Power assembly, motor controller, electric control assembly and vehicle

Abstract

The utility model discloses a power assembly, a motor controller, an electric control assembly and a vehicle, and relates to the field of vehicle motor control equipment, and the power assembly comprises a power module and a capacitor assembly which are stacked; the surface, facing the power module, of the capacitor assembly is connected with a first terminal and a second terminal which are mutually insulated. The first terminal and the second terminal are oppositely arranged in a first direction; the same end part of the power module is connected with a third terminal and a fourth terminal which are insulated from each other; the end part faces the first terminal and the second terminal; the third terminal comprises a first-section terminal connected with the end part, and the fourth terminal comprises a second-section terminal connected with the end part; the first section of terminal and the second section of terminal are parallel to the first direction and are oppositely arranged in the second direction; the second direction is parallel to the stacking direction of the power module and the capacitor assembly, and the first direction is perpendicular to the second direction; the first terminal and the third terminal are fixedly connected based on welding, and the second terminal and the fourth terminal are fixedly connected based on welding.

Description

Technical Field

[0001] This application relates to the field of vehicle motor control equipment, and more particularly to a power component, a motor controller, an electronic control assembly, and a vehicle. Background Technology

[0002] With the continuous development of science and technology, more and more vehicles are being widely used in people's daily lives and work, bringing great convenience and becoming an indispensable tool for people today. Among them, the electronic control assembly is one of the important components of the vehicle. A core component of the electronic control assembly is the power component, which includes capacitor components and power modules.

[0003] In conventional power components, the connection structure between the DC terminals of the power module and the DC terminals of the capacitor component has a large equivalent series inductance (ESL), which affects the performance of the power component. Utility Model Content

[0004] In view of the above problems, this application provides a power component, a motor controller, an electronic control assembly, and a vehicle to at least reduce series inductance. The specific solution is as follows:

[0005] The first aspect of this application provides a power component, including:

[0006] Layered power modules and capacitor assemblies;

[0007] The capacitor assembly has a first terminal and a second terminal that are insulated from each other connected to the surface of the power module; the first terminal and the second terminal are arranged opposite to each other in a first direction.

[0008] The power module has a third terminal and a fourth terminal that are insulated from each other connected at the same end; the end faces the first terminal and the second terminal; the third terminal includes a first segment terminal connected to the end, and the fourth terminal includes a second segment terminal connected to the end; the first segment terminal and the second segment terminal are parallel to a first direction and are arranged opposite to each other in a second direction;

[0009] The second direction is parallel to the stacking direction of the power module and the capacitor assembly, and the first direction is perpendicular to the second direction; the first terminal and the third terminal are fixedly connected by welding, and the second terminal and the fourth terminal are fixedly connected by welding.

[0010] Optionally, in the power component described above, the vertical projections of the first terminal and the second terminal on the first plane at least partially overlap; the first plane is perpendicular to the first direction;

[0011] And / or, the vertical projections of the third terminal and the fourth terminal on the second plane at least partially overlap; the second plane is perpendicular to the second direction.

[0012] Optionally, in the above power component, the edges of the first terminal and the second terminal located on both sides in the second direction satisfy the flush condition;

[0013] And / or, the edges of the third and fourth terminals located on both sides of the first direction satisfy the flush condition.

[0014] Optionally, in the power component described above, the misalignment distance between the opposite edges of the first terminal and the second terminal does not exceed 0.2 mm;

[0015] The misalignment distance between the opposite edges of the third and fourth terminals shall not exceed 0.2mm.

[0016] Optionally, in the power component described above, the fourth terminal is located between the third terminal and the capacitor component;

[0017] The second terminal is located between the first terminal and the end.

[0018] Optionally, in the power assembly described above, the fourth terminal further includes a third terminal connected to the second terminal; the third terminal is parallel to the second direction and extends toward the capacitor assembly;

[0019] The third terminal and the second terminal have a first overlapping area in the first direction, and the third terminal and the second terminal are connected in the first overlapping area.

[0020] Optionally, in the power assembly described above, the third terminal and the first terminal are connected via an adapter terminal.

[0021] Optionally, in the power assembly described above, there is a gap between the third terminal and the first terminal that exposes the first overlapping area, and the adapter terminal covers the gap.

[0022] Optionally, in the power component described above, the adapter terminal and the first terminal have a second overlapping area in a first direction, and the adapter terminal and the first terminal are connected in the second overlapping area;

[0023] The adapter terminal and the third terminal have a third overlapping area, and the adapter terminal and the third terminal are connected in the third overlapping area.

[0024] Optionally, in the power components described above, the first overlapping region and the second overlapping region do not overlap in the first direction.

[0025] Optionally, in the power component described above, in the second direction, the distance between the first overlapping region and the capacitor component is greater than the distance between the second overlapping region and the capacitor component.

[0026] Optionally, in the power assembly described above, the adapter terminal and the third terminal have a third overlapping area, and the adapter terminal and the third terminal are connected in the third overlapping area.

[0027] Optionally, in the power assembly described above, the adapter terminal and the first segment terminal have a third overlapping area in the second direction.

[0028] Optionally, in the power component described above, the third terminal further includes a fourth terminal connected to the first terminal; the fourth terminal is parallel to the second direction and extends away from the capacitor component;

[0029] The adapter terminal and the fourth segment terminal have a third overlapping area in the first direction.

[0030] Optionally, in the power component described above, the third terminal further includes a fourth terminal connected to the first terminal; the fourth terminal is parallel to the second direction and extends toward the capacitor component;

[0031] The adapter terminal and the fourth segment terminal have a third overlapping area in the first direction.

[0032] Optionally, in the power component described above, in the second direction, the distance between the third overlapping region and the capacitor component is greater than the distance between the first overlapping region and the capacitor component; and the distance between the second overlapping region and the capacitor component is less than the distance between the first overlapping region and the capacitor component.

[0033] Optionally, in the power component described above, the fourth terminal further includes a third terminal connected to the second terminal; the third terminal further includes a fourth terminal connected to the first terminal; both the third and fourth terminals extend away from the capacitor assembly.

[0034] The fourth terminal and the first terminal are connected at the end away from the capacitor assembly to form a first connection area; the third terminal and the second terminal are connected at the end away from the capacitor assembly to form a second connection area; in the second direction, the distance between the second connection area and the capacitor assembly is less than the distance between the first connection area and the capacitor assembly.

[0035] Optionally, in the power component described above, the fourth terminal and the first terminal have opposing portions in a first direction;

[0036] The third terminal and the second terminal have a first overlapping area in a first direction; the first overlapping area includes one end of the second connection area located in the receiving space formed by the opposite portion.

[0037] Optionally, in the power assembly described above, in the opposite portions, both the fourth terminal and the first terminal protrude toward the side away from the first overlapping area to form a receiving space.

[0038] Optionally, in the power assembly described above, in the first direction, at least a portion of the third terminal segment is exposed.

[0039] Optionally, in the power assembly described above, an insulating element is provided between the first terminal and the second terminal;

[0040] And / or, there is an insulating element between the third terminal and the fourth terminal.

[0041] Optionally, in the above power component, at least one of the first terminal, the second terminal, the third terminal and the fourth terminal has a thickness of 1 mm to 2 mm.

[0042] Optionally, in the above power component, the distance between the first terminal and the second terminal is 1.5mm to 2mm;

[0043] And / or, the distance between the third terminal and the fourth terminal is 1.5mm to 2mm.

[0044] Optionally, in the power component described above, the first terminal segment includes an integral first part and a second part, the first part being connected to the end portion, and the second part being located on the side of the first part opposite to the end portion;

[0045] The width of the first part is smaller than the width of the second part;

[0046] Alternatively, the width of the first part is equal to the width of the second part.

[0047] Optionally, in the power component described above, both the first terminal and the second terminal include an integral third part and a fourth part; in the same terminal, the fourth part is connected to the surface, and the third part is located on the side of the fourth part facing away from the surface;

[0048] The width of the third part is smaller than the width of the fourth part;

[0049] Alternatively, the width of the third part is equal to the width of the fourth part.

[0050] Optionally, in the power assembly described above, the first terminal segment includes an integral first part and a second part, the first part being connected to the end, and the second part being located on the side of the first part away from the end.

[0051] Both the first terminal and the second terminal include an integral third part and a fourth part; in the same terminal, the fourth part is connected to the surface, and the third part is located on the side of the fourth part that faces away from the surface;

[0052] The width of the first part is less than the width of the second part, the width of the second part is equal to the width of the third part, and the width of the third part is less than the width of the fourth part.

[0053] Optionally, in the above power components, the power components include at least one of a drive control module and a power generation control module; the drive control module is used to connect to the drive motor; the power generation control module is used to connect to the generator motor;

[0054] Both the drive control module and the power generation control module include stacked power modules and capacitor components.

[0055] Optionally, in the above power components, the power components include both a drive control module and a power generation control module;

[0056] The drive control module and the power generation control module share the same capacitor assembly.

[0057] Optionally, in the above power components, the drive control module includes multiple first sub-power modules, each of which has an independent liner.

[0058] The power generation control module includes multiple second sub-power modules, which share the same substrate.

[0059] Optionally, in the above power components, the drive control module includes three first sub-power modules; the power generation control module includes three second sub-power modules.

[0060] Optionally, in the power assembly described above, the first terminal and the third terminal are connected based on an adapter terminal;

[0061] The power generation control module and the drive control module share the same adapter terminal.

[0062] A second aspect of this application provides a motor controller including the aforementioned power components.

[0063] A third aspect of this application provides an electronic control assembly, including the aforementioned motor controller.

[0064] The fourth aspect of this application provides a vehicle including the aforementioned electronic control assembly.

[0065] By employing the above technical solution, in this application, the capacitor assembly is connected to a first terminal and a second terminal that are positioned opposite each other in a first direction. This allows the first and second terminals to be stacked in the first direction, reducing the series inductance of the current loop. Furthermore, the first segment of the third terminal and the second segment of the fourth terminal are positioned opposite each other in a second direction, allowing the first and second segments to be stacked in the second direction, further reducing the series inductance of the current loop. Therefore, this application can reduce the series inductance in the power component, avoiding the adverse effects of excessive series inductance on the performance of the power component.

[0066] Optionally, the first and third terminals, and the second and fourth terminals, can be connected and fixed by welding. This reduces the contact resistance between the welded terminals, lowers the risk of heat, and enhances the vibration resistance of each terminal. This ensures that the connection between the terminals will not loosen when the power component experiences significant vibration or is used for an extended period, thereby avoiding increased contact resistance due to poor contact between the terminals and reducing the risk of abnormal temperature in the power component.

[0067] Alternatively, compared to the conventional connection scheme where terminals are fixed with screws, the technical solution of this application uses welding to fix the terminals, which eliminates the need for separate space for screws, greatly simplifies the assembly process, improves assembly efficiency, reduces the size of power components, and lowers material costs. Attached Figure Description

[0068] To more clearly illustrate the technical solutions in the embodiments of this application or related technologies, the drawings used in the description of the embodiments or prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this application. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0069] The structures, proportions, sizes, etc., shown in the accompanying drawings are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the implementation conditions of this application. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and purposes that this application can produce, should still fall within the scope of the technical content disclosed in this application.

[0070] Figure 1 A three-dimensional view of the layout of two parallel and series-connected copper busbars;

[0071] Figure 2 for Figure 1 The front view;

[0072] Figure 3 A three-dimensional view of a power component;

[0073] Figure 4 for Figure 3 Top view;

[0074] Figure 5 for Figure 3 A magnified view of a portion of the image;

[0075] Figure 6 A top view of the connection structure between a sub-power module and a capacitor assembly in a power component;

[0076] Figure 7 for Figure 6 Side view of the structure shown;

[0077] Figure 8 for Figure 6 Right view of the structure shown;

[0078] Figure 9 This is a schematic diagram of the structure of a power component provided in an embodiment of this application;

[0079] Figure 10 A three-dimensional view of a power component provided in an embodiment of this application;

[0080] Figure 11 A partial side view of the terminal connection structure of a power module and a capacitor assembly in a power component provided in an embodiment of this application;

[0081] Figure 12 for Figure 11 Top view of the power component shown;

[0082] Figure 13 for Figure 11 Right view of the power component before the adapter terminals are connected;

[0083] Figure 14 for Figure 11 The right view of the power component after it has been connected to the adapter terminal;

[0084] Figure 15 A side view of the terminal connection structure of a power module and a capacitor assembly in a power component provided in an embodiment of this application;

[0085] Figure 16 A side view of the terminal connection structure of a power module and a capacitor assembly in another power assembly provided in an embodiment of this application;

[0086] Figure 17 A side view of the terminal connection structure of the power module and capacitor assembly in another power component provided in an embodiment of this application;

[0087] Figure 18 A schematic flowchart illustrating a method for fabricating a power component according to an embodiment of this application;

[0088] Figure 19 and Figure 20 This is a schematic diagram illustrating the principle of a terminal connection method according to an embodiment of this application;

[0089] Figure 21 This is a schematic diagram of the terminal structure of a capacitor assembly before it is connected and assembled with a power module.

[0090] Figure 22 This is a schematic diagram of the terminal structure of another capacitor assembly before it is connected and assembled with the power module;

[0091] Figure 23 A topology diagram of a range-extended new energy vehicle provided in this application embodiment;

[0092] Figure 24 An equivalent circuit diagram of a power component provided in an embodiment of this application.

[0093] Figure label:

[0094] 1-Power module; 2-Capacitor assembly; 3-Surface; 4-End; 5-Insulator; 6-Backing plate; 7-Pin; 8-Screw; 9-AC terminal; 10-Correction fixture; 11-Electric drive unit; 12-Drive motor; 13-Inverter; 14-Power battery; 15-Power generation assembly; 16-Generator motor; 17-Engine; 18-Range extender; 19-Heat sink; 101-Drive control module; 102-Power generation control module; 701-First sub-power module; 702-Second sub-power module; 801-First copper busbar; 802-Second copper busbar; 901-Upper bridge arm circuit; 902-Lower bridge arm circuit; 903-Positive busbar; 904-Negative busbar ; 905 - First power chip; 906 - Second power chip; X - First direction; Y - Second direction; Z - Third direction; T1 - First terminal; T2 - Second terminal; T3 - Third terminal; T4 - Fourth terminal; T5 - Adapter terminal; T01 - First segment terminal; T02 - Second segment terminal; T03 - Third segment terminal; T04 - Fourth segment terminal; T05 - Fifth segment terminal; T06 - Sixth segment terminal; A1 - First overlapping area; A2 - Second overlapping area; A3 - Third overlapping area; B1 - First connection area; B2 - Second connection area; C - Opposite part; D1 - First area; D2 - Second area; D3 - Third area; D4 - Fourth area. Detailed Implementation

[0095] The embodiments of this application will now be clearly and completely described with reference to the accompanying drawings. Those skilled in the art will recognize that, with technological advancements and the emergence of new scenarios, the technical solutions provided in the embodiments of this application are equally applicable to similar technical problems.

[0096] Power components are used to control the operating state of motors in vehicles, which are typically three-phase motors. When the power component performs high-speed on / off control of the power module, a surge voltage V is applied to the current loop containing the power module. V is proportional to the magnitude of the series inductance Ls introduced into the terminals of the current loop. The formula for calculating the surge voltage is:

[0097]

[0098] in, is the rate of change of current in the current loop.

[0099] refer to Figure 1 and Figure 2 , Figure 1 A 3D view showing the layout of two parallel and series-connected copper busbars. Figure 2 for Figure 1 The front view. Figure 1 The bold unidirectional arrow indicates the direction of current flow in the current loop.

[0100] like Figure 1 and Figure 2 As shown, the first copper busbar 801 and the second copper busbar 802 are two parallel and series-connected DC terminals in the power component. For example, the first copper busbar 801 and the second copper busbar 802 can be the positive and negative terminals of the power module, or the positive and negative terminals of the capacitor component. The width of the first copper busbar 801 and the second copper busbar 802 are both W, the length is both L, the thickness is both t, and the distance between them is d.

[0101] for Figure 1 and Figure 2 The empirical formula for calculating Ls in the current loop for the two copper busbars in the shown copper busbar arrangement is as follows:

[0102]

[0103] Where L1 and L2 represent the self-inductance of the two copper busbars, respectively; M represents the mutual inductance between the two copper busbars; and k represents the coupling coefficient, which characterizes the degree of coupling between the two copper busbars. When the centers of the two copper busbars are not aligned, it affects the value of k. If WS:W ≠ 1, then k < 1. The smaller the value of WS:W, the greater the degree of misalignment between the centers of the two copper busbars, and the smaller the value of k. WS is the overlap width of the two copper busbars.

[0104] Based on formula (2), the formula for Ls can be expressed as:

[0105]

[0106] Where μ0 is the magnetic permeability in vacuum.

[0107] Based on formulas (1) and (3), we know that the smaller L is, the larger W is, the larger t is, the smaller Ls is, and the smaller V is; the larger WS:W is, the larger the overlap ratio of the two terminals is, the larger k is, the smaller Ls is, and the smaller the surge voltage is.

[0108] refer to Figures 3-5 , Figure 3 A three-dimensional view of a power component. Figure 4for Figure 3 Top view, Figure 5 for Figure 3 A partially enlarged view. In this configuration, the power assembly includes a power module 1 and a capacitor assembly 2 stacked together. The power assembly shown is a dual-control structure, and the power module 1 includes a drive control module 101 and a power generation control module 102.

[0109] The drive control module 101 and the power generation control module 102 can be fixed on the surface of the heat sink 19, and the capacitor assembly 2 is located below the heat sink 19.

[0110] The drive control module 101 is the core component that converts DC to AC and is used to connect to the drive motor. The generator control module 102 is the core component that converts AC to DC and is used to connect to the generator motor. Both the drive motor and the generator motor can be three-phase motors. The drive control module 101 and the generator control module 102 are arranged coplanarly on the surface of the capacitor assembly 2, which can reduce the product's footprint. The capacitor assembly 2 can be used in conjunction with the power module 1 in the power assembly and is a key component for balancing the DC bus voltage.

[0111] like Figures 3-5 As shown, capacitor assembly 2 includes a first terminal T1 and a second terminal T2, one of which is the positive terminal and the other is the negative terminal. Power module 1 includes a third terminal T3 and a fourth terminal T4, one of which is the positive terminal and the other is the negative terminal. The first terminal T1 and the third terminal T3 are connected and fixed by screws 8, and the second terminal T2 and the fourth terminal T4 are connected and fixed by screws 8, so that the positive terminals of capacitor assembly 2 and power module 1 are connected, and their negative terminals are also connected. The positive terminal is used to connect to the positive terminal of the vehicle's power battery through the positive DC bus, and the negative terminal is used to connect to the negative terminal of the vehicle's power battery through the negative DC bus.

[0112] Both the drive control module 101 and the power generation control module 102 include three sub-power modules. Within the same control module, each of the three sub-power modules can be connected one-to-one to the three-phase AC terminals of the three-phase motor. The connection structure between the sub-power modules and the capacitor assembly 2 is as follows... Figures 6-8 As shown.

[0113] refer to Figures 6-8 , Figure 6 This is a top view of the connection structure between a sub-power module and a capacitor assembly in a power component. Figure 7 for Figure 6 The side view of the structure shown. Figure 8 for Figure 6The right view of the structure shown. The terminal connection path between the sub-power module and capacitor assembly 2 includes four regions, which are, in order, region D1, region D2, region D3, and region D4.

[0114] Combination Figures 3-8 As shown, in the sub-power module, the third terminal T3 and the fourth terminal T4 are respectively led out from the substrate 6 of the sub-power module; the third terminal T3 and the fourth terminal T4 are stacked and overlapped in the first region D1, both with a width of W1; in the second region D2, the third terminal T3 and the fourth terminal T4 are connected to the first terminal T1 and the second terminal T2 respectively by screws 8. Figure 6 In the vertical direction, the terminals T1 and T2 are staggered and parallel, with widths of W2- and W2+ respectively. In capacitor assembly 2, the first terminal T1 and the second terminal T2 are also staggered and parallel in the second region D2, with widths of W2- and W2+ respectively; the first terminal T1 and the second terminal T2 are staggered and parallel in the third region D3, with widths of W3- and W3+ respectively; the first terminal T1 and the second terminal T2 are stacked and overlapped in the fourth region D4, both with a width of W4.

[0115] The sub-power module includes a half-bridge circuit located on the substrate 6, and the half-bridge circuit includes a power chip. Due to limitations such as chip size and quantity, as well as the size of the substrate 6, each sub-power module requires a separate substrate 6, resulting in larger dimensions of b1 and b2. The width of the single-phase sub-power module in the drive control module 101 is b1, and the width of the drive control module 101 is b01. The width of the single-phase sub-power module in the power generation control module 102 is b2, and the width of the power generation control module 102 is b02. To meet the terminal connection requirements between the power module 1 and the capacitor assembly 2 in the dual-control structure, the six sub-power modules in the drive control module 101 and the power generation control module 102 each have positive and negative terminals, requiring a total of six positive terminals and six negative terminals. This results in larger overall dimensions of the two control modules, b01 and b02, leading to a larger ESL of the power components and higher material costs.

[0116] Furthermore, regions D1 to D4 are important areas affecting the ESL of the current loop containing power module 1 and capacitor assembly 2. In region D1, the terminal width W1 is relatively large and they are stacked vertically, resulting in a smaller ESL. In region D2, to accommodate the connection of the positive terminals of power module 1 and capacitor assembly 2 via screws 8, and the connection of the negative terminals via screws 8, the terminal widths W2- and W2+ are relatively small, and there is no overlapping area between the positive and negative terminals (WS = 0 in this region). Based on formula (3), the ESL between the positive and negative terminals is relatively large. Similarly, in region D3, the terminal widths W3- and W3+ are also limited, and there is no overlapping area between the positive and negative terminals (WS = 0 in this region). Based on formula (3), the ESL between the positive and negative terminals is relatively large.

[0117] Since the terminals between capacitor assembly 2 and power module 1 need to be fixed with screws 8, the screw fixing scheme has at least the following disadvantages: the traditional screw solution increases the amount of materials, and increases the process complexity in screw storage, feeding, and tightening; during automatic feeding, occasional failures such as jamming may occur due to screw consistency or other factors, requiring manual intervention, reducing the degree of automation and affecting the production cycle; screw fixing assembly time is long and inefficient, and for applications with a large number of screws, multiple batches need to be assembled to meet the production cycle, increasing the screw tightening equipment; under high vibration or dynamic load conditions, screws may loosen or fail, resulting in poor product reliability; the screw method has a large contact resistance (generally 20μΩ~30μΩ), and the screws require a large layout space, and the parallel staggered design of the terminals is also required, which will increase the series inductance.

[0118] Therefore, the screw fixing method results in a complex assembly process, requires a large assembly space, and the screw 8 will occupy a large space after assembly. Moreover, the screw 8 fixing method is prone to loosening, increased contact resistance, and thermal deviation after vibration.

[0119] To address the aforementioned problems, this application provides a power component, comprising:

[0120] Layered power modules and capacitor assemblies;

[0121] The capacitor assembly is connected to a first terminal and a second terminal that are insulated from each other on the surface facing the power module; the first terminal and the second terminal are arranged opposite to each other in a first direction.

[0122] The power module has a third terminal and a fourth terminal that are insulated from each other connected at the same end; the end faces the first terminal and the second terminal; the third terminal includes a first segment terminal connected to the end, and the fourth terminal includes a second segment terminal connected to the end; the first segment terminal and the second segment terminal are parallel to the first direction and are arranged opposite to each other in the second direction;

[0123] Wherein, the second direction is parallel to the stacking direction of the power module and the capacitor assembly, and the first direction is perpendicular to the second direction; the first terminal and the third terminal are connected, and the second terminal and the fourth terminal are connected.

[0124] In this application's technical solution, the capacitor assembly is connected to a first terminal and a second terminal that are positioned opposite each other in a first direction. This allows the first and second terminals to be stacked in the first direction, reducing the series inductance of the current loop. Furthermore, the first segment of the third terminal and the second segment of the fourth terminal are positioned opposite each other in a second direction, allowing the first and second segments to be stacked in the second direction, further reducing the series inductance of the current loop. Therefore, this application can reduce the series inductance in the power component, avoiding the adverse effects of excessive series inductance on the performance of the power component.

[0125] Optionally, the first and third terminals, and the second and fourth terminals, are connected and fixed by welding. This reduces the contact resistance between the welded terminals, lowers the risk of thermal damage, and enhances the vibration resistance of each terminal. This ensures that the connection between the terminals will not loosen when the power component experiences significant vibration or is used for an extended period of time. This avoids problems such as increased contact resistance and thermal deviation caused by poor contact between terminals, and reduces the risk of abnormal temperature in the power component.

[0126] Compared to conventional connection methods that use screws to fix terminals, the technical solution of this application uses welding to fix terminals. This allows for automated welding processes, improving automation, reducing material usage and management, eliminating the need for dedicated space for screws, significantly simplifying the assembly process, increasing assembly efficiency, reducing the size of power components, and lowering material costs. Furthermore, welding has low contact resistance; using laser welding, the contact resistance can be reduced to approximately 5μΩ. Additionally, this application avoids the problem of increased series inductance caused by the staggered parallel design required by screw-fixing methods, which reduces the area of ​​the terminals facing each other.

[0127] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0128] refer to Figure 9 , Figure 9 This application provides a schematic diagram of the structure of a power component, which includes:

[0129] The power module 1 and capacitor assembly 2 are stacked together.

[0130] The capacitor assembly 2 is connected to a first terminal T1 and a second terminal T2 that are insulated from each other on the surface 3 facing the power module 1; the first terminal T1 and the second terminal T2 are arranged opposite to each other in the first direction X; the first terminal T1 and the second terminal T2 can both be led out perpendicularly from the surface 3.

[0131] The same end 4 of the power module 1 is connected to a third terminal T3 and a fourth terminal T4 that are insulated from each other. The third terminal T3 and the fourth terminal T4 can both be led out perpendicularly from the end 4. The end 4 faces the first terminal T1 and the second terminal T2, that is, the first terminal T1 and the second terminal T2 are located on the same side of the end 4. The third terminal T3 includes a first segment terminal T01 connected to the end 4, and the first segment terminal T01 is perpendicular to the end 4. The fourth terminal T4 includes a second segment terminal T02 connected to the end 4, and the second segment terminal T02 is perpendicular to the end 4. The first segment terminal T01 and the second segment terminal T02 are parallel to the first direction X and are arranged opposite to each other in the second direction Y.

[0132] Wherein, the second direction Y is parallel to the stacking direction of the power module 1 and the capacitor assembly 2, and the first direction X is perpendicular to the second direction Y; the first terminal T1 and the third terminal T3 are connected, and the second terminal T2 and the fourth terminal T4 are connected.

[0133] Optionally, the first terminal T1 and the third terminal T3 can be fixedly connected by welding, and the second terminal T2 and the fourth terminal T4 can be fixedly connected by welding. Welding can be laser welding or other welding methods, and this application embodiment does not limit this. In subsequent embodiments of this application, the connection between terminals is achieved by welding. In this application embodiment, other fixed connection methods can also be used, not limited to laser welding, and screw fixing or snap-fit ​​connection can also be used.

[0134] Optionally, the individual sub-power modules in the power component can be arranged sequentially along the third direction Z.

[0135] Since the first terminal T1 and the second terminal T2 are arranged opposite each other in the first direction X, they can be stacked in the first direction X, which is equivalent to increasing the width WS of the overlapping area between them, thereby reducing the series inductance of the current loop. Similarly, since the first terminal T01 and the second terminal T02 are arranged opposite each other in the second direction Y, they can be stacked in the second direction Y, which is equivalent to increasing the width WS of the overlapping area between them, thereby reducing the series inductance of the current loop. Therefore, this application can reduce the series inductance in the power component and avoid the adverse effects of excessive series inductance on the performance of the power component.

[0136] Furthermore, the first terminal T1 and the third terminal T3, as well as the second terminal T2 and the fourth terminal T4, can be connected and fixed by welding. This results in low contact resistance between the two welded terminals, reducing the risk of thermal damage. Additionally, each terminal has strong vibration resistance, ensuring that the connection between the terminals will not loosen even when the power component experiences significant vibration or is used for an extended period. This avoids problems such as increased contact resistance and thermal deviation caused by poor contact between terminals, thus reducing the risk of abnormal temperature in the power component.

[0137] Compared to the connection scheme where terminals are fixed together by screws 8, the technical solution of this application uses welding to fix the terminals together, which eliminates the need for separate space for screws 8, greatly simplifies the assembly process, improves assembly efficiency, reduces the size of power components, and lowers material costs.

[0138] Furthermore, the technical solution of this application can also optimize the size of the power chip in the power module 1 and the layout of the pins 7 used to connect the PCB, so as to reduce the size of b1 and b2, and then reduce the size of b01 and b02, thereby reducing material costs.

[0139] In this embodiment, the fourth terminal T4 is located between the third terminal T3 and the capacitor assembly. In the second direction Y, the fourth terminal T4 faces the capacitor assembly 2, and the third terminal T3 is located on the side of the fourth terminal T4 away from the capacitor assembly 2. The second terminal T2 is located between the first terminal T1 and the end 4. In the first direction X, the first terminal T1 faces away from the end 4, and the second terminal T2 faces the end 4. Thus, as... Figure 9 As shown, the connection structure formed by the first terminal T1 and the third terminal T3 can be stacked with the connection structure formed by the second terminal T2 and the fourth terminal T4, which facilitates the connection between the positive terminals of the capacitor assembly 2 and the power module 1, as well as between the negative terminals.

[0140] refer to Figure 10 , Figure 10This is a three-dimensional view of a power component provided in an embodiment of this application. The power component includes at least one of a drive control module 101 and a power generation control module 102. The drive control module 101 is used to connect to a drive motor; the power generation control module 102 is used to connect to a generator motor; wherein, both the drive control module 101 and the power generation control module 102 include a power module 1 and a capacitor assembly 2 stacked together. The third terminal T3 and the first terminal T1 can be connected as follows: Figure 10 As shown, it can be connected via adapter terminal T5, or as described below, the two can be directly connected.

[0141] If the power component includes both a drive control module 101 and a power generation control module 102, when the first terminal T1 and the third terminal T3 are connected based on the adapter terminal T5, one embodiment can be as follows: Figure 10 As shown, the drive control module 101 and the power generation control module 102 share the same adapter terminal T5. At this time, the first terminal T1 and the third terminal T3 in the drive control module 101 and the first terminal T1 and the third terminal T3 in the power generation control module 102 are connected through the same adapter terminal T5.

[0142] In other embodiments, if the power component includes both a drive control module 101 and a power generation control module 102, when the first terminal T1 and the third terminal T3 are connected based on the adapter terminal T5, the drive control module 101 and the power generation control module 102 may be configured to use independent adapter terminals respectively. In this case, the first terminal T1 and the third terminal T3 in the drive control module 101 are connected by an adapter terminal T5, and the first terminal T1 and the third terminal T3 in the power generation control module 102 are connected by another adapter terminal T5.

[0143] In the drive control module 101, by setting the first terminal T1 and the second terminal T2 to be stacked in the first direction X, the width WS of the overlapping area between them is increased; by setting the first segment terminal T01 and the second segment terminal T02 to be stacked in the second direction Y, the width WS of the overlapping area between them is increased. Therefore, based on the above formula (3), the embodiment of this application can increase WS, thus reducing the series inductance in the current loop. Similarly, in the power generation control module 102, the width WS of the overlapping area between the first terminal T1 and the second terminal T2 can also be increased, thereby reducing the series inductance in the current loop.

[0144] like Figure 10As shown, the power component can adopt a dual-control structure, meaning the power component includes both a drive control module 101 and a power generation control module 102; wherein the drive control module 101 and the power generation control module 102 share the same capacitor component 2. This method integrates the drive control module 101 and the power generation control module 102 into one unit, allowing them to share the same capacitor component 2. Compared to a scheme where the two control modules are packaged independently, this improves the integration of the power component, reduces the overall size, and facilitates the miniaturization of the dual-control structure.

[0145] The drive control module 101 includes multiple first sub-power modules 701, and the power generation control module 102 includes multiple second sub-power modules 702. Optionally, the drive control module 101 includes three first sub-power modules 701, and the AC terminals 9 of the three first sub-power modules 701 are respectively used to connect to one phase AC terminal of the drive motor. Each of the three first sub-power modules 701 has an independent substrate 6. The power generation control module 102 includes three second sub-power modules 702, and the AC terminals 9 of the three second sub-power modules 702 are respectively used to connect to one phase AC terminal of the generator motor. The three second sub-power modules 702 share the same substrate 6. Compared with the conventional solution where the three second sub-power modules 702 in the power generation control module 102 each use separate substrates 6, this application can improve the integration of the power generation control module 102 and reduce the product size.

[0146] The drive control module 101 is used to connect to the drive motor to control its operating state. The drive motor requires precise control of its output torque and speed to meet the vehicle's driving needs under different operating conditions. In this embodiment, each first sub-power module 701 in the drive control module 101 is fixed to the surface of the heat sink 19 using a separate liner 6. This allows for accurate and precise control of the power chips in each first sub-power module 701, thereby more accurately controlling the amplitude, phase, and frequency of the drive motor's current, ensuring that the torque and speed output by the drive motor accurately respond to operating commands and the requirements of the vehicle control system.

[0147] The power generation control module 102 is used to connect to the generator motor to control its operating state. The main function of the generator motor is to convert mechanical energy into electrical energy to charge the power battery. In this process, energy conversion efficiency is paramount, aiming to convert as much mechanical energy as possible into electrical energy and store it in the power battery. In this embodiment, each of the second sub-power modules 702 in the power generation control module 102 is fixed to the surface of the heat sink 19 based on the same substrate 6. This reduces costs and increases integration while maintaining certain performance, without significantly impacting energy conversion efficiency.

[0148] In addition, compared with the drive motor, the operating current characteristics of the generator motor are relatively simple. During the power generation process, the AC power is converted into DC power by the power generation control module 102. The frequency and amplitude of the current change are relatively stable. It does not require complex control and regulation of the current as the drive motor. Therefore, the basic control requirements of the generator motor can be met by all the second sub-power modules 702 in the power generation control module 102 sharing the same liner 6.

[0149] When the power component includes both a drive control module 101 and a power generation control module 102, the two control modules can each use a separate heat sink 19, or they can share the same heat sink 19.

[0150] Optionally, the substrate 6 can be a double-sided copper-clad ceramic plate. The power chip in the sub-power module is fixed to the copper-clad surface on the upper surface of the substrate 6.

[0151] Both the first sub-power module 701 and the second sub-power module 702 include a single-phase half-bridge circuit located on the substrate 6. The single-phase half-bridge circuit is a control circuit formed by interconnecting multiple power chips. Multiple single-phase half-bridge circuits in the same control module form a full-bridge circuit. The embodiments of this application do not limit the specific circuit form of the single-phase half-bridge circuit.

[0152] As described above, such as Figures 3-8 As shown, in a typical dual-control structure, screw connections result in high contact resistance, posing a high risk of thermal failure. Furthermore, the misaligned parallel arrangement of positive and negative terminals in a localized area leads to high ESL in that region, resulting in large bus surge voltage and significant bus voltage fluctuations, severely impacting the performance of the power module. In this embodiment, by stacking the first terminal T1 and the second terminal T2 in the first direction X, and stacking the first segment terminal T01 and the second segment terminal T02 in the second direction Y, the width WS of the overlapping area of ​​the positive and negative terminals can be increased. This reduces the ESL in the current loop, thereby mitigating the adverse effects of high ESL on the power module performance and improving its overall performance.

[0153] As described above, in this embodiment, each second sub-power module 702 in the power generation control module 102 can use the same substrate 6. Compared to the scheme where each second sub-power module 702 in the power generation control module 102 uses an independent substrate 6, the scheme of this application can achieve miniaturization of the substrate of the power generation control module 102. Moreover, each second sub-power module 702 can be integrated from multiple independent half-bridge circuits into a full-bridge circuit located on the same DBC (Direct Bonded Copper). This allows each second sub-power module 702 of the power generation control module 102 to share the same third terminal T3, the same fourth terminal T4, that is, to share the same positive terminal and the same negative terminal. This reduces the number of DC terminals, makes the size of the power generation control module 102 smaller, and makes the size of the power components smaller. While improving product performance, it reduces material costs and maximizes the stack-up area of ​​the positive and negative terminals to further reduce ESL.

[0154] In this embodiment, the two DC terminals of the power module 1 can also be designed to be stacked in a large area in the area where the first terminal T01 and the second terminal T02 are directly opposite each other, so that the area where the two are directly opposite each other in the area is equal to or approximately equal to 100%, which can reduce ESL, make the current loop have a larger terminal width, increase the width WS of the terminal overlap area, and further reduce ESL.

[0155] In capacitor assembly 2, the first terminal T1 and the second terminal T2 are directly led out perpendicularly to surface 3, resulting in a simple structure. The capacitor assembly 2 and the terminals of the power module 1 can be connected and fixed by welding, which reduces the connection resistance between the terminals.

[0156] Furthermore, the welding areas corresponding to the third terminal T3 and the fourth terminal T4 can be designed in parallel, or the welding areas corresponding to the third terminal T3 and the fourth terminal T4 can be designed in perpendicular, such that the welding area corresponding to one terminal is located in the overlapping area of ​​the terminal in the second direction Y, and the welding area corresponding to the other terminal is located in the overlapping area of ​​the terminal in the first direction X.

[0157] In one approach, such as Figure 10 As shown, the first terminal T1 and the second terminal T2 of the capacitor assembly 2 are perpendicular to the surface 3. After the second terminal T2 is directly connected to the fourth terminal T4, the first terminal T1 and the third terminal T3 can be connected through the adapter terminal T5 so as to reserve a connection window between the second terminal T2 and the fourth terminal T4 between the first terminal T1 and the third terminal T3, which facilitates the connection and assembly of the terminals between the capacitor assembly 2 and the power module 1.

[0158] Optionally, both the second terminal T2 and the fourth terminal T4 can be positive terminals, and both the first terminal T1 and the third terminal T3 can be negative terminals. In this case, the positive terminals of the power module 1 and the capacitor assembly 2 can be directly soldered together, and their negative terminals can be connected via an adapter terminal T5, which can be soldered to both the first terminal T1 and the third terminal T3. Alternatively, in other configurations, both the second terminal T2 and the fourth terminal T4 can be negative terminals, and both the first terminal T1 and the third terminal T3 can be positive terminals.

[0159] When used to control a three-phase motor, in the dual-control structure, the drive control module 101 and the generator control module 102 can be configured with three first sub-power modules 701 as three independent single-phase half-bridge circuits, each first sub-power module 701 encapsulated with a separate small-sized substrate 6, according to different usage requirements; the three second sub-power modules 702 share the same substrate 6 (this substrate is a full-bridge substrate), adopting an integrated three-phase full-bridge circuit, sharing the same positive terminal and the same negative terminal. The drive control module 101 and the generator control module 102 use a total of four substrates 6. (Compared to...) Figure 4 In this application, while keeping the size of b1 unchanged, the size of b2 can be reduced, thereby reducing the size of b02 and the overall size of the power component b01+b02. This application embodiment does not limit the size of the liner 6 used in the drive control module 101 and the power generation control module 102.

[0160] In this embodiment of the application, when used to control a three-phase motor, the three first sub-power modules 701 in the drive control module 101 can also be three-phase full-bridge circuits; the three second sub-power modules 702 in the power generation control module 102 can also be three-phase full-bridge circuits. In the dual-control structure, the drive control module 101 and the power generation control module 102 can be six-phase full-bridge circuit structures, or each of the first sub-power modules 701 in the drive control module 101 can be a single-phase half-bridge circuit structure independently packaged with a small-size substrate 6, and the three second sub-power modules 702 in the power generation control module 102 can be a three-phase full-bridge circuit structure using an integrated substrate 6.

[0161] It should be noted that the embodiments in this application are not limited to those described above. Figure 10 The dual-electric control structure shown is as follows. Figure 10The illustrations are provided using an example where the power component includes both a drive control module 101 and a power generation control module 102. Alternatively, the power component can be configured to include only the drive control module 101 or only the power generation control module 102. Both implementations can reduce the ESL of the current loop. When the power component includes either the drive control module 101 or the power generation control module 102, it can be a three-phase full-bridge circuit structure or other circuit structures. This application does not limit the circuit structure of the power module 1 in the embodiments.

[0162] In this embodiment, the power module 1 and the capacitor assembly 2 are stacked in the second direction Y. Compared to a layout where the capacitor assembly 2 and the power module 1 are coplanar, the area occupied by the power assembly can be reduced. The capacitor assembly 2 can be positioned above the power module 1, or the power module 1 can be positioned above the capacitor assembly 2; this embodiment does not limit the specific arrangement.

[0163] refer to Figures 11-14 , Figure 11 This is a partial side view of the terminal connection structure of a power module and a capacitor assembly in a power component according to an embodiment of this application. Figure 12 for Figure 11 Top view of the power component shown. Figure 13 for Figure 11 The right view shown is before the power component is connected to the adapter terminal. Figure 14 for Figure 11 The diagram shows a right view of the power assembly after the adapter terminals are connected. In this configuration, the terminal connection path between capacitor assembly 2 and power module 1 also includes a first region D1 to a fourth region D4. The spacing between the third terminal T3 and the fourth terminal T4 of power module 1, and the spacing between the first terminal T1 and the second terminal T2 of capacitor assembly 2, can both be H0.

[0164] The first terminal T01 includes an integral first part and a second part. The first part is connected to the end 4, and the second part is located on the side of the first part away from the end 4. The first part of the first terminal T01 is located in a portion of the first region D1, and the second part is located in a portion of the second region D2.

[0165] like Figure 12 As shown, the width W1 of the first part is less than the width W2 of the second part, where W1 and W2 are the lengths of the terminal in the third direction Z, which is perpendicular to the first direction X and parallel to surface 3. If W1 is less than W2, it is possible to... Figure 12 The upper and lower ends of the first region D1 are reserved for installation to facilitate fixing the outer casing, and to facilitate the use of the casing to encapsulate and protect the internal components of the power assembly. In other methods, the width W1 of the first part can also be set to be equal to the width W2 of the second part.

[0166] The lengths of the first region D1 and the second region D2 in the first direction X can be adjusted according to product layout requirements, and this application does not limit the lengths of these two regions. The values ​​of W1 and W2 can be designed according to performance requirements and molding requirements. Theoretically, the larger the values ​​of W1 and W2, the smaller the ESL.

[0167] like Figure 13 and Figure 14 As shown, both the first terminal T1 and the second terminal T2 include an integral third part and a fourth part; in the same terminal, the fourth part is connected to surface 3, and the third part is located on the side of the fourth part facing away from surface 3; wherein, the width W3 of the third part is less than the width W4 of the fourth part. W3 and W4 are the nominal widths of the third part and the fourth part, respectively. The first terminal T1 and the second terminal T2 are partially part of the fourth region D4, and the width of the fourth part of both is W4. The first terminal T1 and the second terminal T2 are partially part of the third region D3, wherein the actual width of the third part of the first terminal T1 is W3-, and the actual width of the third part of the second terminal T2 is W3+, and W3+ and W3- are equal to or approximately equal to W3. In this configuration, W3 is less than W4, which allows for... Figure 13 and Figure 14 The left and right sides of the third region D3 have reserved installation space to facilitate fixing the external housing and to allow for the encapsulation and protection of the internal components of the power module. In other configurations, the width W3 of the third part can be equal to the width W4 of the fourth part.

[0168] Optionally, setting W1 < W2 = W3 < W4 not only facilitates reserving space for housing installation, but also ensures a greater degree of relative area of ​​the terminal stack, which can reduce the ESL of the current loop.

[0169] In this embodiment, at least one of the first terminal T1, the second terminal T2, the third terminal T3, and the fourth terminal T4 has a thickness of 1mm to 2mm. In this embodiment, the numerical range includes endpoint values. The thickness of each terminal can be 1.2mm, 1.5mm, 1.7mm, or 1.9mm, etc. Within this range, the terminal thickness allows for a larger terminal thickness with a smaller ESL (Electrostatic Displacement). Furthermore, it avoids excessive thickness affecting product volume and prevents excessive mechanical strength, facilitating layered connections and bending / shaping of the terminals.

[0170] Optionally, to facilitate process fabrication, the first terminal T1, the second terminal T2, the third terminal T3, and the fourth terminal T4 can be configured to have the same or similar thicknesses, so as to facilitate the fabrication of terminals in the capacitor assembly 2 and the power module 1.

[0171] In one embodiment, the distance between the first terminal T1 and the second terminal T2 is 1.5mm to 2mm, which can be 1.4mm, 1.7mm, or 1.9mm, etc.; and / or, the distance between the third terminal T3 and the fourth terminal T4 is 1.5mm to 2mm, which can be 1.4mm, 1.7mm, or 1.9mm, etc. When the distance between the terminals is within this range, the distance between the terminals is moderate. On the one hand, it allows for a smaller gap between the terminals, which can reduce ESL; on the other hand, it avoids short circuit problems caused by excessively small gaps.

[0172] Optionally, to facilitate process preparation, the distance between the first terminal T1 and the second terminal T2 can be set to be equal to or approximately equal to the distance between the third terminal T3 and the fourth terminal T4.

[0173] In addition to other embodiments, the vertical projections of the first terminal T1 and the second terminal T2 on the first surface may at least partially overlap; the first surface is perpendicular to the first direction X. For example... Figure 13 As shown, the first surface is Figure 13 The projection plane of the right view shown. Setting the vertical projections of the first terminal T1 and the second terminal T2 to at least partially overlap allows them to form a stacked opposing region, thereby reducing the series inductance.

[0174] In addition to other implementation methods, the third terminal T3 and the fourth terminal T4 may be configured such that their vertical projections onto the second plane at least partially overlap; the second plane is perpendicular to the second direction. For example... Figure 12 As shown, the second surface is Figure 12 The projection plane of the top view shown. Setting the vertical projections of the third terminal T3 and the fourth terminal T4 to at least partially overlap allows them to form a stacked opposing region, thereby reducing the series inductance.

[0175] The edges of the first terminal T1 and the second terminal T2 located on both sides of the second direction Y satisfy the flush condition, which allows their vertical projections to overlap to a large extent, and / or the edges of the third terminal T3 and the fourth terminal T4 located on both sides of the first direction X satisfy the flush condition, which allows their vertical projections to overlap to a large extent. Here, "edges satisfying the flush condition" means that the edges of the two terminals are flush or approximately flush.

[0176] When the edges of the first terminal T1 and the second terminal T2 on both sides of the second direction Y meet the flush condition, such as Figure 13 and Figure 14As shown, the left edges of the first terminal T1 and the second terminal T2 are flush or nearly flush, and the right edges of the first terminal T1 and the second terminal T2 are flush or nearly flush. Within the height overlap range of the first terminal T1 and the second terminal T2, the first terminal T1 and the second terminal T2 can achieve 100% or nearly 100% overlap. The graphic structures of the two within this height overlap range can be completely identical or nearly identical, thereby allowing them to have a large overlap area along the second direction Y, which can significantly reduce ESL. Optionally, the misalignment distance between the opposite edges of the first terminal T1 and the second terminal T2 does not exceed 0.2mm, so that the edges of the first terminal T1 and the second terminal T2 on both sides of the second direction Y meet the flush condition.

[0177] When the edges of the third terminal T3 and the fourth terminal T4 on both sides of the first direction X meet the flush condition, such as Figure 12 As shown, the upper edges of the third terminal T3 and the fourth terminal T4 are flush or nearly flush, and the lower edges of the third terminal T3 and the fourth terminal T4 are flush or nearly flush. Within the length overlap range of the first segment terminal T01 and the second segment terminal T02, the fourth terminal T4 and the third terminal T3 can achieve 100% or nearly 100% overlap. The graphic structures of the two within this length overlap range can be completely identical or nearly identical, thereby allowing them to have a large overlap area along the first direction X, which can significantly reduce ESL. Optionally, the misalignment distance between the opposite edges of the third terminal T3 and the fourth terminal T4 does not exceed 0.2mm, so that the edges of the third terminal T3 and the fourth terminal T4 on both sides of the first direction X meet the flush condition.

[0178] It should be noted that, based on assembly requirements, through holes for the terminals can be added to the relative areas where the edges of the first terminal T1 and the second terminal T2 meet the flush condition, as well as the relative areas where the edges of the third terminal T3 and the fourth terminal T4 meet the flush condition.

[0179] like Figures 11-14 As shown, the fourth terminal T4 also includes a third terminal T03 connected to the second terminal T02; the third terminal T03 is parallel to the second direction Y and extends toward the capacitor assembly 2; wherein the third terminal T03 and the second terminal T2 have a first overlapping area A1 in the first direction X, and the two are connected in the first overlapping area A1; the third terminal T3 and the first terminal T1 are connected through the adapter terminal T5.

[0180] The third terminal T03 is perpendicular to the second terminal T02. The third terminal T03 is the output terminal of the fourth terminal T4, used for direct connection to the second terminal T2. With surface 3 as a reference, the third terminal T03 is perpendicular to surface 3; therefore, the fourth terminal T4 has a vertical output structure, with its soldering surface facing... Figure 11 On the right side of the middle section. The third terminal T3 can be connected to the first terminal T01 and the adapter terminal T5. The first terminal T01 is the output terminal of the third terminal T3. With surface 3 as a reference, the first terminal T01 is parallel to surface 3. Therefore, the third terminal T3 has a parallel output structure, and its soldering surface faces... Figure 11 On the upper middle side. In this configuration, the welding surfaces of the third terminal T3 and the fourth terminal T4 are perpendicular to each other, which allows for two more distinct connection positions to be formed within a limited space, facilitating the connection of terminals between the capacitor assembly 2 and the power module 1.

[0181] exist Figures 11-14 In the illustrated configuration, the second segment terminal T02 and the third segment terminal T03 of the fourth terminal T4 are vertically bent. The fourth terminal T4 can form a first overlapping region A1 in the first direction X based on the third segment terminal T03 extending towards the capacitor assembly 2 and the second terminal T2, facilitating connection between the fourth terminal T4 and the second terminal T2 within the first overlapping region A1. Furthermore, a connection window can be formed between the first terminal T1 and the third terminal T3 for connection within the first overlapping region A1, further facilitating connection between the fourth terminal T4 and the second terminal T2.

[0182] Optionally, in the first direction X, at least a portion of the third segment terminal T03 is exposed at the third terminal T3 to form a connection window between the third segment terminal T03 and the counterpart (second terminal T2), facilitating connection between the third segment terminal T03 and the second terminal T2. The length of the third segment terminal T03 exposed by the third terminal T3 does not exceed 10 mm, and this value can be adjusted according to actual needs. Figure 11 In the configuration shown, in the first direction X, the third terminal T3 exposes the entire third segment terminal T03.

[0183] like Figure 13 As shown, the width of the third terminal T03 can be W3+, and the width W3+ of the third terminal T03 can be set to be the same as or approximately the same as the width W2 of the fourth terminal T4 in the second region D2.

[0184] Compared to Figures 6-8 As shown, Figures 11-14 In the illustrated configuration, with the same dimensions for the first region D1 to the fourth region D4 (the length of the extension path between the first region D1 and the fourth region D4 remains unchanged), it is possible to achieve a larger width for the terminals in the first region D1 to the fourth region D4 without altering the length of the current loop containing the positive and negative terminals of the power module 1 and the capacitor assembly 2, and to ensure a large overlap between the positive and negative terminals in their respective regions. The W1 value of the positive and negative terminals of the power module 1 in the first region D1, where the width is smallest, is also... Figures 6-8The W1 in the shown configuration is at least twice that of the W1. In the first region D1 to the fourth region D4, the stacked positive and negative extrema have an overlap of approximately 100%, which can result in a large coupling coefficient k. Combined with the above formula (3), when k is large, ESL can be effectively reduced.

[0185] In the first direction X, there is a gap between the third terminal T3 and the first terminal T1 that exposes the first overlapping area A1, and the adapter terminal T5 covers this gap. Based on the gap between the third terminal T3 and the first terminal T1, a connection window can be formed for the fourth terminal T4 and the second terminal T2 to connect in the first overlapping area A1, facilitating the connection between the fourth terminal T4 and the second terminal T2.

[0186] like Figure 11 As shown, the adapter terminal T5 and the first terminal T1 have a second overlapping area A2 in the first direction X, and the two are connected in the second overlapping area A2; the adapter terminal T5 and the third terminal T3 have a third overlapping area A3, and the two are connected in the third overlapping area A3. The adapter terminal T5 can be connected to the first terminal T1 and the third terminal T3 respectively based on the second overlapping area A2 and the third overlapping area A3, and by adjusting the position of the second overlapping area A2 and the third overlapping area A3 relative to the first overlapping area A1, the gap between the third terminal T3 and the first terminal T1 can form a connection window for the fourth terminal T4 and the second terminal T2 to connect in the first overlapping area A1, which facilitates the connection between the capacitor assembly 2 and the power module 1.

[0187] Optionally, the first overlapping region A1 and the second overlapping region A2 do not overlap in the first direction X, and the first overlapping region A1 and the second overlapping region A2 are designed to be staggered in the first direction X. If the first overlapping region A1 and the second overlapping region A2 have an overlapping portion in the first direction X, the overlapping portion will have a large thickness in the first direction X, which will increase the product volume.

[0188] In one approach, such as Figure 11 As shown, in the second direction Y, the distance between the first overlapping region A1 and the capacitor assembly 2 is greater than the distance between the second overlapping region A2 and the capacitor assembly 2. In other words, with surface 3 as a reference, the minimum height of the first overlapping region A1 is greater than the maximum height of the second overlapping region A2. In this method, when the length of the third terminal T03 is fixed, the space between it and surface 3 can be used to arrange the second overlapping region A2, avoiding a large thickness of the product in the second direction Y.

[0189] In one approach, such as Figure 11As shown, the adapter terminal T5 and the third terminal T3 have a third overlapping area A3, and they are connected in the third overlapping area A3. This method can connect the adapter terminal T5 and the third terminal T3 in the third overlapping area A3, and can also form a larger overlapping area with the fourth terminal T4 based on the third overlapping area A3, thereby reducing ESL.

[0190] Optionally, such as Figure 11 As shown, the adapter terminal T5 and the first segment terminal T01 have a third overlapping area A3 in the second direction Y. In this case, the adapter terminal T5 can be directly connected to the first segment terminal T01, eliminating the need for the third terminal T3 to have other segments connected to the first segment terminal T01, thus simplifying the design of the third terminal T3. In this configuration, the adapter terminal T5 and the third terminal T3 have overlapping portions in the second direction Y, forming the third overlapping area A3, and overlap with the first terminal T1 in the first direction X, forming the second overlapping area A2. The third segment terminal T03 and the second terminal T2 form the first overlapping area A1 in the first direction X. The connection directions of the third terminal T3 and the fourth terminal T4 of the power module 1 are perpendicular to each other.

[0191] refer to Figure 15 , Figure 15 This is a side view of the terminal connection structure of a power module and a capacitor assembly in a power component according to an embodiment of this application. Based on the above-described implementation, Figure 15 In the illustrated configuration, the third terminal T3 further includes a fourth terminal T04 connected to the first terminal T01; the fourth terminal T04 extends parallel to the second direction Y and away from the capacitor assembly 2; the adapter terminal T5 and the fourth terminal T04 have a third overlapping area A3 in the first direction X. In this configuration, the output end of the third terminal T3 is the fourth terminal T04, which is perpendicular to surface 3. With surface 3 as a reference, the third terminal T3 has a vertical output structure, and its soldering surface faces... Figure 15 On the right side of the middle. Figure 15 In the illustrated configuration, the design of the positive and negative terminals in capacitor assembly 2 can be consistent with... Figure 11 The method shown is the same. This method can also increase the terminal width and the overlapping area of ​​the positive and negative terminals, which can reduce ESL.

[0192] The fourth terminal T04 serves as a connection window for connecting to the connecting counterpart (adapter terminal T5). Its length can not exceed 10mm, and this length can be adjusted according to requirements. Optionally, the fourth terminal T04 can be configured to have the same or approximately the same width as the first terminal T01.

[0193] Figure 15In the diagram, shaded ellipses represent the connection areas in each overlapping region. Both the third terminal T3 and the fourth terminal T4 have vertical outgoing wire structures, and their symmetrical shapes facilitate the structural design of the terminals in power module 1. Simultaneously, the adapter terminal T5 can be connected to the fourth terminal T04 and the first terminal T1 in the same orientation, facilitating the connection and assembly of the adapter terminal T5.

[0194] In the embodiments of this application, it can be as follows Figure 15 As shown, an insulating element 5 is provided between the first terminal T1 and the second terminal T2; an insulating element 5 is also provided between the third terminal T3 and the fourth terminal T4. Based on the insulating element 5, insulation isolation can be achieved between the positive and negative terminals of the capacitor assembly 2 with a small terminal spacing, and insulation isolation can be achieved between the positive and negative terminals of the power module 1 with a small terminal spacing. While ensuring insulation isolation between the positive and negative terminals, the positive and negative terminals have a small terminal spacing in their parallel opposing portions, which can reduce ESL.

[0195] Optionally, the insulating element 5 can be an insulating layer covering the surface of the terminal or an insulating plastic shell. This application does not limit the implementation method of the insulating element 5.

[0196] refer to Figure 16 , Figure 16 A side view of the terminal connection structure of the power module and capacitor assembly in another power component provided in this application embodiment, and... Figure 15 The difference is that, Figure 16 In the configuration shown, the fourth terminal T04 is parallel to the second direction Y and extends toward the capacitor assembly 2; the adapter terminal T5 and the fourth terminal T04 have a third overlapping area A3 in the first direction X. Figure 16 The connection areas in each overlapping region are represented by shaded ellipses. In this method, bending the fourth terminal T04 toward the capacitor assembly 2 reduces the height of the third overlapping region A3 relative to the surface 3, thereby reducing the thickness of the power assembly in the second direction Y. Figure 16 In the illustrated configuration, the design of the positive and negative terminals in capacitor assembly 2 can be consistent with... Figure 11 The method shown is the same. This method can also increase the terminal width and the overlapping area of ​​the positive and negative terminals, which can reduce ESL.

[0197] exist Figure 16 In the configuration shown, both the third terminal T3 and the fourth terminal T4 are vertically bent structures, and both the fourth terminal T04 and the third terminal T03 are bent toward the capacitor assembly 2, perpendicular to the surface 3, and are vertically exiting structures. The connection windows of both are oriented towards... Figure 16 On the right side of the middle.

[0198] The third terminal T3 includes a vertical first terminal T01 and a fourth terminal T04. The length and width of the first terminal T01 and the fourth terminal T04 can be set according to requirements. The fourth terminal T04 is a connection window used to connect with the adapter terminal T5. The length of the fourth terminal T04 can not exceed 10mm. The third terminal T3 can be designed with a through-hole structure according to product assembly requirements.

[0199] The fourth terminal T4 includes a vertical second terminal T02 and a third terminal T03. The length and width of the second terminal T02 and the third terminal T03 can be set according to requirements. The third terminal T03 is a connection window for direct connection with the second terminal T2. The length of the third terminal T03 can not exceed 10mm. The fourth terminal T4 can be designed with a through-hole structure according to product assembly requirements.

[0200] like Figure 16 As shown, in the second direction Y, the distance between the third overlapping region A3 and the capacitor assembly 2 is greater than the distance between the first overlapping region A1 and the capacitor assembly 2; and the distance between the second overlapping region A2 and the capacitor assembly 2 is less than the distance between the first overlapping region A1 and the capacitor assembly 2. That is, the height of the third overlapping region A3 is greater than the height of the first overlapping region A1, and the height of the first overlapping region A1 is greater than the height of the second overlapping region. This allows a connection window to be formed between the third overlapping region A3 and the second overlapping region A2, exposing the first overlapping region A1. This connection window facilitates the connection of the third terminal T03 and the second terminal T2 within the first overlapping region A1.

[0201] Optionally, such as Figure 16 As shown, in the first direction X, the first overlapping area A1 and the third overlapping area A3 have no opposite parts, and they also have no opposite parts with the second overlapping area A2, so as to avoid the connection areas of the two overlapping areas having overlapping parts in the first direction X, which would cause the terminals to need to reserve a large gap in the first direction X to ensure the insulation isolation of the connection areas.

[0202] In this embodiment, the connection between the first terminal T1 and the third terminal T3 is achieved based on the adapter terminal T5, which can achieve the same effect of reducing ESL without increasing product cost or process complexity.

[0203] refer to Figure 17 , Figure 17This is a side view of the terminal connection structure of the power module and capacitor assembly in another power component provided in this application embodiment. Based on the above embodiment, the fourth terminal T4 further includes a third terminal T03 connected to the second terminal T02; the third terminal T3 further includes a fourth terminal T04 connected to the first terminal T01; both the third terminal T03 and the fourth terminal T04 extend away from the capacitor assembly 2; the fourth terminal T04 and the first terminal T1 are connected at the end away from the capacitor assembly 2, forming a first connection area B1; the third terminal T03 and the second terminal T2 are connected at the end away from the capacitor assembly 2, forming a second connection area B2; in the second direction Y, the distance between the second connection area B2 and the capacitor assembly 2 is less than the distance between the first connection area B1 and the capacitor assembly 2. This method can also increase the terminal width and the overlapping area of ​​the positive and negative terminals, and can reduce ESL.

[0204] exist Figure 17 In the configuration shown, the end of the first terminal T1 away from the capacitor assembly 2 can be directly connected to the end of the third terminal T3 away from the power module 1, and the end of the second terminal T2 away from the capacitor assembly 2 can be directly connected to the end of the fourth terminal T4 away from the power module 1. The connection between the corresponding terminals of the power module 1 and the capacitor assembly 2 can be achieved without the need for the adapter terminal T5.

[0205] like Figure 17 As shown, the fourth terminal T04 and the first terminal T1 have opposing portions C in the first direction X; the third terminal T03 and the second terminal T2 have a first overlapping region A1 in the first direction X; the first overlapping region A1, including one end of the second connecting region B2, is located in the accommodating space formed by the opposing portions C. This method can reuse the accommodating space formed by the opposing portions C to accommodate at least a portion of the first overlapping region A1, can reduce the space occupied by the first overlapping region A1 in the second direction Y, and can reduce the size of the product.

[0206] Optionally, such as Figure 17 As shown, in the opposite portion C, both the fourth terminal T04 and the first terminal T1 protrude towards the side opposite to the first overlapping area A1 to form a receiving space. Based on the outward protrusion design, the fourth terminal T04 and the first terminal T1 can form a sufficiently large receiving space to at least place the end of the first overlapping area A1 within the receiving space. Alternatively, the first terminal T1 and the third terminal T3, with their zigzag structure, can form a rectangular or triangular receiving space above the first overlapping area A1, and the opposite portion C is not limited to this configuration. Figure 17 The design shown is an outwardly protruding arc.

[0207] As described above, in this embodiment, if the power component includes a power generation control module 102, the three-phase sub-power modules in the power generation control module 102 can share the same positive terminal and the same negative terminal. That is, the three-phase sub-power modules share the same third terminal T3 and the same fourth terminal T4. Compared to the scheme where each of the three-phase sub-power modules in the same power generation control module 102 has a separate set of positive and negative terminals, this reduces the number of positive terminals and negative terminals by two. If the power component includes a drive control module 101, the structure of the drive control module 101 is not limited to the above embodiments. The three sub-power modules in the drive control module 101 can also be a full-bridge circuit, sharing the same positive terminal and the same negative terminal. The three-phase power modules in the drive control module 101 share the same third terminal T3 and the same fourth terminal T4. Based on the terminal sharing design, material costs can be reduced. The drive control module 101 can also adopt other multi-phase full-bridge circuits. This embodiment does not limit the circuit structure in the power module 1.

[0208] Furthermore, the technical solution of this application can achieve a large-area stacked design between the first terminal T1 and the second terminal T2, and between the third terminal T3 and the fourth terminal T4. The entire current loop can adopt a wide terminal design, which functionally solves the problem of excessive ESL, reduces bus surge voltage, and optimizes the switching loss of the module. In addition, based on the graphic structure design of the third terminal T3 and the fourth terminal T4 in the power module 1 provided in the embodiment of this application, the structure of the first terminal T1 and the second terminal T2 led out by the capacitor assembly 2 is relatively simple, reducing the material cost of the capacitor assembly 2.

[0209] In some embodiments of the technical solution of this application, the connection between the first terminal T1 and the third terminal T3 can also be realized based on the adapter terminal T5. The terminal structure of the power module 1 and the capacitor assembly 2 can be optimized by setting the shape of the adapter terminal T5.

[0210] In this application, the terminals can be connected by laser welding, resulting in lower contact resistance and reducing the risk of thermal failure. Furthermore, welding increases the connection strength at the joint, offering higher vibration durability and reliability than screw connections, and also improves assembly efficiency.

[0211] Based on the power components provided in the above embodiments, another embodiment of this application provides a manufacturing method for preparing the power components provided in any of the above embodiments. This manufacturing method can be as follows: Figure 18 As shown.

[0212] refer to Figure 18 , Figure 18 This is a schematic flowchart of a power component fabrication method provided in an embodiment of this application, combined with... Figure 18 As shown in the structural diagram of the power component in the above embodiments, the fabrication method includes:

[0213] Step S11: The power module 1 and the capacitor assembly 2 are stacked; the capacitor assembly 2 is connected to an insulated first terminal T1 and a second terminal T2 on the surface 3 facing the power module 1; the first terminal T1 and the second terminal T2 are arranged opposite to each other in the first direction X; an insulated third terminal T3 and a fourth terminal T4 are connected to the same end 4 of the power module 1; the end 4 faces the first terminal T1 and the second terminal T2; the third terminal T3 includes a first segment terminal T01 connected to the end 4, and the fourth terminal T4 includes a second segment terminal T02 connected to the end 4; the first segment terminal T01 and the second segment terminal T02 are parallel to the first direction X and are arranged opposite to each other in the second direction Y; wherein, the second direction Y is parallel to the stacking direction of the power module 1 and the capacitor assembly 2, and the first direction X is perpendicular to the second direction Y;

[0214] Step S12: Connect the first terminal T1 and the third terminal T3, and connect the second terminal T2 and the fourth terminal T4.

[0215] The fabrication method provided in this application can be used to fabricate the power components described in the above embodiments, resulting in a large stacked area between the positive and negative terminals of the capacitor component 2 and the power module 1. In the second direction Y, the positive and negative terminals can achieve 100% or approximately 100% overlap, meaning that the vertical projections of the positive and negative terminals on surface 3 can coincide or approximately coincide with the vertical projection of the negative terminal on surface 3, thereby reducing the ESL of the entire current loop. Simultaneously, the terminals are fixedly connected using a connection method, making the assembly process simpler and more convenient.

[0216] In one embodiment, the method of connecting the first terminal T1 and the third terminal T3, and connecting the second terminal T2 and the fourth terminal T4, includes: connecting the end of the second terminal T2 away from the capacitor assembly 2 and the end of the fourth terminal T4 away from the power module 1, and then connecting the end of the first terminal T1 away from the capacitor assembly 2 and the end of the third terminal T3 away from the power module 1. The second terminal T2 and the fourth terminal T4 can be directly connected. The first terminal T1 and the third terminal T3 can be connected via an adapter terminal T5, or they can be directly connected.

[0217] If the first terminal T1 and the third terminal T3 are directly connected to prepare Figure 17 Taking the power component with the structure shown as an example, the principle of connecting the terminals of capacitor component 2 and power module 1 can be as follows: Figure 19 and Figure 20 As shown.

[0218] refer to Figure 19and Figure 20 , Figure 19 and Figure 20 This is a schematic diagram illustrating the principle of a terminal connection method according to an embodiment of this application. The method includes:

[0219] First, such as Figure 19 As shown, capacitor assembly 2 and power module 1 are stacked and assembled. Before connecting the terminals of capacitor assembly 2 and power module 1, as shown... Figure 19 As shown, the second terminal T2 located inside the capacitor assembly 2 is perpendicular to surface 3, and the first terminal T1 outside the capacitor assembly 2 includes a fifth terminal T05 and a sixth terminal T06. The fifth terminal T05 is perpendicularly connected to surface 3. The sixth terminal T06 is connected to the end of the fifth terminal T05 away from the capacitor assembly 2. The sixth terminal T06 is bent outwards, forming an angle α with the first direction X, where α is less than 90°. Optionally, the value of α can be 70° to 80°. Before connecting the terminals of the capacitor assembly 2 and the power module 1, as follows... Figure 19 As shown, the fourth terminal T04 is bent inwards, forming an angle b with the first terminal T01, where b is less than 90°. Optionally, the value of b can be 70° to 80°.

[0220] Then, as Figure 20 As shown, the end of the second terminal T2 furthest from the capacitor assembly 2 and the end of the fourth terminal T4 furthest from the power module 1 are connected. Due to the included angles a and b, an outward-flaring flared structure can be formed between the fourth terminal T04 and the sixth terminal T06. This outward-flaring flared structure can serve as a welding window between the third terminal T03 and the second terminal T2, facilitating the welding of the third terminal T03 and the second terminal T2. Based on the welding window formed by a and b, the second terminal T2 and the fourth terminal T4 are welded and fixed.

[0221] Finally, increase a and b, and bring the end of the fourth terminal T04 furthest from the first terminal T01 and the end of the sixth terminal T06 furthest from the fifth terminal T05 into contact and weld them together to form a shape as shown. Figure 17 The power assembly with the structure shown. In this step, the fourth terminal T04 and the sixth terminal T06 can be fixed relative to each other at their ends using a tooling before their ends are connected. Optionally, by using an adapter to adjust and increase a and b, the end of the fourth terminal T04 away from the first terminal T01 and the end of the sixth terminal T06 away from the fifth terminal T05 can be brought into contact for welding and fixing.

[0222] For ease of illustration, Figure 19 and Figure 20 The insulating element 5 is not shown in the diagram. The implementation of the insulating element 5 can be referred to the previous description, and will not be repeated here.

[0223] for Figure 19 and Figure 20 As shown, in practical applications, if factors such as assembly and sealing prevent the sixth terminal T06 from being directly designed as an external expansion structure, a different approach can be adopted. Figure 21 or Figure 22 The capacitor assembly 2 shown in the diagram is connected to the power module 1 via terminals.

[0224] refer to Figure 21 , Figure 21 This is a schematic diagram of the terminal structure of a capacitor assembly before it is connected and assembled with a power module. In this configuration, the first terminal T1 includes separate fifth terminal T05 and sixth terminal T06. After the main body of the capacitor assembly 2 completes the necessary assembly / encapsulation processes, then... Figure 21 As shown, the fifth terminal T05 and the sixth terminal T06 are connected and fixed on surface 3, and the following steps are performed as follows: Figure 19 and Figure 20 As shown, by connecting the terminals corresponding to those of power module 1, a configuration can be formed as follows: Figure 17 The power component with the structure shown.

[0225] refer to Figure 22 , Figure 22 This is a schematic diagram of the terminal structure of another capacitor assembly before it is connected and assembled with the power module. In this method, the first terminal T1 is still an integral structure, and before being connected with the power module 1, as shown... Figure 22 As shown by the vertical dashed line, the first terminal T1 is an integral structure perpendicular to surface 3. After the main body of capacitor assembly 2 completes the necessary assembly / encapsulation processes, then... Figure 22 As shown, the first terminal T1 is bent into two parts by the calibration fixture 10, which are the fifth terminal T05 and the sixth terminal T06. The specific shape and calibration stroke of the calibration fixture 10 can be adjusted and designed according to requirements, and this embodiment does not limit this.

[0226] If the first terminal T1 and the third terminal T3 are connected by an adapter terminal T5, the method for connecting the first terminal T1 and the third terminal T3 and connecting the second terminal T2 and the fourth terminal T4 mentioned above includes: after connecting the second terminal T2 and the fourth terminal T4, using the adapter terminal T5 to connect the first terminal T1 and the third terminal T3.

[0227] If the first terminal T1 and the third terminal T3 can be connected via an adapter terminal T5, in order to prepare... Figure 15Taking the power component with the structure shown as an example, when connecting the terminals of capacitor component 2 and power module 1, after stacking and assembling capacitor component 2 and power module 1, the third terminal T03 and the second terminal T2 are first connected by laser welding in the first overlapping area A1. Then, the adapter terminal T5 is assembled, and by laser welding, the adapter terminal T5 is connected to the first terminal T1 in the second overlapping area A2, and to the fourth terminal T04 in the third overlapping area A3, thereby forming a structure as shown. Figure 15 The power component with the structure shown. The inner surface of the adapter terminal T5 is covered with an insulating element 5 to provide insulation between the second terminal T2 and the fourth terminal T4. Fabrication Figure 16 When fabricating a power component with the structure shown, the fabrication process is similar to... Figure 15 The corresponding method is the same, and will not be described again in the embodiments of this application.

[0228] Based on the power components provided in the above embodiments, another embodiment of this application also provides a motor controller including the power components described above.

[0229] Based on the power components provided in the above embodiments, another embodiment of this application also provides an electronic control assembly, including the above-described motor controller.

[0230] Based on the electronic control assembly provided in the above embodiments, another embodiment of this application also provides a vehicle, which includes the above-described electronic control assembly.

[0231] In this embodiment, the vehicle includes a range-extended vehicle with independent motor drive and power generation requirements. To meet these requirements, the industry commonly integrates motor drive (DC to AC) and motor power generation (AC to DC) into a single dual-controller assembly. In this application scenario, due to the large package size of conventional full-bridge modules, the mechanical integration of the drive control module and power generation control module offers limited size benefits, resulting in a large integrated size. Furthermore, it suffers from excessive warpage, poor chip soldering processability, and low application reliability, necessitating separate independent packaging for the two control modules. The technical solution of this application, however, achieves integrated packaging of both control modules, resolving these issues.

[0232] In addition, in conventional technologies, there is a large ESL between the positive and negative terminals of capacitor components and power modules. The technical solution of this application can increase the overlapping area between the positive and negative terminals, which can greatly reduce the ESL and thus solve the problems of high switching losses and low efficiency caused by excessive ESL.

[0233] In this embodiment, the vehicle includes a new energy vehicle, which includes an electric control assembly, enabling it to drive using electric energy. The power components in the electric control assembly may simultaneously include a drive control module and a power generation control module. The new energy vehicle uses an electric drive assembly to drive using electric energy. Taking a range-extended electric vehicle as an example, its topology is as follows... Figure 23 As shown.

[0234] refer to Figure 23 , Figure 23 This is a topology diagram of a range-extended new energy vehicle provided in an embodiment of this application. Figure 23 In the diagram, solid lines represent mechanical connections, and dashed lines represent electrical connections.

[0235] like Figure 23 As shown, one of the core components of a range-extended electric vehicle is the range extender 18, which includes a generator motor 16 and a power generation component 15 connected thereto; the generator motor 16 is also connected to an engine 17. The power generation component 15 is connected to a power battery 14 and an inverter 13. The inverter 13 is connected to a drive motor 12, and the drive motor 12 is connected to an electric drive unit 11. The electric drive unit 11 includes a reducer and a differential.

[0236] Taking a range-extended electric vehicle as an example, its core component is the range extender 18. Its main function is to activate the range extender 18 when the power battery 14's charge drops to a certain level, causing the engine 17 to drive the generator motor 16 to generate electricity. Part of the generated electricity can be used to power the drive motor 12, and the other part can be used to charge the power battery 14.

[0237] Range-extended electric vehicles have many advantages, including:

[0238] In daily urban commutes, range-extended electric vehicles can run on pure electric power with zero emissions, reducing exhaust pollution and meeting environmental protection requirements. At the same time, electric drive is more energy-efficient than gasoline drive, reducing energy consumption and operating costs.

[0239] The range-extended electric vehicle is equipped with an engine 17 as a range extender. When the battery power is low, the engine 17 can start to generate electricity to provide continuous power to the vehicle, avoiding the additional problem of range anxiety caused by the limited range of pure electric vehicles, and making long-distance travel more convenient.

[0240] In addition, range-extended electric vehicles also have the following advantages in terms of driving experience:

[0241] Pure electric drive: The range-extended topology is essentially a pure electric drive system. The vehicle's driving power is entirely provided by the drive motor 12. The engine 17 does not directly participate in driving the vehicle, but plays the role of generating electricity. It starts when the battery power is low, converting fuel into electrical energy to power the drive motor 12 or charge the battery. This pure electric drive method makes the vehicle's power source singular and pure, consistent with the drive method of pure electric vehicles, fundamentally ensuring the comfort of the driving experience.

[0242] Rapid power response: The characteristics of the drive motor 12 enable it to output maximum torque instantly. In range-extended electric vehicles, when the driver presses the accelerator pedal, the drive motor 12 can respond immediately, rapidly delivering strong power for quick starts and acceleration. This instantaneous power response is far superior to traditional gasoline vehicles, allowing the driver to experience a more direct and rapid push-back feeling. Whether in frequent start-stop situations in urban traffic or overtaking maneuvers on highways, it can easily handle the situation, bringing a smooth driving experience.

[0243] No power interruption: During the operation of the range-extended vehicle, since it is always driven by the drive motor 12, there is no power interruption problem as seen in traditional gasoline vehicles when shifting gears. Whether driving at low or high speeds, the power output remains continuous and smooth. Even when the battery is low and the engine starts generating electricity, the system can use precise control strategies to ensure that the power output of the drive motor 12 is not affected, without any jerking or power interruption. This provides the driver with a consistently stable driving experience, improving driving comfort and safety.

[0244] The power components of a range-extended electric vehicle (REEV) include a generator motor 16, a drive motor 12, and other power components. In conventional REEVs, the drive control module and the generator control module are two independent components, each with its own independent power module (e.g., using diodes, IGBTs, SiC semiconductors for AC-DC conversion), current sensors, temperature sensors, and motor rotor position sensors. This results in higher weight, size, and cost, necessitating optimization.

[0245] In the vehicle provided in this application embodiment, two control modules can be integrated into the same power component, which can reduce the overall weight and volume of the product, reduce ESL in the current loop, and improve the performance of the electronic control assembly.

[0246] refer to Figure 24 , Figure 24An equivalent circuit diagram of a power component provided in this application embodiment is shown. The power component includes a drive control module 101 for connecting a drive motor 12 and a power generation control module 102 for connecting a generator motor 16. The drive control module 101 includes a plurality of first sub-power modules 701, and the power generation control module 102 includes a plurality of second sub-power modules 702.

[0247] Both the first sub-power module 701 and the second sub-power module 702 include a half-bridge circuit, which comprises an upper bridge arm circuit 901 and a lower bridge arm circuit 902. Both the upper bridge arm circuit 901 and the lower bridge arm circuit 902 include a first power chip 905 and a second power chip 906 connected in parallel. The first power chip 905 can be an IGBT (Insulated Gate Bipolar Transistor), optionally a SiC chip. The second power chip 906 can be an FRD (Fast Recovery Diode). The collector of the IGBT is connected to the positive terminal of the FRD, and the emitter of the IGBT is connected to the negative terminal of the FRD.

[0248] For the first sub-power module 701, the two ends of the upper bridge arm circuit 901 are respectively connected to the positive bus 903 and an AC terminal of the drive motor 12, and the two ends of the lower bridge arm circuit 902 are respectively connected to the negative bus 904 and an AC terminal of the drive motor 12. Within the same first sub-power module 701, the upper bridge arm circuit 901 and the lower bridge arm circuit 902 are connected to the same AC terminal of the drive motor 12. Different first sub-power modules 701 are connected to different AC terminals of the drive motor 12.

[0249] For the second sub-power module 702, the two ends of the upper bridge arm circuit 901 are respectively connected to the positive bus 903 and an AC terminal of the generator 16, and the two ends of the lower bridge arm circuit 902 are respectively connected to the negative bus 904 and an AC terminal of the generator 16. Within the same second sub-power module 702, the upper bridge arm circuit 901 and the lower bridge arm circuit 902 are connected to the same AC terminal of the generator 16. Different first sub-power modules 701 are connected to different AC terminals of the generator 16.

[0250] It should be noted that, in this application embodiment, the vehicle type is not limited to range-extended new energy vehicles, and can also be used for other types of vehicles. This application embodiment does not limit this.

[0251] The various embodiments in this application are described in a progressive, parallel, or combined manner. Each embodiment focuses on its differences from other embodiments, and similar or identical parts between embodiments can be referred to interchangeably. The embodiments provided in this application can be combined with each other without contradiction.

[0252] It should be noted that, in the description of this application, the accompanying drawings and embodiments are illustrative rather than restrictive. The same reference numerals throughout the embodiments identify the same structures. Additionally, for ease of understanding and description, the thicknesses of some layers, films, panels, regions, etc., may be exaggerated in the drawings. It is also understood that when an element such as a layer, film, region, or substrate is referred to as being "on" another element, the element may be directly on the other element or there may be intermediate elements. Furthermore, "on" means positioning an element on or below another element, but does not inherently mean positioning it above another element according to the direction of gravity.

[0253] The terms "upper," "lower," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application. When a component is considered to be "connected" to another component, it can be directly connected to the other component or there may be a component positioned centrally in the middle.

[0254] It should also be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that an article or apparatus comprising a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such an article or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the article or apparatus that includes the aforementioned element.

[0255] The above description of the disclosed embodiments enables those skilled in the art to make or use this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A power component, characterized in that, include: Layered power modules and capacitor assemblies; The capacitor assembly is connected to a first terminal and a second terminal that are insulated from each other on the surface facing the power module; the first terminal and the second terminal are arranged opposite to each other in a first direction. The power module has a third terminal and a fourth terminal that are insulated from each other connected at the same end; the end faces the first terminal and the second terminal; the third terminal includes a first segment terminal connected to the end, and the fourth terminal includes a second segment terminal connected to the end; the first segment terminal and the second segment terminal are parallel to the first direction and are arranged opposite to each other in the second direction; Wherein, the second direction is parallel to the stacking direction of the power module and the capacitor assembly, and the first direction is perpendicular to the second direction; the first terminal and the third terminal are fixedly connected by welding, and the second terminal and the fourth terminal are fixedly connected by welding.

2. The power component according to claim 1, characterized in that, The vertical projections of the first terminal and the second terminal on the first plane at least partially overlap; the first plane is perpendicular to the first direction; And / or, the vertical projections of the third terminal and the fourth terminal on the second plane at least partially overlap; The second plane is perpendicular to the second direction.

3. The power component according to claim 2, characterized in that, The edges of the first terminal and the second terminal located on both sides of the second direction satisfy the condition of being flush; And / or, the edges of the third terminal and the fourth terminal located on both sides of the first direction satisfy the flush condition.

4. The power component according to claim 3, characterized in that, The misalignment distance between the opposite edges of the first terminal and the second terminal does not exceed 0.2 mm; The misalignment distance between the opposite edges of the third terminal and the fourth terminal does not exceed 0.2 mm.

5. The power component according to claim 1, characterized in that, The fourth terminal is located between the third terminal and the capacitor assembly; The second terminal is located between the first terminal and the end.

6. The power component according to claim 5, characterized in that, The fourth terminal also includes a third terminal connected to the second terminal segment; the third terminal segment is parallel to the second direction and extends toward the capacitor assembly; Wherein, the third terminal segment and the second terminal segment have a first overlapping area in the first direction, and the third terminal segment and the second terminal segment are connected in the first overlapping area.

7. The power component according to claim 6, characterized in that, The third terminal and the first terminal are connected via an adapter terminal.

8. The power component according to claim 7, characterized in that, In the first direction, there is a gap between the third terminal and the first terminal that exposes the first overlapping area, and the adapter terminal covers the gap.

9. The power component according to claim 7, characterized in that, The adapter terminal and the first terminal have a second overlapping area in the first direction, and the adapter terminal and the first terminal are connected in the second overlapping area; The adapter terminal and the third terminal have a third overlapping area, and the adapter terminal and the third terminal are connected in the third overlapping area.

10. The power component according to claim 9, characterized in that, The first overlapping region and the second overlapping region do not overlap in the first direction.

11. The power component according to claim 10, characterized in that, In the second direction, the distance between the first overlapping region and the capacitor assembly is greater than the distance between the second overlapping region and the capacitor assembly.

12. The power component according to claim 9, characterized in that, The adapter terminal and the first segment terminal have the third overlapping area in the second direction.

13. The power component according to claim 9, characterized in that, The third terminal also includes a fourth terminal connected to the first terminal segment; the fourth terminal segment extends parallel to the second direction and away from the capacitor assembly; The adapter terminal and the fourth segment terminal have the third overlapping area in the first direction.

14. The power component according to claim 9, characterized in that, The third terminal also includes a fourth terminal connected to the first terminal segment; the fourth terminal segment is parallel to the second direction and extends toward the capacitor assembly; The adapter terminal and the fourth segment terminal have the third overlapping area in the first direction.

15. The power component according to claim 14, characterized in that, In the second direction, the distance between the third overlapping region and the capacitor assembly is greater than the distance between the first overlapping region and the capacitor assembly; and the distance between the second overlapping region and the capacitor assembly is less than the distance between the first overlapping region and the capacitor assembly.

16. The power component according to claim 5, characterized in that, The fourth terminal further includes a third terminal connected to the second terminal; the third terminal further includes a fourth terminal connected to the first terminal; both the third terminal and the fourth terminal extend away from the capacitor assembly. The fourth terminal segment and the first terminal segment are connected at the end opposite to the capacitor assembly to form a first connection area; the third terminal segment and the second terminal segment are connected at the end opposite to the capacitor assembly to form a second connection area; in the second direction, the distance between the second connection area and the capacitor assembly is less than the distance between the first connection area and the capacitor assembly.

17. The power component according to claim 16, characterized in that, The fourth terminal segment and the first terminal segment have opposite portions in the first direction; The third terminal segment and the second terminal segment have a first overlapping area in the first direction; the first overlapping area includes one end of the second connection area located in the accommodating space formed by the opposing portions.

18. The power component according to claim 17, characterized in that, In the opposite portion, both the fourth terminal and the first terminal protrude toward the side opposite to the first overlapping area to form the receiving space.

19. The power component according to any one of claims 6-18, characterized in that, In the first direction, at least a portion of the third terminal segment is exposed.

20. The power component according to any one of claims 1-18, characterized in that, An insulating element is provided between the first terminal and the second terminal; And / or, an insulating element is provided between the third terminal and the fourth terminal.

21. The power component according to any one of claims 1-18, characterized in that, The thickness of at least one of the first terminal, the second terminal, the third terminal, and the fourth terminal is 1 mm to 2 mm.

22. The power component according to any one of claims 1-18, characterized in that, The distance between the first terminal and the second terminal is 1.5mm to 2mm; And / or, the distance between the third terminal and the fourth terminal is 1.5mm to 2mm.

23. The power component according to any one of claims 1-18, characterized in that, The first terminal segment includes an integral first part and a second part, the first part being connected to the end, and the second part being located on the side of the first part opposite to the end; Wherein, the width of the first part is smaller than the width of the second part; Alternatively, the width of the first part is equal to the width of the second part.

24. The power component according to any one of claims 1-18, characterized in that, Both the first terminal and the second terminal include an integral third part and a fourth part; in the same terminal, the fourth part is connected to the surface, and the third part is located on the side of the fourth part away from the surface; The width of the third part is smaller than the width of the fourth part; Alternatively, the width of the third part is equal to the width of the fourth part.

25. The power component according to any one of claims 1-18, characterized in that, The first terminal segment includes an integral first part and a second part, the first part being connected to the end, and the second part being located on the side of the first part opposite to the end; Both the first terminal and the second terminal include an integral third part and a fourth part; in the same terminal, the fourth part is connected to the surface, and the third part is located on the side of the fourth part away from the surface; The width of the first part is less than the width of the second part, the width of the second part is equal to the width of the third part, and the width of the third part is less than the width of the fourth part.

26. The power component according to any one of claims 1-18, characterized in that, The power component includes at least one of a drive control module and a power generation control module; the drive control module is used to connect to a drive motor; the power generation control module is used to connect to a generator motor; Both the drive control module and the power generation control module include the power module and the capacitor assembly stacked together.

27. The power component according to claim 26, characterized in that, The power component includes both the drive control module and the power generation control module; The drive control module and the power generation control module share the same capacitor assembly.

28. The power component according to claim 26, characterized in that, The drive control module includes multiple first sub-power modules, each of which has an independent liner. The power generation control module includes multiple second sub-power modules, which share the same liner.

29. The power component according to claim 28, characterized in that, The drive control module includes three first sub-power modules; the power generation control module includes three second sub-power modules.

30. The power component according to claim 27, characterized in that, The first terminal and the third terminal are connected based on an adapter terminal; The power generation control module and the drive control module share the same adapter terminal.

31. A motor controller, characterized in that, Includes the power components as described in any one of claims 1-30.

32. An electronic control assembly, characterized in that, Including the motor controller as described in claim 31.

33. A vehicle, characterized in that, include: The electronic control assembly as described in claim 32.

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