Three-phase copper bar structure for secondary injection molding

Abstract

The utility model discloses a three-phase copper bar structure for secondary injection molding, which comprises a three-phase copper bar module, an injection molding module and a filtering module, the three-phase copper bar module and the filtering module are both arranged on the injection molding module, the three-phase copper bar module comprises a U-phase copper bar, a V-phase copper bar and a W-phase copper bar, the U-phase copper bar, the V-phase copper bar and the W-phase copper bar are respectively provided with a plurality of stamping grooves. According to the secondary injection molding three-phase copper bar structure disclosed by the utility model, the filtering module is integrated to improve the electromagnetic compatibility, and a conventional glue filling sealing scheme and a conventional infiltration scheme are replaced by a secondary injection molding sealing scheme. The novel connecting structure can be suitable for low-voltage and high-voltage platforms, multiple functions such as high-voltage current transmission, insulation protection, structure supporting, oil-resistant sealing and noise attenuation are achieved, the high integration degree can reduce the product arrangement space, and the cost is reduced.

Description

Technical Field

[0001] This utility model belongs to the field of three-phase copper busbar technology, specifically relating to a three-phase copper busbar structure with secondary injection molding. Background Technology

[0002] The electric drive system is a core component of new energy vehicles, mainly consisting of the motor, motor controller, and reducer. In recent years, with the continuous development of the new energy vehicle industry, electric drive systems are facing requirements for higher integration and reliability. Furthermore, the application of oil-cooled drive motors is becoming increasingly widespread. In this case, the motor housing is an oil-cooled chamber, while the controller housing is a dry chamber. Cooling oil can seep into the controller housing through gaps. Prolonged use of electronic components in this oily and volatile environment can accelerate product aging, cause short circuits, and ultimately lead to serious risks such as power loss.

[0003] To improve system integration, the existing solution integrates the motor controller directly with the motor and reducer. The three-phase output of the power module in the motor controller is directly connected to the three-phase input of the motor using copper busbars, which are then encased in plastic to fix the motor in place, thus reducing the system's size and cost.

[0004] To achieve a tight seal between the motor housing and the controller housing, existing solutions use end face sealing rings on the connecting copper busbars to prevent the flow of cooling oil between the housings. At the same time, potting compound and impregnation processes are used between the copper busbars and the plastic coating to prevent the cooling oil from flowing through the gaps between the plastic and the copper busbars.

[0005] The specific structure of the existing solution is as follows: Figure 1 As shown:

[0006] 6 is a plastic body formed by injection molding, which encapsulates the U-phase copper busbar 1, V-phase copper busbar 2, W-phase copper busbar 3, and through-hole insert 4, serving as a fixing and insulating element. Bolts are used to fix 6 to the controller housing via 4, while providing sufficient pressure to the sealing ring 5 to ensure reliable sealing. 7 is potting compound, used to impregnate and seal the gap between the copper busbars and plastic at both ends of the product.

[0007] In recent years, new energy drive systems have been rapidly developing towards high-voltage platformization and SiC drivers. As a result, the dv / dt and di / dt caused by the switching transistors of the drive devices have increased, and the EMC problems of the controllers have become particularly prominent. The industry's requirements for EMC levels are constantly increasing, and various methods are needed to suppress differential and common-mode components. However, existing structures and methods are often unable to meet the ever-increasing EMC level requirements, which leads to noise and other problems.

[0008] Existing solutions use potting compound for sealing, requiring pre-reserved potting grooves at the plastic location. This potting process is cumbersome, the potting compound has a long curing period, hindering rapid product delivery, and requires additional potting equipment. Impregnation sealing is also complex and expensive, failing to reduce costs. Using end-face sealing rings with overlapping potting grooves requires significant lateral space, preventing the integration of magnetic rings and thus failing to effectively address EMC issues. Utility Model Content

[0009] The main objective of this invention is to provide a two-stage injection-molded three-phase copper busbar structure, propose a novel connection structure between the motor controller and the oil-cooled motor, integrate a filter module to improve electromagnetic compatibility, and eliminate conventional potting and impregnation sealing methods, replacing them with a two-stage injection-molded sealing solution. This new connection structure is applicable to both low-voltage and high-voltage platforms, achieving multiple functions such as high-voltage current transmission, insulation protection, structural support, oil-resistant sealing, and noise attenuation. Its high integration reduces product layout space and lowers costs.

[0010] To achieve the above objectives, this utility model provides a three-phase copper busbar structure with secondary injection molding, comprising a three-phase copper busbar module, an injection molding module, and a filtering module. Both the three-phase copper busbar module and the filtering module are installed within the injection molding module, wherein:

[0011] The three-phase copper busbar module includes a U-phase copper busbar, a V-phase copper busbar, and a W-phase copper busbar. Each of the U-phase copper busbar, the V-phase copper busbar, and the W-phase copper busbar is provided with a plurality of stamping grooves, and the stamping grooves are provided with a plurality of serrated patterns.

[0012] The injection molding module includes an elastomer formed by a first injection molding and a main body formed by a second injection molding. The elastomer is fixedly installed in the stamping groove. The main body surrounds the elastomer and also partially surrounds the U-phase copper busbar, the V-phase copper busbar, and the W-phase copper busbar. The main body is provided with a sealing ring mounting groove and a dispensing groove. The sealing ring mounting groove surrounds the dispensing groove and a sealing ring is installed in the sealing ring mounting groove. The filter module is fixedly installed in the dispensing groove by potting compound.

[0013] As a further preferred technical solution to the above technical solution, the main body is also provided with several through-hole inserts.

[0014] As a further preferred embodiment of the above technical solution, the U-phase copper busbar, the V-phase copper busbar, and the W-phase copper busbar are all bent and installed on the main body.

[0015] As a further preferred embodiment of the above technical solution, the first end of the U-phase copper busbar, the first end of the V-phase copper busbar, and the first end of the W-phase copper busbar are all provided with a first mounting hole, and the second end of the U-phase copper busbar, the second end of the V-phase copper busbar, and the second end of the W-phase copper busbar are all provided with a second mounting hole (so that the entire copper busbar structure is installed between the controller power module and the three-phase motor).

[0016] As a further preferred technical solution to the above technical solution, the through-hole insert is made of stainless steel. Attached Figure Description

[0017] Figure 1 This is a diagram of the existing copper busbar structure.

[0018] Figure 2 This is a schematic diagram of the structure of this utility model.

[0019] Figure 3 This is a schematic diagram of the structure of this utility model.

[0020] Figure 4 This is a schematic diagram of the structure of this utility model.

[0021] Figure 5 This is a schematic diagram of the structure of this utility model.

[0022] Figure 6 This is a schematic diagram of the structure of this utility model.

[0023] Figure 7 This is a schematic diagram of the structure of this utility model.

[0024] The reference numerals in the attached drawings include: 10, U-phase copper busbar; 11, stamped groove; 20, V-phase copper busbar; 30, W-phase copper busbar; 40, through-hole insert; 50, sealing ring; 51, sealing ring mounting groove; 60, filter module; 70, elastomer; 80, main body; 90, dispensing groove; 100, potting compound. Detailed Implementation

[0025] The following description is intended to disclose the present invention so that those skilled in the art can implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art. The basic principles of the present invention defined in the following description can be applied to other embodiments, modifications, improvements, equivalents, and other technical solutions that do not depart from the spirit and scope of the present invention.

[0026] This utility model discloses a three-phase copper busbar structure with secondary injection molding. The specific embodiments of the utility model are further described below with reference to preferred embodiments.

[0027] In the embodiments of this utility model, those skilled in the art will note that the three-phase motor and power module involved in this utility model can be regarded as prior art.

[0028] Preferred embodiment.

[0029] like Figure 2-7 As shown, this utility model discloses a three-phase copper busbar structure with secondary injection molding, including a three-phase copper busbar module, an injection molding module, and a filter module 60. Both the three-phase copper busbar module and the filter module 60 are installed in the injection molding module, wherein:

[0030] The three-phase copper busbar module includes a U-phase copper busbar 10, a V-phase copper busbar 20 and a W-phase copper busbar 30. The U-phase copper busbar 10, the V-phase copper busbar 20 and the W-phase copper busbar 30 are each provided with a plurality of stamping grooves 11, and the stamping grooves 11 are provided with a plurality of serrated patterns.

[0031] The injection molding module includes an elastomer 70 formed by a first injection molding and a main body 80 formed by a second injection molding. The elastomer 70 is fixedly installed in the stamping groove 11. The main body 80 surrounds the elastomer 70 and also partially surrounds the U-phase copper busbar 10, the V-phase copper busbar 20, and the W-phase copper busbar 30. The main body 80 is provided with a sealing ring mounting groove 51 and a dispensing groove 90. The sealing ring mounting groove 51 surrounds the dispensing groove 90 and a sealing ring 50 is installed in the sealing ring mounting groove 51. The filter module 60 is fixedly installed in the dispensing groove 90 by potting compound 100.

[0032] Specifically, the main body 80 is also provided with several through-hole inserts 40.

[0033] More specifically, the U-phase copper busbar 10, the V-phase copper busbar 20, and the W-phase copper busbar 30 are all bent and installed on the main body 80.

[0034] Furthermore, the first end of the U-phase copper busbar 10, the first end of the V-phase copper busbar 20, and the first end of the W-phase copper busbar 30 are all provided with first mounting holes, and the second end of the U-phase copper busbar 10, the second end of the V-phase copper busbar 20, and the second end of the W-phase copper busbar 30 are all provided with second mounting holes (so that the entire copper busbar structure is installed between the controller power module and the three-phase motor).

[0035] Furthermore, the through-hole insert 40 is made of stainless steel (or other materials).

[0036] Regarding this utility model:

[0037] It has the function of connecting the motor controller power module and the three-phase line of the drive motor. It uses copper busbar bending and is combined with the first plastic coating of the elastomer and the second plastic coating of the main body. The main body is matched with fixed product features, sealing features and magnetic ring installation features.

[0038] The concept of this utility model:

[0039] ① The three-phase copper busbar passes through the motor controller housing, with one end directly connected to the controller power module output interface and the other end directly connected to the motor three-phase input interface;

[0040] ② The three-phase copper busbar uses two-stage injection molding. The first injection is of the elastomer, and the second injection is of the plastic body. The elastomer is located between the copper busbar and the plastic body.

[0041] ③ The elastomer used in the injection molding of three-phase copper busbars has extremely strong adhesion to both the copper busbars and the main body. In addition, it is elastic and can avoid structural gaps caused by the different thermal expansion coefficients between different materials under temperature shock test conditions, thus achieving a seal between the copper busbars and the main body.

[0042] ④ The copper busbar of the three-phase copper busbar has a stamped groove added to the side at the position of the plastic-coated elastomer to prevent the material flow impact during the second plastic injection from causing the elastomer to shift. Furthermore, the injection molding bonding effect is enhanced by adding stamped serrated patterns to the surface of the copper busbar.

[0043] ⑤ The elastomer used in the plastic coating of three-phase copper busbars has a lower melting point than plastic. During the plastic coating process, the surface melts and merges with the plastic liquid. Furthermore, after plastic coating, the plastic will exert pressure on the elastomer, causing the elastomer to compress and generate a rebound force on the copper busbar and plastic, thereby enhancing the sealing effect.

[0044] ⑥ The injection-molded elastomer of the three-phase copper busbar is located far from the pin connection point of the copper busbar. The axial pin deformation of the copper busbar will not be transmitted to the elastomer. Therefore, it can withstand the leakage risk caused by pin deformation of any amplitude in the axial direction of the copper busbar.

[0045] ⑦ The surface design of the main body is reserved with radial sealing ring mounting grooves, which are used in conjunction with the sealing ring to achieve sealing between the product and the controller housing, and the structure has good assemblability;

[0046] ⑧ The main surface of the three-phase copper busbar connected to the motor side is designed with a pre-reserved glue groove. After the magnetic ring (filter module) is installed in the glue groove, it can be fixed by potting to achieve the size compatibility of different magnetic rings.

[0047] The beneficial effects of this utility model are as follows:

[0048] ① Using copper busbars for direct connection improves the integration of the drive system and reduces system cost and weight;

[0049] ② By using secondary injection molding and sealing design at the sealing ring, the oil-cooled motor cavity and the controller cavity achieve excellent sealing performance. This design can withstand temperature shock tests of more than 2000 hours and deformation of copper busbars with arbitrary axial amplitude, which can meet the sealing requirements of different occasions and improve the reliability of the system.

[0050] ③ By using a sealing solution involving the first injection molding of the elastomer and the second injection molding of the plastic body, the traditional cumbersome processes such as potting and impregnation are eliminated; the elastomer has a simple structure and small size, and its position, quantity, and size can be adjusted at will according to different product requirements, offering high flexibility; the elastomer injection mold and process are simple and have low cost; the elastomer injection solution does not require a potting tank or an additional impregnation process, resulting in low process cost, short production cycle, and high sealing reliability;

[0051] ④ The three-phase copper busbar adopts a radial sealing scheme, which saves the lateral space of the three-phase copper busbar and reduces the number of screws used compared with the end face sealing, thus reducing costs;

[0052] ⑤ The three-phase copper busbar eliminates the potting groove and adopts a radial sealing scheme, saving lateral space and enabling the integration of nanocrystalline magnetic rings (filter modules). This integration optimizes the layout space and improves space utilization. By fixing the magnetic ring with potting compound, the magnetic ring can be flexibly changed in size according to different needs, making adjustment convenient. The three-phase copper busbar does not need to be re-molded to accommodate changes in magnetic ring size, saving mold costs and reducing overall costs. At the same time, the potting compound provides high structural strength, strong vibration resistance, and good dust and oil resistance.

[0053] ⑥ Nanocrystalline magnetic rings have the characteristics of high permeability and wide frequency response, which can increase common-mode impedance, reduce common-mode current component, and suppress common-mode conducted emission noise. In PEB controllers, they can achieve different degrees of noise suppression for different frequency bands.

[0054] ⑦ Good heat dissipation effect: the high-temperature copper busbar is in direct contact with the plastic body, and the heat generated by the copper busbar is transferred to the metal shell through the plastic body, realizing solid conduction heat dissipation.

[0055] It is worth mentioning that the technical features of the three-phase motor and power module involved in this utility model patent application should be regarded as prior art. The specific structure, working principle and possible control method and spatial arrangement of these technical features can be adopted by conventional choices in the field and should not be regarded as the inventive point of this utility model patent. This utility model patent will not be further elaborated in detail.

[0056] For those skilled in the art, modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A three-phase copper busbar structure subjected to secondary injection molding, characterized in that, The system includes a three-phase copper busbar module, an injection molding module, and a filter module. Both the three-phase copper busbar module and the filter module are mounted within the injection molding module. The three-phase copper busbar module includes a U-phase copper busbar, a V-phase copper busbar, and a W-phase copper busbar. Each of the U-phase copper busbar, the V-phase copper busbar, and the W-phase copper busbar is provided with a plurality of stamping grooves, and the stamping grooves are provided with a plurality of serrated patterns. The injection molding module includes an elastomer formed by a first injection molding and a main body formed by a second injection molding. The elastomer is fixedly installed in the stamping groove. The main body surrounds the elastomer and also partially surrounds the U-phase copper busbar, the V-phase copper busbar, and the W-phase copper busbar. The main body is provided with a sealing ring mounting groove and a dispensing groove. The sealing ring mounting groove surrounds the dispensing groove and a sealing ring is installed in the sealing ring mounting groove. The filter module is fixedly installed in the dispensing groove by potting compound.

2. The three-phase copper busbar structure with secondary injection molding according to claim 1, characterized in that, The main body is also provided with several through-hole inserts.

3. The three-phase copper busbar structure with secondary injection molding according to claim 1, characterized in that, The U-phase copper busbar, the V-phase copper busbar, and the W-phase copper busbar are all bent and installed on the main body.

4. The three-phase copper busbar structure with secondary injection molding according to claim 1, characterized in that, The first end of the U-phase copper busbar, the first end of the V-phase copper busbar, and the first end of the W-phase copper busbar are each provided with a first mounting hole, and the second end of the U-phase copper busbar, the second end of the V-phase copper busbar, and the second end of the W-phase copper busbar are each provided with a second mounting hole.

5. A three-phase copper busbar structure with secondary injection molding according to claim 2, characterized in that, The through-hole insert is made of stainless steel.

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