coolant to form a double-layer flow channel, cooling the busbar capacitor and the three-phase bridge arm, thereby improving the cooling efficiency of the motor controller module. Utilizing the groove formed by the housing of the busbar capacitor to form a liquid cooling chamber can also improve the integration of the motor controller module, facilitate the miniaturization of the motor controller module, and thus facilitate the miniaturization of the motor controller.

[0086] The motor controller module 100 with a capacitor housing forming a dual liquid cooling chamber provided by an embodiment of the present application will be described in detail below.

[0087] Figure 4 This is an exploded view of the motor controller module 100 provided in an embodiment of the present application. Figure 5 This is a cross-sectional view of the motor controller module 100 provided in an embodiment of the present application. Figure 6 for Figure 5 A partial enlarged view of the M1 portion of the motor controller module 100.

[0088] In one embodiment, the motor controller module 100 includes a bus capacitor 101 and a heat sink 102. Figures 1 to 4 As shown, the inner cavity of a shell 110 of the bus capacitor 101 is used to accommodate a capacitor core package 111, and the heat sink 102 is stacked on the outside of the shell 110. Along the stacking direction Z of the heat sink 102 and the shell 110, the heat sink 102 includes two side surfaces 121 and 122. One side surface 121 is used to fix the three-phase bridge arm 103. The three-phase bridge arm 103 is used to receive power from the power battery 30 of the electric vehicle 1 through the capacitor core package 111 and output three-phase current to drive the motor 11 of the electric vehicle 1.

[0089] In the embodiment of the present application, the bus capacitor 101 is used to smooth the bus voltage, reduce inductance parameters, absorb high pulse currents, or prevent overcharging and transient voltage effects to ensure the safe operation of the motor controller 13. The three-phase bridge arm 103 is used to realize the mutual conversion between three-phase AC and DC.

[0090] In one embodiment, the housing 110 includes a recess 113, such as Figure 5 and Figure 6 As shown, along the stacking direction Z of the heat sink 102 and the housing 110, the notch 113a of the groove 113 faces the heat sink 102. The groove 113 is used to accommodate a partition 104. The partition 104 includes two surfaces 141 and 142. One surface 141 is used to form a liquid cooling cavity 105a with the groove bottom 113b of the groove 113 and a portion of the groove peripheral wall 113c of the groove 113. The other surface 142 is used to form another liquid cooling cavity 105b with the other side surface 122 of the heat sink 102 and another portion of the groove peripheral wall 113d of the groove 113. The maximum distance between the other surface 142 and the groove bottom 113b of the groove 113 is less than the depth of the groove 113.

[0091] In an embodiment of the present application, the shell 110 includes a groove 113. Along the stacking direction Z of the heat sink 102 and the shell 110, the notch 113a of the groove 113 faces the heat sink 102. The groove 113 is used to accommodate a partition 104, so that the groove 113, the heat sink 102, and the partition 104 can enclose two liquid cooling chambers 105a and 105b. The liquid cooling chamber 105a and the liquid cooling chamber 105b are used to circulate cooling liquid. The liquid cooling chamber 105a and the liquid cooling chamber 105b are stacked. The cooling liquid in the liquid cooling chamber 105a is used to cool the bus capacitor 101, and the cooling liquid in the liquid cooling chamber 105b is used to cool the three-phase bridge arm 103. The double-layer flow channel cools the three-phase bridge arm 103 and the bus capacitor 101, which can improve the heat dissipation efficiency of the motor controller module 100 and ensure the smooth operation of the motor controller module 100.

[0092] In the embodiment of the present application, one surface 141 is used to form a liquid cooling cavity 105a with the bottom 113b of the groove 113 and a portion of the groove peripheral wall 113c of the groove 113, and the other surface 142 is used to form another liquid cooling cavity 105b with the other side surface 122 of the heat sink 102 and the other portion of the groove peripheral wall 113d of the groove 113. The liquid cooling cavity 105a is formed directly by using the bottom 113b and a portion of the groove peripheral wall 113c of the groove 113 formed by the shell 110 and the surface 141 of the partition 104, and then the liquid cooling cavity 105b is formed by using the surface 142 of the partition 104 and the side surface 122 of the heat sink 102 and the other portion of the groove peripheral wall 113d of the groove 113, so that the bus capacitor 101 and the heat sink 102 in the motor controller module 100 have a higher degree of integration. Directly using the groove 113 of the shell 110 to form two liquid cooling chambers 105a and 105b can not only improve the integration of the motor controller module 100, but also enable the motor controller module 100 to have a smaller volume along the stacking direction Z of the heat sink 102 and the shell 110, which is beneficial to the miniaturization of the motor controller module 100 and the miniaturization of the motor controller 13.

[0093] In the embodiments of this application, Figure 6 As shown, the maximum distance between the surface 142 and the bottom 113b of the groove 113 is recorded as L1, and the depth of the groove 113 is recorded as L2. L1<L2, so that a portion of the groove wall 113c of the groove 113 can participate in forming the liquid cooling cavity 105a, and another portion of the groove wall 113d of the groove 113 can participate in forming the liquid cooling cavity 105b. When forming a double-layer flow channel, it will not occupy too much space of the motor controller module 100 along the stacking direction Z of the heat sink 102 and the shell 110, which is beneficial for the motor controller module 100 to improve the heat dissipation efficiency while having a smaller volume.

[0094] In one embodiment, if Figure 6 As shown, along the stacking direction Z of the heat dissipation plate 102 and the housing 110 , the distance between the surface 141 and the bottom 113 b of the groove 113 is greater than the distance between the surface 142 and the notch 113 a of the groove 113 .

[0095] In the embodiment of the present application, the distance between surface 141 and the bottom 113b of groove 113 along the stacking direction Z of heat sink 102 and housing 110 is denoted as L3, and the distance between surface 142 and notch 113a of groove 113 is denoted as L4. L3>L4, thereby providing a larger space for liquid cooling cavity 105a formed by surface 141 and bottom 113b of groove 113. This facilitates the circulation of more coolant within liquid cooling cavity 105a, improves the heat dissipation effect of liquid cooling cavity 105a on bus capacitor 101, and thereby improves the cooling efficiency of motor controller module 100. A smaller L4 helps prevent partition 104 and groove 113 from excessively occupying the space of motor controller module 100 along the stacking direction Z of heat sink 102 and housing 110, thereby facilitating miniaturization of motor controller module 100.

[0096] In one embodiment, along the stacking direction Z of the heat sink 102 and the housing 110, the distance between the surface 141 and the bottom 113b of the groove 113 is equal to the distance between the surface 142 and the notch 113a of the groove 113. This allows the liquid cooling cavity 105b formed by the surface 142, the other portion of the groove peripheral wall 113d of the groove 113, and the side surface 122 of the heat sink 102 to be larger in volume, thereby improving the heat dissipation and cooling effect of the three-phase bridge arm 103.

[0097] In one embodiment, when the side surface 122 of the heat sink 102 is flat, L3 = L4 can be set to make the liquid cooling cavity 105b and the liquid cooling cavity 105a have the same height, thereby improving the overall heat dissipation effect on the bus capacitor 101 and the three-phase bridge arm 103.

[0098] In one embodiment, when L3>L4, a groove (not shown) can be formed on the side surface 122 of the heat sink 102 facing away from the partition. The groove on the side surface 122 of the heat sink 102, the surface 142, and another portion of the groove wall 113d of the groove 113 form a liquid cooling cavity 105b, thereby increasing the height of the liquid cooling cavity 105b and thereby improving the heat dissipation and cooling effect on the three-phase bridge arm 103.

[0099] Figure 7 This is a schematic structural diagram of the housing 110 provided in an embodiment of the present application. Figure 8 This is a cross-sectional view of the housing 110 provided in an embodiment of the present application.

[0100] In one embodiment, the housing 110 further includes a plurality of spoiler teeth 115, such as Figure 7 and Figure 8 As shown, along the stacking direction Z of the heat sink 102 and the housing 110, each spoiler tooth 115 extends from the groove bottom 113b of the groove 113 toward the notch 113a of the groove 113, and Figure 6 and Figure 8 As shown, the height of each spoiler tooth 115 is smaller than the depth of the groove 113 .

[0101] In the embodiment of the present application, each spoiler tooth 115 extends from the bottom 113b of the groove 113 toward the notch 113a of the groove 113 along the stacking direction Z of the heat sink 102 and the housing 110, so that the spoiler tooth 115 can stir the coolant in the liquid cooling cavity 105a formed at the bottom 113b of the groove 113, thereby increasing the heat dissipation area of ​​the coolant and the housing 110, and extending the flow path of the coolant in the liquid cooling cavity 105a, which is beneficial to improving the heat dissipation effect of the liquid cooling cavity 105a on the bus capacitor 101 and improving the cooling efficiency of the motor controller module 100.

[0102] In the embodiment of this application, combined with Figure 6 and Figure 8 As shown, the height of each spoiler tooth 115 is L5, the depth of the groove 113 is L2, L5<L2, so that there is space above the spoiler tooth 115 for accommodating the partition 104 and forming the liquid cooling cavity 105b.

[0103] In one embodiment, the height of each spoiler tooth 115 is greater than the distance between the surface 142 and the notch 113a of the groove 113. Figure 6 and Figure 8 As shown, the height of each spoiler tooth 115 is L5, and the distance between the surface 142 and the notch 113a of the groove 113 is L4, L5>L4, so that each spoiler tooth 115 has a higher height in the groove 113, and more fully utilizes the space of the liquid cooling cavity 105a, which is beneficial for each spoiler tooth 115 to have a larger contact area with the coolant in the liquid cooling cavity 105a, which is beneficial for improving the heat dissipation effect of the liquid cooling cavity 105a on the bus capacitor 101, thereby improving the heat dissipation efficiency of the motor controller module 100.

[0104] In one embodiment, the height of each spoiler tooth 115 is equal to the maximum distance between the partition 104 and the bottom 113b of the groove 113. The maximum distance between the partition 104 and the bottom 113b of the groove 113 is recorded as L6, and L5 is equal to L6, so that the partition 104 can fit each spoiler tooth 115, so that the coolant flows through the gap between each spoiler tooth 115, thereby improving the heat dissipation effect and avoiding the formation of laminar flow due to the gap between the spoiler teeth 115 and the partition 104, which reduces the cooling effect.

[0105] Figure 9 This is a schematic structural diagram of the partition 104 provided in an embodiment of the present application.

[0106] In one embodiment, the three-phase bridge arm 103 includes a plurality of power modules 131, such as Figure 4As shown, multiple power modules 131 are arranged at intervals along the length direction X of the three-phase bridge arm 103. Each power module 131 includes two groups of copper bars 131a and 131b. The two groups of copper bars 131a and 131b are opposite to each other along the width direction Y of the three-phase bridge arm 103. The length of the three-phase bridge arm 103 along its length direction X is greater than its length along its width direction Y. Figure 4 and Figure 9 As shown, the partition 104 includes multiple pairs of through holes 143a, which are used to connect the liquid cooling chamber 105a and the liquid cooling chamber 105b. Along the stacking direction Z of the heat sink 102 and the shell 110, multiple pairs of through holes 143a pass through the partition 104, each pair of through holes 143a includes two through holes 143, and the multiple pairs of through holes 143a are arranged at intervals along the length direction X of the three-phase bridge arm 103. The two through holes 143 of each pair of through holes 143a are arranged at intervals along the width direction Y of the three-phase bridge arm 103. Along the stacking direction Z of the heat sink 102 and the shell 110, each power module 131 is aligned with a pair of through holes 143a.

[0107] In the embodiment of the present application, multiple power modules 131 are arranged at intervals along the length direction X of the three-phase bridge arm 103, so that the multiple power modules 131 can operate relatively independently without interfering with each other. Each power module 131 includes two groups of copper bars 131a and 131b, and the two groups of copper bars 131a and 131b are opposite to each other along the width direction Y of the three-phase bridge arm 103. After receiving the DC power supplied by the power battery 30, one group of copper bars 131a of the power module 131 converts the DC power into AC power, which is output to the motor 11 through the other group of copper bars 131b. The two groups of copper bars 131a and 131b are arranged relative to each other along the width direction Y of the three-phase bridge arm 103, which facilitates the layout of the circuit within the motor controller 13 and is also conducive to the smoother operation of the power battery 30 current driving the motor 11.

[0108] In the embodiment of the present application, the length of the three-phase bridge arm 103 along its length direction X is greater than the length along its width direction Y, so that the three-phase bridge arm 103 does not occupy too much space of the motor controller module 100 along the width direction Y of the three-phase bridge arm 103.

[0109] In the embodiment of the present application, multiple pairs of through holes 143a are used to connect the liquid cooling cavity 105a and the liquid cooling cavity 105b. Multiple pairs of through holes 143a penetrate the partition 104 along the stacking direction Z of the heat sink 102 and the shell 110, so that the two liquid cooling cavities 105a and 105b in the motor controller module 100 have a higher degree of integration. Multiple pairs of through holes 143a connect the liquid cooling cavity 105a and the liquid cooling cavity 105b so that the coolant flowing into the motor controller module 100 can flow in parallel in the liquid cooling cavity 105a and the liquid cooling cavity 105b, cooling the three-phase bridge arm 103 and the bus capacitor 101, which is beneficial to improving the cooling efficiency of the motor controller module 100.

[0110] In the embodiment of the present application, each pair of through holes 143a includes two through holes 143, and multiple pairs of through holes 143a are spaced apart along the length direction X of the three-phase bridge arm 103, allowing more coolant in the liquid-cooling cavity 105a and the liquid-cooling cavity 105b to flow through the multiple pairs of through holes 143a, which helps to accelerate the exchange of coolant in the liquid-cooling cavity 105a and the liquid-cooling cavity 105b and improve heat dissipation efficiency. Multiple pairs of through holes 143a are spaced apart along the length direction X of the three-phase bridge arm 103, and the two through holes 143 of each pair of through holes 143a are spaced apart along the width direction Y of the three-phase bridge arm 103, allowing the coolant in the liquid-cooling cavity 105b to flow through each pair of through holes 143a to achieve parallel flow, which helps the coolant flow through the liquid-cooling cavity 105b faster, quickly removing heat from the three-phase bridge arm 103, and improving the heat dissipation efficiency of the motor controller module 100.

[0111] In the embodiment of the present application, alignment of each power module 131 with a pair of through-holes 143a along the stacking direction Z of the heat sink 102 and the housing 110 means that the projections of each power module 131 and the pair of through-holes 143a in the stacking direction Z of the heat sink 102 and the housing 110 at least partially overlap. In the embodiment of the present application, alignment of each power module 131 with a pair of through-holes 143a along the stacking direction Z of the heat sink 102 and the housing 110 is performed, and the two through-holes 143 of each pair of through-holes 143a are arranged at intervals along the width direction Y of the three-phase bridge arm 103, such that the arrangement direction of each pair of through-holes 143a and the two groups of copper busbars 131a and 131b of each power module 131 are the same. This ensures that the direction in which coolant flows between the two through-holes 143 of each pair of through-holes 143a is the same as the direction in which current flows in each power module 131, thereby improving heat dissipation efficiency. Aligning each power module 131 with a pair of through holes 143 a along the stacking direction Z of the heat sink 102 and the housing 110 also helps each power module 131 and the coolant in the liquid cooling cavity 105 b to have a larger heat dissipation area, thereby improving heat dissipation efficiency.

[0112] Figure 10 This is a schematic structural diagram of a partition 104 provided in another embodiment of the present application.

[0113] In one embodiment, if Figure 10 As shown, each through hole 143 of the multiple pairs of through holes 143a on the partition 104 can be a groove opened along the width direction Y of the three-phase bridge arm 103, and the processing technology is simple.

[0114] In one embodiment, if Figure 9 As shown, the length of each through hole 143 along the length direction X of the three-phase bridge arm 103 is greater than its width along the width direction Y of the three-phase bridge arm 103. Figure 5 and Figure 9As shown, the distance between the two through holes 143 of each pair of through holes 143 a along the width direction Y of the three-phase bridge arm 103 is greater than half the width of the groove 113 along the width direction Y of the three-phase bridge arm 103 .

[0115] In the embodiments of this application, Figure 9 As shown, the length of each through hole 143 along the length direction X of the three-phase bridge arm 103 is recorded as L7, and the width of each through hole 143 along the width direction Y of the three-phase bridge arm 103 is recorded as L8, L7>L8, L8 is smaller, so that the coolant flows through a longer path along the width direction Y of the three-phase bridge arm 103, thereby allowing the coolant to contact more spoiler teeth 115 in the groove 113 to enhance the heat dissipation effect on the busbar capacitor. L7 is larger, which is beneficial for each pair of through holes 143a to form a wider parallel flow in the liquid cooling cavity 105b along the length direction X of the three-phase bridge arm 103, which is beneficial for more cooling liquid to flow from the through holes 143a to the upper liquid cooling cavity 105b. The length direction of the through holes 143a is the same as the length direction X of the three-phase bridge arm 103, so that the cooling efficiency of the three-phase bridge arm 103 is more uniform. Therefore, L7>L8 allows the coolant to remove more heat from the capacitor module without affecting the flow efficiency of the through holes 143a, thereby facilitating the coolant to remove heat from the three-phase bridge arm 103 more quickly, thereby improving the heat dissipation efficiency of the motor controller module 100.

[0116] In the embodiments of this application, Figure 5 and Figure 9 As shown, the distance between the two through holes 143 of each pair of through holes 143a along the width direction Y of the three-phase bridge arm 103 is recorded as L9, and the width of the groove 113 along the width direction Y of the three-phase bridge arm 103 is recorded as L10, L9>0.5L10, which is conducive to increasing the flow distance of the coolant between the two through holes 143 of each pair of through holes 143a, thereby effectively taking away the flow of the spoiler teeth 115, so that the coolant in the liquid-cooling cavity 105a and the liquid-cooling cavity 105b flows evenly.

[0117] In one embodiment, the housing 110 further includes a plurality of reinforcing ribs 116, such as Figure 4 and Figure 7 As shown, along the stacking direction Z of the heat sink 102 and the housing 110, each reinforcing rib 116 protrudes from the groove bottom 113b of the groove 113 toward the partition 104. In the stacking direction Z of the heat sink 102 and the housing 110, the height of each reinforcing rib 116 is less than the depth of the groove 113. Figure 7 and Figure 9 As shown, some of the through holes 143 and some of the reinforcing ribs 116 are alternately arranged in sequence along the length direction X of the three-phase bridge arm 103 .

[0118] In an embodiment of the present application, the shell 110 also includes a plurality of reinforcing ribs 116. Along the stacking direction Z of the heat sink 102 and the shell 110, each reinforcing rib 116 protrudes from the bottom 113b of the groove 113 toward the partition 104. The reinforcing ribs 116 protrude from the bottom 113b of the groove 113 toward the partition 104, which can reinforce the partition 104 to compensate for the reduced structural strength caused by the formation of the through hole 143a in the partition 104, thereby helping to improve the overall structural strength of the motor controller module 100.

[0119] In the embodiment of the present application, along the stacking direction Z of the heat sink 102 and the shell 110, the height of each reinforcing rib 116 is less than the depth of the groove 113, so as to avoid the reinforcing rib 116 being too high and causing the partition 104 to be supported at a higher position, so that there is space above the partition 104 to form a liquid cooling chamber 105b.

[0120] In an embodiment of the present application, some of the through holes 143 and some of the reinforcing ribs 116 are alternately arranged in sequence along the length direction X of the three-phase bridge arm 103, so that the reinforcing ribs 116 can reinforce the partition 104 whose structural strength is weakened due to the opening of the through holes 143, which is beneficial to improving the structural strength of the motor controller module 100, and some of the through holes 143 and some of the reinforcing ribs 116 are alternately arranged in sequence to avoid the reinforcing ribs 116 blocking the through holes 143 and affecting the circulation of the coolant.

[0121] Figure 11 for Figure 5 A partial enlarged view of the M2 portion of the motor controller module 100.

[0122] In one embodiment, the housing 110 further includes a protrusion 117 and two inlets and outlets 114a, 114b. Figure 7 and Figure 8 As shown, along the stacking direction Z of the heat sink 102 and the housing 110, the protrusion 117 protrudes from the groove bottom 113b of the groove 113 toward the notch 113a of the groove 113, as shown in FIG. Figure 5 and Figure 11 As shown, the spacer 104 is stacked on the protrusion 117, as shown in FIG. Figure 7 As shown, the protrusion 117 is used to separate the liquid cooling chamber 105a into two liquid cooling sub-cavities 151 and 152 and to separate the two inlets and outlets 114a and 114b. Each liquid cooling sub-cavity 150 is used to connect the liquid cooling chamber 105b with one inlet and outlet 114a or to connect the liquid cooling chamber 105b with another inlet and outlet 114b. The two inlets and outlets 114a and 114b are used to connect to the external flow channel. Figure 11 As shown, along the stacking direction Z of the heat sink 102 and the housing 110, the height of the protrusion 117 is less than the depth of the groove 113. Figure 7 As shown, the length of the protrusion 117 is greater than or equal to the length of the groove 113 along the length direction X of the three-phase bridge arm 103 .

[0123] In the embodiment of the present application, a protrusion 117 protrudes from the bottom 113b of the groove 113 toward the notch 113a of the groove 113 along the stacking direction Z of the heat sink 102 and the housing 110. The partition 104 is stacked on the protrusion 117, so that the protrusion 117 can divide the liquid-cooling chamber 105a into two liquid-cooling sub-chambers 151 and 152. The protrusion 117 is used to separate the two inlets and outlets 114a and 114b. Each liquid-cooling sub-chamber 150 is used to connect the liquid-cooling chamber 105b with one inlet and outlet 114a or to connect the liquid-cooling chamber 105b with the other inlet and outlet 114b. The two inlets and outlets 114a and 114b are used to connect to external flow channels. The protrusion 117 prevents the coolant in the liquid-cooling chamber 105a from flowing directly only through the two inlets and outlets 114a and 114b. The protrusion 117 allows the coolant in the liquid-cooling chamber 105a and the liquid-cooling chamber 105b to communicate through the through hole 143. Exemplarily, the coolant flows from the inlet and outlet 114a into the liquid-cooling sub-cavity 151, flows into the liquid-cooling cavity 105b through some through-holes 143, flows through other through-holes 143 in the liquid-cooling cavity 105b and flows into the liquid-cooling sub-cavity 152, and then flows out of the shell 110 from the inlet and outlet 114b and flows into the cooling system of the entire vehicle.

[0124] In the embodiments of this application, Figure 6 and Figure 11 As shown, along the stacking direction Z of the heat sink 102 and the housing 110, the height of the protrusion 117 is denoted as L11, and the depth of the groove 113 is denoted as L2. L11 is less than L2, so that the partition 104 is stacked on the protrusion 117, and there is still space in the groove 113 above the partition 104 to form the liquid cooling cavity 105b. In one embodiment, the sum of the height of the protrusion 117 and the thickness of the portion of the partition 104 in contact with the protrusion 117 is less than the depth of the groove 113, so that there is still space in the groove 113 above the partition 104 to form the liquid cooling cavity 105b.

[0125] In the embodiments of this application, Figure 7 As shown, along the length direction X of the three-phase bridge arm 103, the length of the protrusion 117 is recorded as L12, and the length of the groove 113 is recorded as L13, L12 ≥ L13, so that the protrusion 117 can enhance the structural strength of the groove 113, and also enable the protrusion 117 to effectively separate the two inlets and outlets 114a and 114b.

[0126] In one embodiment, two inlets and outlets 114a and 114b are formed on the heat sink 102. In another embodiment, one inlet and outlet 114a is formed on the housing 110 of the bus capacitor 101, and one inlet and outlet 114b is formed on the heat sink 102. The two liquid cooling chambers 105a and 105b form two layers of flow channels for series flow.

[0127] In one embodiment, the protrusion 117 includes a sealing groove 117a, such as Figure 8 and Figure 11 As shown, along the stacking direction Z of the heat sink 102 and the housing 110, the sealing groove 117a is recessed away from the partition 104. The sealing groove 117a is used to accommodate a sealing member 1171. The side surface 122 of the heat sink 102 includes a plurality of heat dissipation teeth 123. Along the stacking direction Z of the heat sink 102 and the housing 110, the plurality of heat dissipation teeth 123 protrude toward the partition 104. The sealing member 1171 is used to seal the gap between the partition 104 and the protrusion 117 and to abut the surface 142 of the partition 104 against the plurality of heat dissipation teeth 123. In the stacking direction Z of the heat sink 102 and the housing 110, the distance between the plurality of heat dissipation teeth 123 and the bottom of the sealing groove 117a is less than the sum of the free length of the sealing member 1171 and the length of the portion of the partition 104 in contact with the sealing member 1171.

[0128] In the embodiment of the present application, sealing groove 117a is recessed away from partition 104 along the stacking direction Z of heat sink 102 and housing 110. Sealing groove 117a is used to accommodate a sealing member 1171, so that sealing member 1171 can seal the gap between partition 104 and protrusion 117, effectively isolating the coolant in the two liquid-cooling sub-cavities 151 and 152. The coolant in liquid-cooling sub-cavity 151 must flow through liquid-cooling cavity 105b before flowing back into liquid-cooling sub-cavity 152. In one embodiment, sealing member 1171 is a sealing ring or adhesive.

[0129] In an embodiment of the present application, the side surface 122 of the heat sink 102 includes a plurality of heat sink teeth 123, and the plurality of heat sink teeth 123 protrude toward the partition 104 along the stacking direction Z of the heat sink 102 and the shell 110. The plurality of heat sink teeth 123 are located in the liquid cooling cavity 105b, and are used to increase the heat dissipation area in the liquid cooling cavity 105b, improve the heat dissipation effect of the coolant in the liquid cooling cavity 105b, and improve the cooling efficiency of the coolant on the three-phase bridge arm 103, thereby improving the cooling efficiency of the motor controller module 100.

[0130] In the embodiment of the present application, the seal 1171 is used to seal the gap between the partition 104 and the protrusion 117 and to abut the surface 142 of the partition 104 against the multiple heat dissipation teeth 123, so that the seal 1171 can not only relatively seal and separate the two liquid-cooling sub-cavities 151 and 152, but also prevent the coolant flowing into the liquid-cooling cavity 105b from having a gap between the tooth surface of the heat dissipation teeth 123 and the surface 142 of the partition 104 to generate laminar flow. The laminar flow of the coolant has less resistance than the flow of the coolant between the heat dissipation teeth 123. If laminar flow is generated, the coolant will flow more from the tooth surface of the heat dissipation teeth 123, without more contact with the heat dissipation teeth 123, and will not be stirred by the heat dissipation teeth 123, thereby reducing the cooling effect of the coolant in the liquid-cooling cavity 105b on the three-phase bridge arm 103, which is not conducive to improving the cooling efficiency of the motor controller module 100.

[0131] In the embodiments of this application, Figure 11 As shown, along the stacking direction Z of the heat sink 102 and the shell 110, the distance between the multiple heat dissipation teeth 123 and the bottom of the sealing groove 117a is recorded as L14, and the sum of the free length of the seal 1171 and the length of the portion of the partition 104 in contact with the seal 1171 is recorded as L15. L14<L15, so that the seal 1171 in the sealing groove 117a can apply an upward elastic force to the partition 104 along the stacking direction Z of the heat sink 102 and the shell 110, so that the surface 142 of the partition 104 can abut against the multiple heat dissipation teeth 123, so that the coolant flowing from the liquid cooling cavity 105 through the through hole 143 into the liquid cooling cavity 105b will not generate laminar flow on the tooth surface of the heat dissipation teeth 123, which is beneficial to increase the contact area between the coolant and the heat dissipation teeth 123, thereby improving the cooling effect of the liquid cooling cavity 105b on the three-phase bridge arm 103, and further improving the cooling efficiency of the motor controller module 100.

[0132] In one embodiment, the surface 142 of the partition 104 has a vulcanized rubber or other buffer layer for abutting against the tooth surfaces of the plurality of heat dissipation teeth 123 to prevent gaps between the surface 142 and the heat dissipation teeth 123 from generating laminar flow and affecting the heat dissipation effect.

[0133] Figure 12 This is another structural schematic diagram of the partition 104 provided in an embodiment of the present application.

[0134] In one embodiment, the surface 141 of the partition 104 includes a sealing protrusion 144, such as Figure 11 and Figure 12As shown, along the stacking direction Z of the heat sink 102 and the housing 110, the sealing protrusion 144 protrudes toward the sealing groove 117a. The sealing groove 117a is used to accommodate the sealing protrusion 144, and the sealing protrusion 144 is used to press the sealing member 1171. In the stacking direction Z of the heat sink 102 and the housing 110, the sum of the length of the sealing protrusion 144 and the free length of the sealing member 1171 is greater than the depth of the sealing groove 117a.

[0135] In the embodiment of the present application, the sealing protrusion 144 protrudes toward the sealing groove 117a along the stacking direction Z of the heat sink 102 and the shell 110. The sealing groove 117a is used to accommodate the sealing protrusion 144. The sealing protrusion 144 is used to squeeze the sealing member 1171. The sealing protrusion 144 cooperates with the sealing groove 117a and the sealing member 1171 to make the sealing connection between the partition 104 and the protrusion 117 more stable. It not only allows the liquid-cooling chamber 105a to be divided into two liquid-cooling sub-chambers 151 and 152, but also allows the sealing member 1171 to better exert a force on the partition 104, so that the surface 142 of the partition 104 abuts against the multiple heat dissipation teeth 123, thereby preventing the coolant in the liquid-cooling chamber 105b from flowing between the heat dissipation teeth 123 and the partition 104, and allowing more coolant to flow between the heat dissipation teeth 123, thereby improving the cooling effect of the liquid-cooling chamber 105b on the three-phase bridge arm 103.

[0136] In the embodiments of this application, Figure 11 As shown, along the stacking direction Z of the heat sink 102 and the shell 110, the sum of the length of the sealing protrusion 144 and the free length of the seal 1171 is recorded as L16, and the depth of the sealing groove 117a is recorded as L17, L16>L17, so that the seal 1171 can have an upward elastic force on the partition 104, so that the surface 142 of the partition 104 abuts against the multiple heat dissipation teeth 123, avoiding the coolant in the liquid cooling chamber 105b from flowing between the heat dissipation teeth 123 and the partition 104, so that the coolant flows more between the heat dissipation teeth 123, thereby improving the cooling effect of the liquid cooling chamber 105b on the three-phase bridge arm 103.

[0137] In one embodiment, the sealing protrusion 144 and the partition 104 are independent components. The sealing protrusion 144 is a separate component, and the sealing protrusion 144 is accommodated in the sealing groove 117 a to separate the two liquid-cooling sub-cavities 151 and 152.

[0138] In one embodiment, the surface 141 of the partition 104 lacks a sealing protrusion 144 and is flat. Along the stacking direction Z of the heat sink 102 and the housing 110, the thickness of the seal 1171 is greater than the distance between the bottom of the sealing groove 117a and the partition 104, or greater than the depth of the sealing groove 117a. The seal 1171 can abut and seal the partition 104. The seal 1171 can also apply a force to the partition 104, forcing the surface 142 of the partition 104 into contact with the plurality of heat dissipation teeth 123, thereby preventing the coolant in the liquid-cooling chamber 105b from laminar flow due to gaps between the tooth surfaces of the heat dissipation teeth 123 and the surface 142 of the partition 104.

[0139] In one embodiment, the sealing protrusion 144 of the partition 104 includes a sealing groove, which is used to accommodate a seal and a protrusion 117. The seal has an elastic force on the protrusion 117 downward along the stacking direction Z of the heat sink 102 and the shell 110, so that the sealing protrusion 144 separates the two liquid-cooled sub-cavities 151 and 152 and makes the surface 142 of the partition 104 abut against the heat dissipation teeth 123 to eliminate the gap between the tooth surface of the heat dissipation teeth 123 and the surface 142 of the partition 104.

[0140] In one embodiment, if Figure 7 As shown, protrusion 117 includes a first section 117b, a second section 117c, and a third section 117d, which are sequentially connected. The first section 117b and the second section 117c are arranged on either side of the two inlets and outlets 114a and 114b along the length direction X of the three-phase bridge arm 103. The two ends of the second section 117c are arranged on different sides of the two inlets and outlets 114a and 114b along the width direction Y of the three-phase bridge arm 103.

[0141] In the embodiment of the present application, the first section 117b and the second section 117c are arranged on both sides of the two inlets and outlets 114a and 114b along the length direction X of the three-phase bridge arm 103, so that the protrusion 117 can better isolate the two inlets and outlets 114a and 114b, and can also improve the problem of reduced strength of the housing 110 due to the provision of the two inlets and outlets 114a and 114b.

[0142] In the embodiment of the present application, the two ends of the second section 117c along its length direction are arranged on different sides of the two inlets and outlets 114a and 114b along the width direction Y of the three-phase bridge arm 103, so that the two inlets and outlets 114a and 114b can be respectively isolated in the two liquid-cooling sub-cavities 151 and 152, so that the coolant flowing into the liquid-cooling cavity 105a will not only flow between the two inlets and outlets 114a and 114b but also flow through the liquid-cooling cavity 105b, which is conducive to constructing a double-layer flow channel of the motor controller module 100, so that the three-phase bridge arm 103 and the bus capacitor 101 of the motor controller module 100 can be cooled and cooled at the same time, thereby improving the cooling efficiency of the motor controller module 100.

[0143] In one embodiment, the two ends of the protrusion 117 are respectively connected to the two groove side walls of the groove 113 along the length direction X of the three-phase bridge arm 103, the protrusion 117 and a portion of the groove peripheral wall 113c of the groove 113 enclose a liquid-cooled sub-cavity 151, and the protrusion 117 and another portion of the groove peripheral wall 113d of the groove 113 enclose another liquid-cooled sub-cavity 152.

[0144] In one embodiment, if Figure 6 and Figure 7 As shown, the peripheral wall of the groove 113 includes a plurality of retaining protrusions 113e, which are used to limit the position of the partition 104. In the stacking direction Z of the heat sink 102 and the housing 110, the distance between each retaining protrusion 113e and the bottom 113b of the groove 113 is greater than the distance between the surface 142 of the partition 104 and the bottom 113b of the groove 113.

[0145] In the embodiment of the present application, the groove 113 includes a plurality of retaining protrusions 113e on the groove periphery. The retaining protrusions 113e are used to limit the position of the partition 104. The plurality of retaining protrusions 113e enable the partition 104 to be fixedly placed above the housing 110, thereby facilitating the formation of two relatively stable liquid cooling chambers 105a and 105b, thereby improving the structural reliability of the motor controller module 100 and, in turn, the structural reliability of the motor controller 13. The retaining protrusions 113e are located on the groove periphery of the groove 113 and are used to retain the partition 104 below the retaining protrusions 113, so that the other portion of the groove periphery 113d where the retaining protrusions 113 are located, the surface 142 of the partition 104, and the heat sink 102 enclose and form the liquid cooling chamber 105b, thereby improving the integration and degree of structural harmony between the motor controller module 100.

[0146] In the embodiments of this application, Figure 6As shown, along the stacking direction Z of the heat sink 102 and the shell 110, the distance between each locking protrusion 113e and the bottom 113b of the groove 113 is recorded as L18, and the distance between the surface 142 of the partition 104 and the bottom 113b of the groove 113 is L1, L18>L1, so that the locking protrusion 113e can be stacked on the partition 104 along the stacking direction Z of the heat sink 102 and the shell 110, and along the stacking direction Z of the heat sink 102 and the shell 110, the locking protrusion 113e, the partition 104, and the notch 113a of the groove 113 are arranged in sequence, so that the locking protrusion 113e can limit the partition 104, fix the partition 104 on the groove 113, and make the structure of the motor controller module 100 more stable.

[0147] Figure 13 for Figure 5 A partial enlarged view of the M1 portion of the motor controller module 100.

[0148] In one embodiment, the side surface 122 of the heat dissipation plate 102 further includes another groove 124 and a plurality of heat dissipation teeth 123. Figure 5 and Figure 13 As shown, along the stacking direction Z of the heat sink 102 and the housing 110, the groove 124 is recessed away from the partition 104, and a plurality of heat dissipation teeth 123 protrude from the bottom of the groove 124 toward the partition 104. The surface 142 is used to form a liquid cooling chamber 105b with the groove 124 on the side surface 122 of the heat sink 102 and the other portion of the groove peripheral wall 113d of the groove 113. In particular, along the stacking direction Z of the heat sink 102 and the housing 110, the depth of the groove 124 is less than the length of at least a portion of the heat dissipation teeth 123, the depth of the groove 124 is less than the maximum distance between the bottom 113b of the groove 113 and the partition 104, and the length of the plurality of heat dissipation teeth 123 is less than the depth of the groove 113.

[0149] In the embodiments of this application, Figure 3 、 Figure 5 and Figure 13 As shown, along the stacking direction Z of the heat sink 102 and the housing 110, the groove 124 is recessed away from the partition 104, allowing the groove 124 of the heat sink 102 and the partition 104 to form a larger liquid cooling chamber 105b. This also provides sufficient space for the arrangement of multiple heat dissipation teeth 123, allowing more coolant to flow in the liquid cooling chamber 105b, thereby improving the cooling effect of the coolant on the three-phase bridge arm 103. The multiple heat dissipation teeth 123 protrude from the bottom of the groove 124 toward the partition 104, allowing the heat dissipation teeth 123 to be arranged in the liquid cooling chamber 105b to stir the coolant flowing through the liquid cooling chamber 105b, thereby improving the cooling efficiency of the motor controller module 100.

[0150] In the embodiment of the present application, the surface 142 is used to form a liquid cooling cavity 105b with the groove 124 of the side surface 122 of the heat sink 102 and the other part of the groove peripheral wall 113d of the groove 113. The groove peripheral wall of the groove 113 is used not only to form the liquid cooling cavity 105a but also to form the liquid cooling cavity 105b, so that the formation of the two liquid cooling cavities 105a and 105b will not occupy too much space of the motor controller module 100 along the stacking direction Z of the heat sink 102 and the housing 110, which is conducive to the miniaturized arrangement of the motor controller module 100 and can also improve the integration of the motor controller module 100.

[0151] In the embodiments of this application, Figure 13 As shown, along the stacking direction Z of heat sink 102 and housing 110, the depth of groove 124 is denoted as L19, and the length of at least a portion of heat sink teeth 123 is denoted as L20. L19 < L20 allows at least a portion of heat sink teeth 123 to abut against surface 142 of partition 104, preventing laminar flow of coolant in liquid cooling chamber 105b due to gaps between the tooth surfaces of heat sink teeth 123 and surface 142 of partition 104, thereby improving heat dissipation efficiency. The longer length of heat sink teeth 123 also increases the contact area between the coolant and the heat sink teeth 123, thereby improving the cooling effect of the coolant and the cooling efficiency of motor controller module 100.

[0152] In the embodiments of this application, Figure 13 As shown, the depth of the groove 124 is L19, and the maximum distance between the groove bottom 113b of the groove 113 and the partition 104 is L6, L19<L6, so that after the liquid cooling cavity 105a and the liquid cooling cavity 105b are formed, too much space of the motor controller module 100 along the stacking direction Z of the heat sink 102 and the shell 110 will not be occupied, which is conducive to the miniaturization of the motor controller module 100.

[0153] In the embodiments of this application, Figure 13 As shown, the length of the plurality of heat dissipation teeth 123 is L20, the depth of the groove 113 is L2, and L20<L2. Therefore, when the heat dissipation plate 102 forms the liquid cooling cavity 105b by means of the groove 113, the liquid cooling cavity 105b does not occupy too much space of the motor controller module 100 along the stacking direction Z of the heat dissipation plate 102 and the housing 110, which is conducive to the miniaturization of the motor controller module 100.

[0154] Figure 14 This is another exploded view of the motor controller module 100 provided in an embodiment of the present application.

[0155] In one embodiment, the capacitor core package 111 includes two groups of capacitor cores 111a and 111b. Figure 4 and Figure 14As shown, one group of capacitor cores 111a and another group of capacitor cores 111b are arranged adjacent to each other in the width direction Y of the three-phase bridge arm 103. Along the length direction X of the three-phase bridge arm 103, the length of one group of capacitor cores 111a is shorter than the length of the other group of capacitor cores 111b. The other group of capacitor cores 111b and the grooves 113 are stacked along the stacking direction Z of the heat sink 102 and the housing 110.

[0156] In an embodiment of the present application, along the length direction X of the three-phase bridge arm 103, the length of one group of capacitor cores 111a is smaller than the length of another group of capacitor cores 111b, so that the portion along the length direction X of the three-phase bridge arm 103 where the length of one group of capacitor cores 111a is smaller than the length of the other group of capacitor cores 111b provides space for the arrangement of other components of the motor controller module 100, which is conducive to improving the integration of the motor controller module 100.

[0157] In an embodiment of the present application, another group of capacitor cores 111b and the grooves 113 are stacked along the stacking direction Z of the heat sink 102 and the shell 110, so that the coolant flowing in the grooves 113 can more directly take away the heat of the capacitor core package 111, which is beneficial to cooling the bus capacitor 101 and improving the heat dissipation efficiency of the motor controller module 100.

[0158] In one embodiment, the housing 110 of the busbar capacitor 101 further includes a window 118. Figure 4 and Figure 14 As shown, the window 118 is used to accommodate the bus capacitor 101. The bus capacitor 101 also includes two input copper sheets 112. The opening of the window 118 is oriented along the width direction Y of the three-phase bridge arm 103 and along the stacking direction Z of the heat sink 102 and the shell 110. The two input copper sheets 112 are stacked on the bus capacitor 101. The two input copper sheets 112 are bent from the window 118 toward the three-phase bridge arm 103. The two input copper sheets 112 are electrically connected to a group of copper busbars 131a of multiple power modules 131.

[0159] In the embodiment of the present application, the opening of a window 118 along the width direction Y of the three-phase bridge arm 103 is arranged on the same side as a group of copper busbars 131a of the power module 131, so that the two input copper sheets 112 can be bent from the window 118 toward the three-phase bridge arm 103 in a short path and electrically connected to a group of copper busbars 131a of multiple power modules 131, so that the DC power of the power battery 30 can be transmitted to the three-phase bridge arm 103 for converting DC power into AC power output, and the integration and integration of the motor controller module 100 can also be improved.

[0160] Figure 15 This is another structural schematic diagram of the motor controller module 100 provided in an embodiment of the present application.

[0161] In one embodiment, the motor controller module 100 further includes a filter tank 119, such as Figure 4 、 Figure 14 and Figure 15 As shown, along the stacking direction Z of the heat sink 102 and the housing 110, the notch of the filter slot 119 faces away from the notch 113a of the groove 113. The filter slot 119 is used to accommodate an EMC filter assembly 106 and two input connection copper bars 107. The two input connection copper bars 107 are used to receive DC power from the DC power supply and transmit the DC power to the two input copper plates 112 of the bus capacitor 101 after filtering by the EMC filter assembly 106. Along the length direction X of the three-phase bridge arm 103, the filter slot 119 is adjacent to and spaced apart from a group of capacitor cores 111a.

[0162] In the embodiment of the present application, the filter slot 119 is formed by utilizing the space where one group of capacitor cores 111a is smaller than the length of another group of capacitor cores 111b along the length direction X of the three-phase bridge arm 103, without occupying too much space of the motor controller module 100 along the width direction Y and the length direction X of the three-phase bridge arm 103, which is conducive to the miniaturized layout of the motor controller module 100 and can also improve the integration of the motor controller module 100.

[0163] In the embodiment of the present application, the filter slot 119 is used to accommodate the EMC filter component 106 and the two input connection copper bars 107. The DC power input from the DC power supply is input into the motor controller module 100 through the two input connection copper bars 107, and is filtered and stabilized by the EMC filter component 106, so that the current signal transmitted to the bus capacitor 101 is more stable and accurate.

[0164] In one embodiment, the motor controller module 100 further includes an output copper sheet 108, such as Figure 3 、 Figure 4 and Figure 14 As shown, output copper sheet 108 is used to electrically connect to another set of copper bars 131b of multiple power modules 131. Along the stacking direction Z of heat sink 102 and housing 110, output copper sheet 108 is stacked on a set of capacitor cores 111a. Along the width direction Y of three-phase bridge arm 103, output copper sheet 108 is arranged adjacent to groove 113.

[0165] In one embodiment, the motor controller module 100 further includes a plurality of reinforcing ribs 109, such as Figure 4 and Figure 7As shown, multiple reinforcing ribs 109 and windows 118 are stacked along the stacking direction Z of the heat sink 102 and the shell 110. The opening of windows 118 and grooves 113 in the shell 110 will reduce the structural strength of the shell 110. The structural strength is compensated by the provision of reinforcing ribs 109, which is beneficial to the stability of the overall structure of the motor controller module 100.

[0166] In one embodiment, if Figure 5 and Figure 6 As shown, the heat sink 102 and the housing 110 are sealed by a sealing ring 102a, so that the coolant in the two liquid cooling chambers 105a and 105b will not leak, thereby avoiding short circuits in other electrical components in the motor controller module 100 and affecting the normal operation of the motor controller module 100.

[0167] The motor controller module, motor controller, powertrain and electric vehicle provided in the embodiments of the present application are introduced in detail above. Specific examples are used herein to illustrate the principles and embodiments of the present application. The description of the above embodiments is only used to help understand the method of the present application and its core idea. At the same time, for those skilled in the art, according to the ideas of the present application, there will be changes in the specific embodiments and application scope. In summary, the content of this specification should not be understood as a limitation on the present application.

Claims

1. A motor controller module, characterized in that: The motor controller module includes a busbar capacitor and a heat sink. The inner cavity of a shell of the busbar capacitor is used to accommodate a capacitor core package. The heat sink is stacked on the outside of the shell. The heat sink includes two side surfaces along the stacking direction of the heat sink and the shell. One of the side surfaces is used to fix a three-phase bridge arm. The three-phase bridge arm is used to receive power from the power battery of the electric vehicle through the capacitor core package and output a three-phase current to drive the motor of the electric vehicle, wherein: The shell includes a groove, and the notch of the groove faces the heat dissipation plate along the stacking direction of the heat dissipation plate and the shell. The groove is used to accommodate a partition. The partition includes two surfaces, one of the surfaces is used to form a liquid cooling cavity with the bottom of the groove and a part of the groove wall of the groove, and the other surface is used to form another liquid cooling cavity with the other side surface of the heat dissipation plate and another part of the groove wall of the groove. The maximum distance between the other surface and the bottom of the groove is less than the depth of the groove.

2. The motor controller module according to claim 1, characterized in that: Along the stacking direction of the one heat dissipation plate and the one housing, a distance between the one surface and the bottom of the one groove is greater than or equal to a distance between the other surface and the groove opening of the one groove.

3. The motor controller module according to claim 1 or 2, characterized in that: The shell further includes a plurality of spoiler teeth, each of which extends from the bottom of the groove toward the notch of the groove along the stacking direction of the heat dissipation plate and the shell, and the height of each spoiler tooth is less than the depth of the groove.

4. The motor controller module according to any one of claims 1 to 3, characterized in that: The three-phase bridge arm includes a plurality of power modules, the plurality of power modules are arranged at intervals along the length direction of the three-phase bridge arm, each of the power modules includes two groups of copper bars, the two groups of copper bars are opposite to each other along the width direction of the three-phase bridge arm, and the length of the three-phase bridge arm along its length direction is greater than its length along its width direction, wherein: The one partition includes multiple pairs of through holes, and the multiple pairs of through holes are used to connect the one liquid-cooling cavity and the other liquid-cooling cavity. The multiple pairs of through holes pass through the one partition along the stacking direction of the one heat sink and the one shell, and each pair of through holes includes two through holes. The multiple pairs of through holes are arranged at intervals along the length direction of the three-phase bridge arm, and the two through holes of each pair of through holes are arranged at intervals along the width direction of the three-phase bridge arm. Each of the power modules is aligned with a pair of through holes along the stacking direction of the one heat sink and the one shell.

5. The motor controller module according to claim 4, characterized in that: The length of each through hole along the length direction of the three-phase bridge arm is greater than the width of each through hole along the width direction of the three-phase bridge arm; A distance between the two through holes of each pair of through holes along the width direction of the three-phase bridge arm is greater than half a width of the one groove along the width direction of the three-phase bridge arm.

6. The motor controller module according to claim 4, characterized in that: The one housing further includes a plurality of reinforcing ribs, each of the reinforcing ribs protruding from the bottom of the one groove toward the one partition along the stacking direction of the one heat dissipation plate and the one housing, wherein: Along the stacking direction of the heat dissipation plate and the housing, the height of each reinforcing rib is smaller than the depth of the groove; Some of the through holes and some of the reinforcing ribs are alternately arranged in sequence along the length direction of the three-phase bridge arm.

7. The motor controller module according to any one of claims 1 to 6, characterized in that: The one shell further includes a protrusion and two inlets and outlets. Along the stacking direction of the one heat sink and the one shell, the one protrusion protrudes from the bottom of the one groove toward the notch of the one groove. The one partition is stacked on the one protrusion. The one protrusion is used to separate the one liquid-cooling cavity into two liquid-cooling sub-cavities and to separate the two inlets and outlets. Each liquid-cooling sub-cavity is used to connect with the other liquid-cooling cavity and one of the inlets and outlets. The two inlets and outlets are used to connect with an external flow channel, wherein: Along the stacking direction of the heat dissipation plate and the housing, the height of the protrusion is smaller than the depth of the groove; The length of the protrusion is greater than or equal to the length of the groove along the length direction of the three-phase bridge arm.

8. The motor controller module according to claim 7, characterized in that: The one protrusion includes a sealing groove, which is recessed away from the one partition along the stacking direction of the one heat dissipation plate and the one housing, and is used to accommodate a sealing member. The other side surface of the one heat dissipation plate includes a plurality of heat dissipation teeth, which protrude toward the one partition along the stacking direction of the one heat dissipation plate and the one housing, and the one sealing member is used to seal the gap between the one partition and the one protrusion and to abut the other surface of the one partition against the plurality of heat dissipation teeth, wherein: Along the stacking direction of the heat dissipation plate and the shell, the distance between the plurality of heat dissipation teeth and the bottom of the sealing groove is smaller than the sum of the free length of the seal and the length of the portion of the partition in contact with the seal.

9. The motor controller module according to claim 8, characterized in that: The one surface of the one partition includes a sealing protrusion, and along the stacking direction of the one heat dissipation plate and the one housing, the one sealing protrusion protrudes toward the one sealing groove, the one sealing groove is used to accommodate the one sealing protrusion, and the one sealing protrusion is used to press the one sealing member, wherein: Along the stacking direction of the one heat dissipation plate and the one housing, the sum of the length of the one sealing protrusion and the free length of the one sealing member is greater than the depth of the one sealing groove.

10. The motor controller module according to claim 7, characterized in that: The one protrusion comprises a first section, a second section and a third section connected in sequence, wherein: The first section and the second section are arranged on both sides of the two inlets and outlets along the length direction of the three-phase bridge arm; The two ends of the second section are arranged on different sides of the two inlets and outlets along the width direction of the three-phase bridge arm.

11. The motor controller module according to any one of claims 1 to 10, characterized in that: The peripheral wall of the groove includes a plurality of positioning protrusions, and the positioning protrusions are used to limit the position of the partition, wherein: Along the stacking direction of the heat dissipation plate and the housing, the distance between each of the positioning protrusions and the bottom of the groove is greater than the distance between the other surface of the partition and the bottom of the groove.

12. The motor controller module according to any one of claims 1 to 11, characterized in that: The other side surface of the one heat sink further includes another groove and a plurality of heat dissipation teeth. The other groove is recessed away from the one partition along the stacking direction of the one heat sink and the one housing. The plurality of heat dissipation teeth protrude from the bottom of the other groove toward the one partition. The other surface is used to form the other liquid cooling cavity with the other groove on the other side surface of the one heat sink and another portion of the peripheral wall of the one groove, wherein: Along the stacking direction of the one heat dissipation plate and the one shell, the depth of the other groove is less than the length of at least part of the heat dissipation teeth, the depth of the other groove is less than the maximum distance between the bottom of the one groove and the one partition, and the length of the multiple heat dissipation teeth is less than the depth of the one groove.

13. A motor controller, characterized in that: The motor controller includes a housing and a motor controller module as described in any one of claims 1-12, the housing is used to accommodate the motor controller module, and the internal flow channel of the housing is used to connect the two inlets and outlets of the shell of the bus capacitor in the motor controller module.

14. A powertrain, characterized in that: The powertrain includes a motor and the motor controller according to claim 13 , wherein the motor is configured to receive power from the motor controller module of the motor controller.

15. An electric vehicle, characterized in that: The electric vehicle includes a frame, a power battery and a powertrain as claimed in claim 14, wherein the frame is used to fix the power battery and the powertrain, and the motor of the powertrain is used to receive power from the power battery through the motor controller to drive the wheels.

Images