Motor controller and vehicle

Abstract

The utility model relates to a motor controller and a vehicle, the motor controller comprises a controller shell and a capacitor core integrated in the controller shell, the controller shell is provided with a cavity for accommodating the capacitor core, and the inner wall of the cavity is provided with an insulating layer. In the motor controller provided by the invention, the capacitor core is integrated in the cavity of the controller shell, and the inner wall of the cavity is provided with the insulating layer, so that the insulating gap between the capacitor core and the inner wall of the cavity can be reduced, the volume of the cavity is smaller, the material of the pouring sealant is less, and the miniaturization and lightweight design of a product is facilitated. The insulating layer is arranged in the cavity, an insulating part and insulating paper can be omitted, the capacitor design and the production process are simpler, the thickness of the insulating layer is small, the thermal resistance is low, and the heat dissipation capability of the motor controller can be improved.

Description

Technical Field

[0001] This disclosure relates to the field of thin-film capacitor technology, and more particularly to motor controllers and vehicles. Background Technology

[0002] With the development of electric vehicles, the requirements for their power performance are becoming increasingly stringent. This necessitates both increased output power from motor controllers and stricter requirements for miniaturization and weight reduction. As a core component of motor controllers, thin-film capacitors face even greater demands in terms of heat dissipation, weight, and size.

[0003] In related technologies, an embedded capacitor solution is used, in which the capacitor core is encapsulated inside the controller housing. An insulating distance needs to be maintained between the capacitor core and the controller housing. The capacitor cavity occupies too much space, making it impossible to achieve a miniaturized design of the motor controller. Utility Model Content

[0004] To overcome the problems existing in the related technologies, this disclosure provides a motor controller and a vehicle.

[0005] According to a first aspect of the present disclosure, a motor controller is provided, the motor controller including a controller housing and a capacitor core integrated within the controller housing, the controller housing having a cavity for accommodating the capacitor core, wherein an insulating layer is provided on the inner wall of the cavity.

[0006] Optionally, the insulating layer is sprayed onto the bottom wall of the cavity and the side walls around it.

[0007] Optionally, the distance between the capacitor core and the inner wall of the cavity is less than 3 mm.

[0008] Optionally, the motor controller includes an input busbar and an output busbar respectively disposed at both ends of the capacitor core. The motor controller includes a first busbar connected to the input busbar and a second busbar connected to the output busbar. The first busbar and the second busbar are arranged opposite to each other. Insulating paper is provided between the first busbar and the second busbar, and on the side of the second busbar facing away from the first busbar.

[0009] Optionally, the first busbar and the second busbar are multiple units arranged at intervals along a first direction of the capacitor core.

[0010] Optionally, a third busbar for connecting to a battery is connected to the input busbar, and a filter module is provided between the third busbar and the battery.

[0011] Optionally, the first busbar and the second busbar are both L-shaped structures, each having a fixed section and a connecting section. The connecting section of the first busbar faces the side where the capacitor core is located, while the connecting section of the second busbar faces away from the side where the capacitor core is located.

[0012] Optionally, the insulating paper located between the first busbar and the second busbar has a bent section arranged parallel to the connecting section of the first busbar.

[0013] Optionally, the motor controller further includes a plastic shell disposed outside the capacitor core, the top surface of the plastic shell extending above the capacitor core.

[0014] According to a second aspect of the present disclosure, a vehicle is provided, including the motor controller described above.

[0015] The technical solutions provided by the embodiments of this disclosure can include the following beneficial effects: In the motor controller provided by this disclosure, the capacitor core is integrated into the cavity of the controller housing, and an insulating layer is provided on the inner wall of the cavity. This can reduce the insulation gap between the capacitor core and the inner wall of the cavity, resulting in a smaller cavity volume and less potting compound, which is beneficial for product miniaturization and lightweight design. The insulating layer inside the cavity eliminates the need for insulating components and insulating paper, simplifying capacitor design and manufacturing processes. The thinner insulating layer results in lower thermal resistance, improving the heat dissipation capacity of the motor controller.

[0016] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and are not intended to limit this disclosure. Attached Figure Description

[0017] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments consistent with this disclosure and, together with the description, serve to explain the principles of this disclosure.

[0018] Figure 1 and Figure 2 This is a perspective view of a motor controller according to an exemplary embodiment.

[0019] Figure 3 This is a perspective view of a controller housing in a motor controller according to an exemplary embodiment.

[0020] Figure 4 This is a schematic diagram illustrating the structure of a capacitor core fixed with potting compound in a motor controller according to an exemplary embodiment.

[0021] Figure 5 This is a schematic diagram illustrating the structure of the outer plastic shell of the capacitor core in a motor controller according to an exemplary embodiment.

[0022] Figure 6 and Figure 7 This is a schematic diagram illustrating the structure of a capacitor core in a motor controller according to an exemplary embodiment.

[0023] Explanation of reference numerals in the attached figures

[0024] 1-Controller housing; 11-Cavity; 12-Insulating layer; 2-Capacitor core; 31-Input busbar; 32-Output busbar; 41-First busbar; 401-Connecting section; 42-Second busbar; 43-Third busbar; 5-Insulating paper; 6-Plastic shell; 7-Potting glue. Detailed Implementation

[0025] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numerals in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this disclosure. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this disclosure as detailed in the appended claims.

[0026] In this disclosure, unless otherwise stated, directional terms such as "upper," "lower," "top," and "bottom" generally refer to the normal installation of the motor controller provided in this disclosure. "Inner" and "outer" may refer to the inner and outer contours of the corresponding component or its location within or outside its environment, depending on the specific context. Furthermore, when the following description relates to the accompanying drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The terms "first," "second," etc., used in this disclosure are for distinguishing one element from another and do not have sequential or importance implications.

[0027] In embedded capacitor technology, the capacitor core 2 is encapsulated within the cavity 11 of the controller housing 1, with plastic insulation between the capacitor core 2 and the controller housing 1. The insulation distance between the capacitor core 2 and the controller housing 11 requires a high margin, needing to be at least 3mm. This results in a larger space occupied by the capacitor cavity, requiring more potting material. Furthermore, the need for insulation further complicates the capacitor design and manufacturing process, leading to thicker insulation, higher thermal resistance, and poorer heat dissipation.

[0028] To solve the above problems, such as Figures 1 to 7As shown, this disclosure provides a motor controller, which includes a controller housing 1 and a capacitor core 2 integrated within the controller housing 1. The controller housing 1 has a cavity 11 for accommodating the capacitor core 2, wherein an insulating layer 12 is provided on the inner wall of the cavity 11. It should be noted that the insulating layer 12 can be epoxy resin, and the insulating layer 12 can be integrally formed on the inner wall of the cavity 11. The insulating layer 12 can be sprayed onto the inner wall of the cavity 11, or onto the bottom wall and the surrounding side walls of the cavity 11, achieving an integrated design. In other embodiments, printing or other methods can also be used, and this disclosure does not limit this.

[0029] In the motor controller provided in this disclosure, the capacitor core 2 is integrated into the cavity 11 of the controller housing 1, and an insulating layer 12 is integrally formed inside the cavity 11. This reduces the insulation gap between the capacitor core 2 and the inner wall of the cavity 11, resulting in a smaller cavity 11 and less potting compound, which is beneficial for product miniaturization and lightweight design. The integrally formed insulating layer 12 inside the cavity 11 eliminates the need for insulating components and insulating paper, simplifying capacitor design and manufacturing processes. The thin insulating layer 12 also has low thermal resistance, improving the heat dissipation capacity of the motor controller.

[0030] In this disclosure, the distance between the capacitor core 2 and the inner wall of the cavity 11 is less than 3 mm, significantly reducing the volume of the cavity 11 used to house the capacitor core 2. This is beneficial for reducing the size of the motor controller and achieving miniaturization. The thin insulation layer 12 shortens the heat dissipation path, improving the capacitor's heat dissipation capacity and giving the capacitor a higher peak current capability.

[0031] In this disclosure, such as Figure 6 and Figure 7 As shown, the motor controller includes an input busbar 31 and an output busbar 32 respectively located at both ends of the capacitor core 2. The motor controller includes a first busbar 41 connected to the input busbar 31 and a second busbar 42 connected to the output busbar 32. The first busbar 41 and the second busbar 42 are arranged opposite to each other. Insulating paper 5 is provided between the first busbar 41 and the second busbar 42, and on the side of the second busbar 42 opposite to the first busbar 41.

[0032] For example, the input busbar 31 and the output busbar 32 are respectively formed as the two poles of the capacitor core 2, one of which is located on the top surface of the capacitor core 2 and the other on the bottom surface of the capacitor core 2. The first busbar 41 is fixed on the input busbar 31, and the output busbar 32 extends upward on one side of the capacitor core 2 and connects to the second busbar 42. The first busbar 41 and the second busbar 42 are arranged back to back and overlapping, and an insulating paper 5 is provided between them. Since the side of the second busbar 42 away from the first busbar 41 is close to the metal controller housing 1, an insulating paper 5 is also required to ensure electrical protection between the first busbar 41 and the second busbar 42, prevent electrical breakdown between the copper busbars, and ensure the reliability of the use of the first busbar 41 and the second busbar 42.

[0033] The first busbar 41 and the second busbar 42 are used to connect to power modules (not shown in the figure). In this disclosure, there can be multiple first busbars 41 and second busbars 42 arranged at intervals along the first direction of the capacitor core 2. In this disclosure, the capacitor core 2 needs to be connected to three power modules. For example, three sets of first busbars 41 and second busbars 42 can be provided. In this disclosure, there can be multiple capacitor cores 2, which are arranged sequentially in a 2-row, 4-column cuboid structure. Here, the first direction can be the length direction of the cuboid.

[0034] In this embodiment, the first busbar 41 and the second busbar 42 can each be an L-shaped structure, with a fixed section and a connecting section 401. The fixed sections of both are arranged side by side and connected to their respective conductive busbars. The connecting section 401 of the first busbar 41 faces the side where the capacitor core 2 is located, while the connecting section of the second busbar 42 faces away from the side where the capacitor core 2 is located. The insulating paper 5 is located between the fixed sections of the first busbar 41 and the second busbar 42 and has a bent section parallel to the connecting section 401 of the first busbar 41.

[0035] A third busbar 43 for connecting to a battery is connected to the input busbar 31, and a filter module is provided between the third busbar 43 and the battery. For example, the third busbar 43 can be welded and fixed to the input busbar 31, and can be designed as an L-shaped structure, with one end fixed to the side of the input busbar 31 away from the first busbar 41 and the second busbar 42, and the other end connected to the filter module.

[0036] A certain gap is maintained between the inner wall of cavity 11 and capacitor core 2. Capacitor core 2 can be fixed inside cavity 11 using potting compound 7. Before potting, to ensure the insulation performance of capacitor core 2, such as... Figure 5 As shown, the motor controller also includes a plastic shell 6 disposed outside the capacitor core 2. The top surface of the plastic shell 6 extends above the capacitor core 2 to ensure the insulation performance of the capacitor core 2. Then, the plastic shell 6, the input conductive bus 31, and the output conductive bus 32 are potted and fixed to form a complete structure. Figure 4 The structure shown forms a potting compound 7 on the outside, which is stably and reliably fixed inside the cavity 11.

[0037] According to a second aspect of this disclosure, a vehicle is provided, including the motor controller described above. This vehicle embodies all the advantages of the aforementioned motor controller, which will not be elaborated upon here.

[0038] In the above detailed description, reference has been made to the accompanying drawings, which illustrate specific aspects of this disclosure by way of illustration. In this regard, terms indicating direction or positional relationship, such as “center,” “longitudinal,” “lateral,” “length,” “width,” “thickness,” “upper,” “lower,” “front,” “rear,” “left,” “right,” “vertical,” “horizontal,” “top,” “bottom,” “inner,” “outer,” “clockwise,” “counterclockwise,” “axial,” “radial,” and “circumferential,” are used with reference to the orientation of the described figures. Since components of the described device can be positioned in multiple different orientations, directional terms are used for illustrative purposes and not for limitation. It should be understood that other aspects can be utilized and structural or logical changes can be made without departing from the concept of this disclosure. Therefore, the following detailed description should not be considered limiting.

[0039] It should be understood that, unless otherwise specifically indicated, features of various embodiments of this disclosure described herein can be combined with each other. As used herein, the term “and / or” includes any one of the relevant listed items and any combination of any two or more; similarly, “at least one of…” includes any one of the relevant listed items and any combination of any two or more.

[0040] It should be understood that, unless otherwise expressly specified and limited, the terms "joining," "attaching," "installing," "connecting," "linking," "fixing," etc., used in the embodiments of this disclosure should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms herein based on the specific circumstances.

[0041] Furthermore, the term "above" as used herein with respect to components, elements, or material layers formed or located "above" a surface may be used to indicate that the component, element, or material layer is "indirectly" positioned (e.g., placed, formed, deposited, etc.) on the surface such that one or more additional components, elements, or layers are arranged between the surface and the component, element, or material layer. However, the term "above" as used with respect to components, elements, or material layers formed or located "above" a surface may also optionally have a specific meaning: that the component, element, or material layer is "directly" positioned (e.g., placed, formed, deposited, etc.) on the surface, for example, in direct contact with the surface.

[0042] Although terms such as “first,” “second,” and “third” may be used herein to describe various components, parts, regions, layers, or sections, these components, parts, regions, layers, or sections are not limited to these terms. Rather, these terms are used only to distinguish one component, part, region, layer, or section from another. Therefore, without departing from the teachings of the examples described herein, the first component, part, region, layer, or section mentioned in the examples may also be referred to as the second component, part, region, layer, or section. Furthermore, the terms “first” and “second” are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as “first” or “second” may explicitly or implicitly include at least one of that feature. In the description herein, “a plurality” means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0043] It should be understood that spatial relative terms, such as “above,” “upper,” “below,” and “lower,” are used herein to describe the relationship between one element and another shown in the figures. In addition to the orientation depicted in the figures, these spatial relative terms are also intended to encompass different orientations of the device in use or operation. For example, if the device in the figures is flipped, an element described as “above” or “upper” relative to another element would be “below” or “lower” relative to that other element. Thus, depending on the spatial orientation of the device, the term “above” encompasses both above and below orientations. Devices may have other orientations (e.g., rotated 90 degrees or in other orientations), and the spatial relative terms used herein should be interpreted accordingly.

[0044] Furthermore, the term “exemplary” is used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” is not necessarily to be construed as advantageous compared to other aspects or designs. Rather, the use of the term “exemplary” is intended to present the concept in a concrete manner. As used herein, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or.” That is, unless otherwise specified or clear from the context, “X applies A or B” is intended to mean any of the natural inclusive arrangements. That is, “X applies A or B” satisfies any of the foregoing instances if X applies A; X applies B; or both X applies A and B. Additionally, unless otherwise specified or clear from the context to refer to the singular form, the articles “a” and “an” as used in this application and the appended claims are generally understood to mean “one or more.”

[0045] Similarly, although this disclosure has been shown and described with respect to one or more implementations, equivalent variations and modifications will occur to those skilled in the art upon reading and understanding this specification and the accompanying drawings. This disclosure includes all such modifications and variations and is limited only by the scope of the claims. In particular, with respect to the various functions performed by the components described above (e.g., elements, resources, etc.), unless otherwise indicated, the terminology used to describe such components is intended to correspond to any component (functionally equivalent) that performs the specific function of the described component, even if structurally not equivalent to the disclosed structure. Furthermore, although specific features of this disclosure may have been disclosed with respect to only one of several implementations, such features may be combined with one or more other features of other implementations, as may be desired and advantageous to any given or particular application. Moreover, with regard to the terms “comprising,” “owning,” “having,” “having,” or variations thereof as used in the detailed description or claims, such terms are intended to be inclusive in a manner similar to the term “including.”

[0046] Other embodiments of this disclosure will readily occur to those skilled in the art upon consideration of the specification and practice of the invention disclosed herein. This application is intended to cover any variations, uses, or adaptations of this disclosure that follow the general principles of this disclosure and include common knowledge or customary techniques in the art not disclosed herein. The specification and examples are to be considered exemplary only, and the true scope and spirit of this disclosure are indicated by the appended claims.

[0047] It should be understood that this disclosure is not limited to the precise structures described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this disclosure is limited only by the appended claims.

Claims

1. An electric motor controller characterized by, The motor controller comprises a controller housing and a capacitor core integrated in the controller housing, the controller housing has a cavity for accommodating the capacitor core, wherein an insulating layer is arranged on the inner wall of the cavity.

2. The motor controller of claim 1, wherein, The insulating layer is sprayed on the bottom wall and the surrounding side wall of the cavity.

3. The motor controller of claim 1, wherein, The distance between the capacitor core and the inner wall of the cavity is less than 3mm.

4. The motor controller of any one of claims 1-3, wherein, The motor controller comprises an input conductive row and an output conductive row arranged at two ends of the capacitor core respectively, the motor controller comprises a first busbar connected with the input conductive row and a second busbar connected with the output conductive row, the first busbar and the second busbar are arranged oppositely, and insulating paper is arranged between the first busbar and the second busbar and on the side of the second busbar away from the first busbar.

5. The motor controller of claim 4, wherein, The first busbar and the second busbar are a plurality of busbars arranged at intervals along a first direction of the capacitor core.

6. The motor controller of claim 4, wherein, The input conductive row is connected with a third busbar for connecting with a battery, and a filter module is arranged between the third busbar and the battery.

7. The motor controller of claim 4, wherein, The first busbar and the second busbar are L-shaped structures respectively, the L-shaped structures have fixed segments and connecting segments, the connecting segment of the first busbar faces the side where the capacitor core is located, and the connecting segment of the second busbar is away from the side where the capacitor core is located.

8. The motor controller of claim 4, wherein, The insulating paper between the first busbar and the second busbar has a bending segment arranged in parallel with the connecting segment of the first busbar.

9. The motor controller of claim 1, wherein, The motor controller further comprises a plastic shell arranged outside the capacitor core, and the top surface of the plastic shell extends above the capacitor core.

10. A vehicle characterized by comprising: The motor controller comprises the motor controller according to any one of claims 1-9. The motor controller comprises the motor controller according to any one of claims 1-9.

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