Copper bar injection molding structure for integrated motor controller

Abstract

The utility model relates to a copper bar injection molding structure for an integrated motor controller, which comprises an insulating wire holder and a plurality of connecting copper bars arranged on the insulating wire holder, the middle part of the insulating wire holder is provided with a connecting filling part, each connecting copper bar is provided with a plurality of filling holes, and the filling holes and the filling connecting parts are subjected to integral injection molding. The connecting copper bar is fixedly connected with the insulating wire holder; adjacent connecting copper bars are arranged in parallel, and an interval is arranged between the adjacent connecting copper bars. In implementation, an original cable connection mode is replaced by the copper bar injection molding structure, the copper bar injection molding structure is compact, the layout space in the motor is saved, the problems of easy installation, insulation and fixation are solved, and meanwhile, the motor has the functions of high-temperature loosening prevention and leakage prevention. Sealing insulation is carried out in a triple mode, oil gas in a motor system is effectively isolated, corrosion to components in a controller is prevented, and the service life is prolonged. The copper bar injection molding structure is high in firmness, and the safety of the motor during operation is ensured.

Description

Technical Field

[0001] This utility model relates to the technical field of motor systems, specifically to a copper busbar injection molding structure for an integrated motor controller, and more particularly to a copper busbar injection molding structure for circuit connection between the motor system and the control system in an all-in-one motor and controller assembly. Background Technology

[0002] In existing technologies, vehicle motor systems are often connected to control systems using cables. When the motor power is high, thicker cables are required. If the controller and motor both use large-diameter drive cables, the large bending radius of these cables restricts their use during turns, necessitating the installation of numerous external cables. This increases the space required for assembly, leading to a significant increase in the overall cost and weight of the motor, making it unsuitable for compact designs. Furthermore, multi-functional motor and controller assemblies, especially oil-cooled motors, often face challenges in addressing the sealing risks at high temperatures. This can result in leaked oil-gas mixtures entering the controller compartment and damaging components.

[0003] At the same time, the use of thicker cables for connection requires larger connectors or waterproof glands, which further increases the weight of the whole machine, compresses and occupies the remaining space in the whole machine, and brings certain obstacles to wiring and maintenance.

[0004] Therefore, there is an urgent need in the market for a connection structure that can be used in motor systems and control systems to replace bulky cable wiring. Summary of the Invention

[0005] The purpose of this utility model is to provide an improved copper busbar injection molding structure for an integrated motor controller. Through structural improvement, the original method of connecting the motor system and the control system by cable is eliminated, making the connection structure simpler, more compact, and easier to maintain and repair.

[0006] To achieve the above objectives, the technical solution of this utility model is: a copper busbar injection molding structure for an integrated motor controller, characterized in that: the copper busbar injection molding structure includes an insulating terminal block and a plurality of connecting copper busbars disposed on the insulating terminal block; the insulating terminal block has a connecting filling part in the middle; the connecting copper busbars have a plurality of filling holes; the filling holes and the filling connecting part are integrally injection molded, so that the connecting copper busbars are fixedly connected to the insulating terminal block to form an integral unit; adjacent connecting copper busbars are arranged parallel to each other and are spaced apart from each other.

[0007] Preferably, the bottom of the copper busbar injection molding structure is provided with an O-ring, and the top is provided with a groove filled with soft insulating material.

[0008] Furthermore, each connecting copper busbar is provided with at least two filling holes, which are arranged vertically along the height of the connecting copper busbar. The filling holes are square holes, oblong holes, or round holes.

[0009] Furthermore, the filling material used for filling the holes and filling the connection parts is a rigid insulating material, which can be any of the following: a polyamide 66 composite material containing 30% glass fiber reinforcement, polyetheretherketone (PEEK), PEEK containing 30% glass fiber reinforcement, polybutylene terephthalate modified material with 30% glass fiber added, or Teflon. The flexible insulating material is a silicone-based potting compound.

[0010] Furthermore, an insulating terminal block is located at one end of the motor housing, and a control system is located at the top of the motor housing. The insulating terminal block is connected to the control system, and the bottom of the connecting copper busbar passes through the insulating terminal block and extends downward.

[0011] Furthermore, there are three connecting copper busbars, arranged parallel to each other on the left, middle and right sides respectively. The tops of the three connecting copper busbars are flush, and the height of the middle connecting copper busbar is shorter than that of the left and right connecting copper busbars. Each connecting copper busbar has a bevel and a connecting screw hole at the bottom. The three bevels are connected to form an arc shape, which can match the cylindrical housing of the motor system. The connecting copper busbar is connected to one end of the motor system through the bevel and the screw in the connecting screw hole.

[0012] Compared with the prior art, the technical solution of this utility model not only improves the overall technical solution, but also includes many detailed improvements. Specifically, it has the following beneficial effects:

[0013] 1. The improved solution of this utility model includes an insulating terminal block and several connecting copper busbars on the insulating terminal block. The insulating terminal block has a connecting filling part in the middle and several filling holes on the connecting copper busbars. By injecting filling material into the filling holes and filling connection parts for overall injection molding, the connecting copper busbars and the insulating terminal block are fixedly connected to form an integral unit, solving the problems of fixing, insulation and easy installation. The copper busbar injection molding structure can directly connect the motor system and the control system, replacing the original bulky and cumbersome cable connection method. This makes the overall connection structure small and compact, greatly saving the space occupied inside the motor, and at the same time, it is easy to disassemble and maintain, saving costs.

[0014] 2. In the technical solution of this utility model, the copper busbar injection molding structure is filled with hard insulating material. The bottom of the copper busbar injection molding structure is provided with an O-ring, and the top is provided with a groove. The groove is filled with soft insulating material. Through the above three-layer sealing and isolation structure, a better sealing effect can be achieved for the cooling oil system inside the motor system, avoiding mutual interference between the internal cooling structures of the motor.

[0015] 3. In the structure of this utility model, each connecting copper busbar is provided with at least 2 filling holes. The filling holes are arranged up and down along the height direction of the connecting copper busbar. The filling holes are square holes, waist-shaped holes or round holes. After the filling holes are filled, they form a stable anti-detachment structure between the connecting copper busbar and the insulating connector, ensuring the positional accuracy between the connecting copper busbar and the insulating connector and providing effective insulation.

[0016] 4. This utility model has a simple structure, is easy to use, saves layout space, reduces usage and maintenance costs, and is easy to promote and utilize. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of this utility model.

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

[0019] Figure 3 This is a structural schematic diagram of an embodiment of the present utility model.

[0020] Figure 4 This is a partially enlarged schematic diagram of the copper busbar injection molding structure of this utility model.

[0021] Figure label:

[0022] 1. Motor system; 2. Control system; 3. Housing; 4. Copper busbar injection molding structure;

[0023] 41 Insulating terminal block, 42 ​​Connecting copper busbar, 43 Rigid insulating material, 44 O-ring seal, 45 Groove, 47 Filling hole, 48 Bevel, 49 Connecting screw hole. Detailed Implementation

[0024] The technical solution of this utility model will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0025] This utility model provides a copper busbar injection molding structure for a motor controller, see details below. Figure 1The difference between this and existing technologies lies in the following: the copper busbar injection molding structure 4 includes an insulating terminal block 41 and several connecting copper busbars 42 disposed on the insulating terminal block. A connecting filling part is provided in the middle of the insulating terminal block, and several filling holes 47 are provided on the connecting copper busbars. The filling holes are integrally cast during the overall injection molding process, stably fixing the injection molded part and the copper busbars. By integrally injection molding the filling holes and the filling connecting part, the connecting copper busbars and the insulating terminal block are fixedly connected as one unit. The filling part is potted with soft insulating materials such as potting compound. Adjacent connecting copper busbars are arranged parallel to each other, with gaps between them. In implementation, the copper busbar injection molding structure is used to connect the motor system and the control system, replacing the original complex and bulky cable connection method. The copper busbar injection molding utilizes the insulation of the injection molded part to ensure the reliability of insulation under extreme working conditions and vibration conditions. The fixed injection molding structure can effectively ensure electrical clearance and creepage distance in a confined space. The overall structure is relatively small and compact, saving internal layout space in the motor, and is convenient for installation and disassembly, facilitating subsequent maintenance. Furthermore, in the injection-molded copper busbar structure, the exposed joints are filled with a soft insulating material, avoiding the risk of cracking due to the difference in thermal expansion coefficients between the copper plate and the injection-molded parts at high temperatures, which could lead to oil and gas leaks and damage to components. For motor and control systems, integral injection molding provides a more robust and stable connection, ensuring the safety of motor operation.

[0026] Therefore, the copper busbar injection molding structure uses a triple method of sealing and insulation, consisting of rigid insulating materials, sealing rings, and soft insulating materials. This effectively isolates oil and gas in the motor system, preventing them from entering the control system, thus preventing corrosion of the components inside the controller and extending the overall service life of the motor.

[0027] Example

[0028] This embodiment describes a copper busbar injection molding structure for a motor controller; see details below. Figure 1The copper busbar injection molding structure 4 is used to connect the motor system 1 and the control system 2 via circuitry, replacing the original complex and bulky cable connection method. The copper busbar injection molding structure is smaller and more compact, saving internal layout space in the motor. It is also easy to install and disassemble, facilitating subsequent maintenance. Specifically, the copper busbar injection molding structure 4 includes an insulating terminal block 41 and several connecting copper busbars 42 located on the insulating terminal block. A connecting filling part is located in the middle of the insulating terminal block, and several filling holes 47 are provided on the connecting copper busbars. During injection molding, the filling holes ensure that the injection medium and the copper busbar structure become an integral whole, acting as fixing pins for the copper busbars, making the connection between the connecting copper busbars and the insulating terminal block more stable. This connection method is firm and reliable, and is not prone to displacement or loosening. The connection part between the filling part and the copper busbars and the injection molded parts is arranged perpendicularly. During operation, due to the difference in thermal expansion coefficients between the copper busbars and the injection molded parts, the high temperature of the copper busbars can easily cause separation or cracking between the copper busbars and the injection molded parts, further allowing oil and gas mixtures from the motor body to enter the controller compartment, posing a risk of component damage. Filling the filling section with soft insulating material can effectively prevent the copper busbar injection molded parts from separating under high temperature conditions and allowing oil and gas mixtures to enter the controller compartment.

[0029] Furthermore, the filling material for the integral injection molding of the filling holes and filling connections is a rigid insulating material 43. The rigid insulating material can be any of the following: a polyamide 66 composite material containing 30% glass fiber reinforcement, polyetheretherketone (PEEK), PEEK containing 30% glass fiber reinforcement, polybutylene terephthalate (PET) modified material with 30% glass fiber added, or Teflon. The flexible insulating material is a silicone-based potting compound or a flexible potting compound with similar function and temperature resistance, such as Wacker Elastosil's RT7620 potting compound.

[0030] Furthermore, an insulating terminal block is located at one end of the motor housing, and a control system is located at the top of the motor housing. The insulating terminal block is connected to the control system, and the bottom of the connecting copper busbar passes through the insulating terminal block and extends downward. In this embodiment, there are three connecting copper busbars, arranged parallel to each other on the left, middle, and right sides, respectively. The tops of the three connecting copper busbars are flush, and the height of the middle connecting copper busbar is shorter than that of the left and right connecting copper busbars. The bottom of each connecting copper busbar is provided with a bevel 48 and a connecting screw hole 49. The line connecting the three bevels is arc-shaped, or the three bevels are tangent to the center of the stator, which can match the cylindrical housing of the motor system. The connecting copper busbar is connected to one end of the motor system through the bevels and the screws provided in the connecting screw holes.

[0031] Furthermore, adjacent connecting copper busbars are arranged parallel to each other with a gap between them to ensure mutual insulation. The bottom of the injection-molded copper busbar structure has an O-ring seal 44, and the top has a cavity 45 filled with soft insulating material. Each connecting copper busbar has at least two filling holes, arranged vertically along the height of the connecting copper busbar. The filling holes are square, oblong, or round. While ensuring current carrying capacity, the filling holes are filled with insulating material after injection molding, thus forming a stable anti-detachment structure. Controlling the relative position of the copper busbar and the insulating material through injection molding maintains accurate assembly positioning while providing effective insulation distance and insulation effect.

[0032] The bottom of the copper busbar injection molding structure 4 is equipped with an O-ring seal 44 to isolate oil and gas in the motor oil cooling chamber. The top of the copper busbar injection molding structure has a cavity 45 to cover the external copper plate, which is filled with a soft insulating material. During high-power motor operation, the copper plate generates significant heat. The thermal expansion coefficients of the copper busbar injection molding structure and the rigid insulating material are different. At high temperatures, a small peeling gap can form between the rigid insulating material and the copper plate. This gap can easily lead to oil and gas leakage in the motor oil cooling system. Filling the top cavity with a soft insulating material effectively seals the oil and gas under thermal expansion conditions, preventing oil and gas from entering the control system. Therefore, the copper busbar injection molding structure uses a triple-layer sealing and insulation method—rigid insulating material, sealing ring, and soft insulating material—to effectively isolate oil and gas in the motor system, preventing them from entering the control system, preventing corrosion of components within the controller, and extending the overall service life of the motor.

[0033] The above description, in conjunction with specific preferred embodiments, provides a further detailed explanation of the present invention. It should not be construed that the specific implementation of the present invention is limited to these descriptions. For those skilled in the art, various simple deductions or substitutions can be made without departing from the concept of the present invention, and all such modifications or substitutions should be considered within the protection scope of the present invention.

Claims

1. A copper bar injection molded structure for an integrated motor controller, characterized by: The copper bar injection molding structure comprises an insulating terminal block and a plurality of connecting copper bars arranged on the insulating terminal block. A connecting filling part is arranged in the middle of the insulating terminal block. A plurality of filling holes are arranged on the connecting copper bars. The filling holes and the connecting filling part are integrally injection molded, so that the connecting copper bars and the insulating terminal block are fixedly connected to form an integrated body. Adjacent connecting copper bars are arranged in parallel and are spaced apart from each other.

2. The copper bar injection molding structure for an integrated motor controller of claim 1, wherein: The bottom of the copper bar injection molding structure is provided with an O-shaped sealing ring, and the top is provided with a groove cavity. The groove cavity is filled with a soft insulating material.

3. The copper bus injection molding structure for an integrated motor controller of claim 1, wherein: At least two filling holes are arranged on each connecting copper bar. The filling holes are arranged up and down along the height direction of the connecting copper bar. The filling holes are square holes, waist-shaped holes or circular holes.

4. The copper bus injection molding structure for an integrated motor controller of claim 2, wherein: The soft insulating material is a silicon-based potting adhesive.

5. The copper bus injection molding structure for an integrated motor controller of claim 1, wherein: The insulating terminal block is arranged at one end of a motor housing. The top of the motor housing is provided with a control system. The insulating terminal block is connected to the control system. The bottom of the connecting copper bar passes through the insulating terminal block and extends downward.

6. The copper bus injection molding structure for an integrated motor controller of claim 1, wherein: There are three connecting copper bars arranged in parallel from left to right. The top of the three connecting copper bars is flush. The middle connecting copper bar is shorter than the left and right connecting copper bars. The bottom of each connecting copper bar is provided with a slope and a connecting screw hole. The three slopes are connected in a circular arc shape and can be matched with the cylindrical shell of the motor system. The connecting copper bar is connected to one end of the motor system through the slope and the screw arranged in the connecting screw hole.

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