Novel filter structure

Abstract

The utility model discloses a novel filter structure, which comprises a busbar module, a capacitor module and a magnetic core module, the capacitor module is arranged on the busbar module, the busbar module penetrates through the magnetic core module, the busbar module comprises a busbar injection molding body, a positive busbar and a negative busbar, and the positive busbar and the negative busbar are respectively arranged on the busbar injection molding body. The novel filter structure disclosed by the utility model has the advantages of short design period, low production cost, common mold, convenience in installation and the like, different electric drive system controllers can be adapted only by redesigning and producing the busbar, the busbar is simple to design and manufacture, the design period is shortened, and the cost of the filter is reduced; the capacitor module is designed in a modularized mode, and the requirements of different products for EMC can be met only by adjusting the capacitance value of the capacitor.

Description

Technical Field

[0001] This utility model belongs to the field of filter technology, and specifically relates to a novel filter structure. Background Technology

[0002] As the voltage levels of electric drive systems in new energy vehicles increase, EMC issues become more prominent, placing increasingly higher demands on high-voltage filters. Intensifying price competition in the new energy vehicle market also makes low-cost, rapid production solutions for sub-components crucial. Because high-voltage filters are significantly affected by space constraints, standardized design is difficult, leading to high mold costs and manufacturing expenses. Furthermore, traditional filter products for electric drive system controllers are designed differently based on the filter envelope and utilize copper busbar injection molding structures, requiring separate design and mold development for each project. This results in long design and production cycles, poor compatibility, high mold costs, and high unit costs. Therefore, a new modular filter structure is needed. Utility Model Content

[0003] The main objective of this invention is to provide a novel filter structure with advantages such as short design cycle, low production cost, shared molds, and convenient installation. Only the busbar needs to be redesigned and manufactured to adapt to different electric drive system controllers. The busbar design and manufacturing are simple, shortening the design cycle and reducing the filter cost. The capacitor module is modularly designed; only the capacitance value needs to be adjusted to meet the EMC requirements of different products. By adjusting the arrangement and combination of the capacitor module and the magnetic core module, filters with different topologies can be designed, offering flexibility and versatility.

[0004] To achieve the above objectives, this utility model provides a novel filter structure, including a busbar module, a capacitor module, and a magnetic core module. The capacitor module is mounted on the busbar module, and the busbar module passes through the magnetic core module, wherein:

[0005] The busbar module includes a busbar injection molded body, a positive busbar, and a negative busbar. The positive busbar and the negative busbar are respectively installed on the busbar injection molded body. The busbar injection molded body is provided with a positive mounting hole, a negative mounting hole, a first guide groove, and a second guide groove. The first guide groove is close to the positive mounting hole and the second guide groove is close to the negative mounting hole.

[0006] The capacitor module includes a capacitor injection molded body and a positive electrode copper plate, a negative electrode copper plate, a first grounding copper plate, a second grounding copper busbar, a first filter capacitor, a second filter capacitor, and a first insert mounted on the capacitor injection molded body. The first end of the positive electrode copper plate is mounted to the positive electrode mounting hole via the first guide groove and contacts the positive electrode busbar (for positive electrode power extraction from the filter capacitor). The second end of the positive electrode copper plate is connected to the first end of the first filter capacitor. The first end of the negative electrode copper plate is mounted to the negative electrode mounting hole via the second guide groove and contacts the negative electrode busbar (for negative electrode power extraction from the filter capacitor). The second end of the negative electrode copper plate is connected to the first end of the second filter capacitor. The first grounding copper plate is connected to the second end of the first filter capacitor, and the second grounding copper plate is connected to the second end of the second filter capacitor (the grounding copper plates are fixed to the controller housing by nuts and provide a grounding circuit for the filter capacitors).

[0007] The magnetic core module includes a magnetic core injection molded body, an annular magnetic core mounted on the magnetic core injection molded body, and a second insert.

[0008] As a further preferred embodiment of the above technical solution, both the positive electrode mounting hole and the negative electrode mounting hole are provided with a guide structure (which serves as a guide when the power-taking copper sheet of the capacitor module is assembled into the busbar module, and / or when the capacitor module is disassembled).

[0009] As a further preferred technical solution to the above technical solution, the material of the toroidal magnetic core includes nanocrystals and ferrite (one of them).

[0010] As a further preferred technical solution to the above technical solution, the annular magnetic core is installed on the magnetic core injection mold by potting (or it can be sealed with a plastic cap).

[0011] As a further preferred technical solution of the above technical solution, the positive electrode copper sheet and the negative electrode copper sheet are L-shaped (injected into the capacitor injection body, forming a clamp-type structure, which can be directly clamped onto the busbar to supply power to the filter capacitor). Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the structure of this utility model.

[0013] Figure 2 This is a structural schematic diagram of the busbar module of this utility model.

[0014] Figure 3 This is a structural schematic diagram of the busbar module of this utility model.

[0015] Figure 4This is a schematic diagram of the structure of the capacitor injection molded body of this utility model.

[0016] Figure 5 This is a schematic diagram of the structure of the capacitor injection molded body of this utility model.

[0017] The reference numerals in the accompanying drawings include: 100, busbar module; 110, busbar injection molding body; 111, positive electrode mounting hole; 112, negative electrode mounting hole; 113, first guide groove; 114, second guide groove; 115, guide structure; 120, positive busbar; 130, negative busbar; 200, capacitor module; 210, capacitor injection molding body; 220, positive electrode power-taking copper sheet; 230, negative electrode power-taking copper sheet; 240, first grounding copper sheet; 250, second grounding copper busbar; 260, first filter capacitor; 270, second filter capacitor; 280, first insert; 300, magnetic core module; 310, magnetic core injection molding body; 320, toroidal magnetic core; 330, second insert. Detailed Implementation

[0018] 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.

[0019] This utility model discloses a novel filter structure. The specific embodiments of the utility model are further described below with reference to preferred embodiments.

[0020] In the embodiments of this utility model, those skilled in the art will note that the controller housing and the like involved in this utility model can be considered as prior art.

[0021] Preferred embodiment.

[0022] like Figure 1-5 As shown, this utility model discloses a novel filter structure, including a busbar module 100, a capacitor module 200, and a magnetic core module 300. The capacitor module 200 is mounted on the busbar module 100, and the busbar module 100 passes through the magnetic core module 300, wherein:

[0023] The busbar module 100 includes a busbar injection molded body 110, a positive busbar 120, and a negative busbar 130. The positive busbar 120 and the negative busbar 130 are respectively installed on the busbar injection molded body 110. The busbar injection molded body 110 is provided with a positive mounting hole 111, a negative mounting hole 112, a first guide groove 113, and a second guide groove 114. The first guide groove 113 is close to the positive mounting hole 111, and the second guide groove 114 is close to the negative mounting hole 112.

[0024] The capacitor module 200 includes a capacitor injection molded body 210 and a positive electrode copper strip 220, a negative electrode copper strip 230, a first grounding copper strip 240, a second grounding copper busbar 250, a first filter capacitor 260, a second filter capacitor 270, and a first insert 280 mounted on the capacitor injection molded body 210. The first end of the positive electrode copper strip 220 is mounted on the positive electrode mounting hole 111 through the first guide groove 113 (guided by the first guide groove 113) and contacts the positive electrode busbar 120 (for positive electrode power extraction from the filter capacitor). The second end of the positive electrode copper strip 220 contacts the first filter capacitor 260. One end is connected; the first end of the negative electrode power-taking copper piece 230 is installed in the negative electrode mounting hole 112 through the second guide groove 114 (for guiding), and contacts the negative electrode busbar 130 (for the negative electrode power taking of the filter capacitor); the second end of the negative electrode power-taking copper piece 230 is connected to the first end of the second filter capacitor 270; the first grounding copper piece 240 is connected to the second end of the first filter capacitor 260, and the second grounding copper piece 250 is connected to the second end of the second filter capacitor 270 (the grounding copper pieces are fixed to the controller housing by nuts and provide a grounding circuit for the filter capacitor);

[0025] The magnetic core module 300 includes a magnetic core injection molded body 310, an annular magnetic core 320 and a second insert 330 installed on the magnetic core injection molded body 310.

[0026] Specifically, both the positive electrode mounting hole 111 and the negative electrode mounting hole 112 are provided with a guide structure 115 (which serves as a guide when the power-taking copper sheet of the capacitor module is assembled into the busbar module, and / or when the capacitor module is disassembled).

[0027] More specifically, the material of the toroidal magnetic core 320 includes nanocrystals and ferrite (one of them).

[0028] Furthermore, the annular magnetic core 320 is installed on the magnetic core injection mold 310 by potting (or it can be sealed with a plastic cap).

[0029] Furthermore, the positive electrode copper strip 220 and the negative electrode copper strip 230 are L-shaped (injected into the capacitor injection body, forming a clamp-type structure, which can be directly clamped onto the busbar to supply power to the filter capacitor).

[0030] Regarding this utility model:

[0031] Capacitor modules and magnetic core modules can be freely arranged and combined according to actual needs to form various topologies such as LC (magnetic core module + capacitor module), CLC (capacitor module + magnetic core module + capacitor module), LCLC (magnetic core module + capacitor module + magnetic core module + capacitor module) or CLCLC (capacitor module + magnetic core module + capacitor module + magnetic core module + capacitor module).

[0032] It is worth mentioning that the technical features such as the controller housing involved in this utility model patent application should be regarded as prior art. The specific structure, working principle, and possible control methods and spatial arrangement of these technical features can be adopted using 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 elaborate further.

[0033] 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 novel filter structure, characterized in that, The system includes a busbar module, a capacitor module, and a magnetic core module. The capacitor module is mounted on the busbar module, and the busbar module passes through the magnetic core module. The busbar module includes a busbar injection molded body, a positive busbar, and a negative busbar. The positive busbar and the negative busbar are respectively installed on the busbar injection molded body. The busbar injection molded body is provided with a positive mounting hole, a negative mounting hole, a first guide groove, and a second guide groove. The first guide groove is close to the positive mounting hole and the second guide groove is close to the negative mounting hole. The capacitor module includes a capacitor injection molded body and a positive electrode copper plate, a negative electrode copper plate, a first grounding copper plate, a second grounding copper busbar, a first filter capacitor, a second filter capacitor, and a first insert mounted on the capacitor injection molded body. The first end of the positive electrode copper plate is mounted to the positive electrode mounting hole through the first guide groove and contacts the positive electrode busbar. The second end of the positive electrode copper plate is connected to the first end of the first filter capacitor. The first end of the negative electrode copper plate is mounted to the negative electrode mounting hole through the second guide groove and contacts the negative electrode busbar. The second end of the negative electrode copper plate is connected to the first end of the second filter capacitor. The first grounding copper plate is connected to the second end of the first filter capacitor, and the second grounding copper busbar is connected to the second end of the second filter capacitor. The magnetic core module includes a magnetic core injection molded body, an annular magnetic core mounted on the magnetic core injection molded body, and a second insert.

2. The novel filter structure according to claim 1, characterized in that, Both the positive electrode mounting hole and the negative electrode mounting hole are provided with guide structures.

3. The novel filter structure according to claim 1, characterized in that, The toroidal magnetic core is made of nanocrystals and ferrite.

4. The novel filter structure according to claim 1, characterized in that, The toroidal magnetic core is installed on the magnetic core injection mold by potting.

5. A novel filter structure according to claim 1, characterized in that, The positive electrode copper sheet and the negative electrode copper sheet are L-shaped.

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