Integrated thin-film capacitor module, power brick assembly, motor controller and vehicle

Abstract

The utility model discloses an integrated thin-film capacitor module, a power brick assembly, a motor controller and a vehicle, a flexible connection section of a switching copper bar is composed of multiple layers of independent copper foils, and the integrated thin-film capacitor module can realize flexible connection with a direct-current bus copper bar through the flexible connection section of the switching copper bar. Flexible connection and sealing of the power brick water channel connector and the driving motor shell water channel connector are achieved through the water pipe connector, the coaxiality tolerance of the power brick water channel connector and the driving motor shell water channel connector is improved, the assembly risk caused by hard connection is avoided, and the service life of the power brick water channel connector and the driving motor shell water channel connector is prolonged. And the assembly reliability is improved.

Description

Technical Field

[0001] This utility model belongs to the field of new energy vehicle motor controller technology, specifically relating to an integrated thin-film capacitor module, power brick assembly, motor controller and vehicle. Background Technology

[0002] Currently, the electric drive system assemblies matched with new energy vehicles on the market are mostly not highly integrated, and are relatively large and heavy. In order to improve the integration and weight reduction of the electric drive system assembly, an electric drive system assembly has emerged. This assembly eliminates the motor controller cover plate and directly connects the motor controller to the drive motor with a hard connection. The adapter copper bus in the motor controller is a hard copper bus, and the power brick water channel interface of the motor controller and the water channel interface of the drive motor housing are directly matched with radial seal. This connection method has the following problems: (1) Since the adapter copper bus is a hard copper bus, the connection between the adapter copper bus and the DC input copper bus and the DC bus copper bus is a hard connection. The hard connection will bring mechanical stress risk and poor assembly reliability; (2) Due to the dimensional deviation caused by the aluminum alloy casting process and assembly, the coaxiality between the power brick water channel interface of the motor controller and the water channel interface of the drive motor housing is poor. The direct matching with radial seal may result in failures such as inability to assemble, edge cutting of the sealing ring, and water leakage due to the sealing ring being too biased to one side. Utility Model Content

[0003] The purpose of this invention is to provide an integrated thin-film capacitor module, power brick assembly, motor controller, and vehicle to avoid assembly risks caused by hard connections, improve assembly reliability, and enhance the reliability of the electric drive system assembly.

[0004] In a first aspect, this utility model provides an integrated thin-film capacitor module, which includes a DC input copper busbar, a transition copper busbar, a filter, a thin-film capacitor, and a mounting frame. A portion of the DC input copper busbar, the filter, and the thin-film capacitor are located within the mounting frame and encapsulated with epoxy resin. Another portion of the DC input copper busbar is exposed above the epoxy resin encapsulation surface and is soldered to the transition copper busbar. The transition copper busbar is composed of multiple layers of copper foil stacked together. One end of the multiple layers of copper foil is soldered together to form a first hard connection segment, and the other end of the multiple layers of copper foil is soldered together to form a second hard connection segment. The remaining portion of the multiple layers of copper foil is a soft connection segment. The first hard connection segment is soldered to the DC input copper busbar, and the second hard connection segment has through holes that can connect to the DC busbar.

[0005] Preferably, the length of the flexible connection segment accounts for 38% to 42% of the total length of the transition copper busbar.

[0006] Preferably, the length of the soft connection segment accounts for 40% of the total length of the transition copper busbar, the length of the first hard connection segment accounts for 15% of the total length of the transition copper busbar, and the length of the second hard connection segment accounts for 45% of the total length of the transition copper busbar.

[0007] Preferably, the copper foil has 25 to 30 layers, and the thickness of each layer is 0.1 mm.

[0008] Secondly, this utility model provides a power brick assembly, which includes an integrated drive and control board, a power module, a current sensor, a heat sink, and the aforementioned integrated thin-film capacitor module. The heat sink has copper busbar clearance holes and a power brick water channel interface. The pins of the power module and the pins of the current sensor are electrically connected to the integrated drive and control board. The integrated thin-film capacitor module is fixedly connected to the lower surface of the heat sink. The power module and the current sensor are located between the integrated drive and control board and the heat sink. The current sensor is fixedly connected to the lower surface of the integrated drive and control board. The integrated drive and control board, the power module, and the upper surface of the heat sink are fixedly connected. The adapter copper busbar of the integrated thin-film capacitor module passes through the copper busbar clearance holes and is located above the heat sink.

[0009] Thirdly, this utility model provides a motor controller, which includes an electrical control housing and the aforementioned power brick assembly mounted on the electrical control housing. The motor controller also includes a water pipe connector with one end pressed into the water channel interface of the power brick and the other end pressable into the water channel interface of the drive motor housing. The water pipe connector is composed of a connecting pipe and a rubber sleeve, and the rubber sleeve is vulcanized and fixed to the outer wall of the connecting pipe.

[0010] Preferably, both ends of the rubber sleeve are frustoconical, with the smaller end face of the frustoconical flush with the end face of the connecting pipe.

[0011] Preferably, the outer sides of both ends of the rubber sleeve are provided with multiple rings of protrusions along the axial direction.

[0012] Preferably, the outer sides of both ends of the rubber sleeve are provided with four rings of protrusions along the axial direction.

[0013] Fourthly, this utility model provides a vehicle that includes the aforementioned motor controller.

[0014] This utility model has the following effects:

[0015] (1) The flexible connection section of the adapter copper bus is composed of multiple independent copper foils. The integrated thin film capacitor module can achieve a flexible connection with the DC bus copper bus through the flexible connection section of the adapter copper bus, thereby achieving a flexible connection of the DC input interface, which improves the assembly tolerance, avoids the assembly risk caused by hard connection, and improves the assembly reliability. In addition, during the operation of the electric drive system assembly, the flexible connection can absorb the stress caused by mechanical shock and mechanical vibration, reduce the mechanical stress risk of hard connection, and improve the reliability of the electric drive system assembly.

[0016] (2) The water pipe joint is used to realize the soft connection and sealing between the power brick water channel interface (of the motor controller) and the drive motor housing water channel interface, which improves the tolerance of the coaxiality between the power brick water channel interface and the drive motor housing water channel interface. It can absorb the assembly size tolerance accumulated due to the long dimensional chain, realize the smooth assembly connection with the drive motor part, and also avoid the damage to the parts caused by interference and scratching during the assembly process. In addition, this soft connection method also greatly reduces the structural damage and sealing failure caused by mechanical pressure and vibration impact, and improves the reliability of the electric drive system assembly. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the integrated thin-film capacitor module in an embodiment of this utility model.

[0018] Figure 2 This is a schematic diagram illustrating the connection between the DC input copper busbar and the adapter copper busbar in an embodiment of this utility model.

[0019] Figure 3 This is a schematic diagram of the power brick assembly in an embodiment of the present invention.

[0020] Figure 4 This is a schematic diagram of the water pipe connector in an embodiment of the present invention.

[0021] Figure 5 This is a cross-sectional view of the water pipe connector in an embodiment of this utility model.

[0022] Figure 6 This is a schematic diagram of the structure of the motor controller in an embodiment of this utility model. Detailed Implementation

[0023] To gain a more detailed understanding of the features and technical content of the embodiments of this utility model, the implementation of the embodiments of this utility model will be described in detail below with reference to the accompanying drawings. The accompanying drawings are for reference and illustration only and are not intended to limit the embodiments of this utility model.

[0024] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing embodiments of the invention only and is not intended to limit the scope of the invention.

[0025] In the following description, references are made to “some embodiments,” which describe a subset of all possible embodiments. However, it is understood that “some embodiments” may be the same subset or different subsets of all possible embodiments and may be combined with each other without conflict.

[0026] like Figure 1 , Figure 2 As shown, the integrated thin-film capacitor module in this embodiment of the present invention includes a DC input copper busbar 11, a transition copper busbar 12, a filter 13, a thin-film capacitor 14, and a mounting frame 15. A portion of the DC input copper busbar 11, the filter 13, and the thin-film capacitor 14 are located within the mounting frame 15 and are encapsulated with epoxy resin. Another portion of the DC input copper busbar 11 is exposed above the epoxy resin encapsulation surface and is welded to the transition copper busbar 12. The DC input copper busbar 11 is a rigid copper busbar, formed by one-time stamping of a copper plate (which is prior art). The transition copper busbar 12 is composed of multiple layers of copper foil (sheets) stacked together. One end of the multiple layers of copper foil is welded together to form a first rigid connection section 121, and the other end of the multiple layers of copper foil is welded together to form a second rigid connection section 122. The remaining portion of the multiple layers of copper foil (the middle portion excluding one end and the other end) is a flexible connection section 123 (the multiple layers of copper foil in the flexible connection section are independent of each other). The first hard connection section 121 is laser welded to the other end of the exposed epoxy resin potting cover of the DC input copper bus 11. The second hard connection section 122 has a through hole 1221 that can be bolted to the DC bus copper bus.

[0027] The flexible connection section 123 of the adapter copper busbar 12 is composed of multiple independent copper foils. The integrated thin film capacitor module can achieve a flexible connection with the DC bus copper busbar through the flexible connection section 123 of the adapter copper busbar 12, thereby achieving a flexible connection of the DC input interface. This can improve assembly tolerance, avoid the assembly risks caused by hard connection, and improve assembly reliability.

[0028] In some embodiments, one end of the multilayer copper foil is welded together by resistance welding to form a first hard connection segment 121, and the other end of the multilayer copper foil is welded together by resistance welding to form a second hard connection segment 122.

[0029] In some embodiments, the length of the flexible connection segment 123 accounts for 38% to 42% of the total length of the transition copper busbar. If the flexible connection segment is too long, it will affect the stiffness and strength of the transition copper busbar, while if the flexible connection segment is too short, its stress absorption function is limited. Therefore, a suitable length of 38% to 42% for the flexible connection segment can meet the stiffness and strength requirements of the transition copper busbar, and also ensure that the transition copper busbar has sufficient tolerance to absorb the stress caused by mechanical impact and mechanical vibration.

[0030] In some embodiments, the length of the flexible connection segment 123 accounts for 40% of the total length of the transition copper bus, the length of the first hard connection segment 121 accounts for 15% of the total length of the transition copper bus, and the length of the second hard connection segment 122 accounts for 45% of the total length of the transition copper bus. Since the first hard connection segment 121 is used for welding to the DC input copper bus 11, it can be designed to be shorter; since the second hard connection segment 122 needs to have a through hole 1221 and needs to ensure a firm connection with the DC bus copper bus, it needs to be designed to be longer.

[0031] In some embodiments, the number of copper foil layers is 25 to 30, and the thickness of each copper foil layer is 0.1 mm. As an example, the number of copper foil layers is 30, thereby ensuring the rigidity and strength of the transition copper busbar.

[0032] like Figure 3 As shown, the power brick assembly in this embodiment includes a drive and control integrated board 2, a power module 3, a current sensor 4, a heat sink 5, and an integrated thin-film capacitor module 1. The heat sink 5 has copper busbar clearance holes and a power brick water channel interface 51. The pins of the power module 3 and the current sensor 4 are electrically connected to the drive and control integrated board 2. The integrated thin-film capacitor module 1 is fixedly connected to the lower surface of the heat sink 5 by bolts. The power module 3 and the current sensor 4 are located between the drive and control integrated board 2 and the heat sink 5. The current sensor 4 is fixedly connected to the lower surface of the drive and control integrated board 2 by bolts, and the drive and control integrated board 2 and the power module 3 are fixedly connected to the upper surface of the heat sink 5 by bolts (this is prior art). The integrated thin-film capacitor module 1 here adopts... Figure 1 The integrated thin-film capacitor module shown has its adapter copper busbar 12 passing through a copper busbar clearance hole and located above the heat sink 5.

[0033] like Figures 4 to 6 As shown, the motor controller in this embodiment of the present invention includes an electrical control housing 6 and a power brick assembly 7 (which belongs to the prior art) mounted on the electrical control housing 6. The power brick assembly 7 adopts the following... Figure 3 The power brick assembly shown includes a motor controller that also includes a water pipe connector 8, one end of which is press-in into the power brick water channel interface 51 (of the motor controller), and the other end of which can be press-in into the water channel interface of the drive motor housing. The water pipe connector 8 consists of a connecting pipe 81 and a rubber sleeve 82, with the rubber sleeve 82 vulcanized and fixed to the outer wall of the connecting pipe 81 (equivalent to the rubber sleeve 82 being fixedly fitted onto the outside of the connecting pipe 81). As an example, the connecting pipe 81 is a steel pipe.

[0034] In use, one end of the water pipe connector 8 is pressed into the power brick water channel interface 51 (of the motor controller), forming an interference fit; the other end of the water pipe connector 8 is pressed into the drive motor housing water channel interface, also forming an interference fit. Utilizing the water pipe connector 8 to achieve a flexible connection and seal between the power brick water channel interface and the drive motor housing water channel interface improves the coaxiality tolerance between them, enabling smooth assembly and connection with the drive motor section. This significantly reduces structural damage and sealing failure caused by mechanical pressure, vibration, and impact.

[0035] In some embodiments, both ends of the rubber sleeve 82 are frustoconical, with the small end face of the frustum flush with the end face of the connecting pipe 81. The frustoconical shape of both ends of the rubber sleeve 82 makes it easier to press the two ends of the water pipe connector 8 into the power brick water channel interface and the drive motor housing water channel interface.

[0036] In some embodiments, multiple rings of protrusions 821 are provided axially on the outer sides of both ends of the rubber sleeve 82, which can make the seal more reliable.

[0037] In some embodiments, four rings of protrusions 821 are provided on the outer sides of both ends of the rubber sleeve 82 along the axial direction, and the four rings of protrusions 821 can make the seal more reliable.

[0038] In addition, this utility model embodiment also provides a vehicle, which includes the above-mentioned motor controller.

[0039] The above description is only a specific embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present utility model should be included within the protection scope of the present utility model.

Claims

1. An integrated thin-film capacitor module, comprising a DC input copper busbar (11), a connecting copper busbar (12), a filter (13), a thin-film capacitor (14), and a mounting frame (15); a portion of the DC input copper busbar (11), the filter (13), and the thin-film capacitor (14) are located within the mounting frame (15) and encapsulated with epoxy resin; another portion of the DC input copper busbar (11) is exposed above the epoxy resin encapsulation surface and welded to the connecting copper busbar (12); characterized in that: The adapter copper bus (12) is composed of multiple layers of copper foil stacked together. One end of the multiple layers of copper foil is welded together to form a first hard connection section (121), and the other end of the multiple layers of copper foil is welded together to form a second hard connection section (122). The remaining part of the multiple layers of copper foil is a soft connection section (123). The first hard connection section (121) is welded to the DC input copper bus (11), and the second hard connection section (122) is provided with a through hole (1221) that can be connected to the DC bus copper bus.

2. The integrated thin film capacitor module of claim 1, wherein: The length of the flexible connection section (123) accounts for 38% to 42% of the total length of the transition copper busbar.

3. The integrated thin film capacitor module of claim 1, wherein: The length of the soft connection segment (123) accounts for 40% of the total length of the transition copper busbar, the length of the first hard connection segment (121) accounts for 15% of the total length of the transition copper busbar, and the length of the second hard connection segment (122) accounts for 45% of the total length of the transition copper busbar.

4. The integrated thin film capacitor module of claim 1, wherein: The copper foil has 25 to 30 layers, and each layer has a thickness of 0.1 mm.

5. A power brick assembly, comprising a drive and control integrated board (2), a power module (3), a current sensor (4), a heat sink (5), and an integrated thin-film capacitor module (1), wherein the heat sink (5) has copper busbar clearance holes and a power brick water channel interface (51), the pins of the power module (3) and the pins of the current sensor (4) are electrically connected to the drive and control integrated board (2), the integrated thin-film capacitor module (1) is fixedly connected to the lower surface of the heat sink (5), the power module (3) and the current sensor (4) are located between the drive and control integrated board (2) and the heat sink (5), the current sensor (4) is fixedly connected to the lower surface of the drive and control integrated board (2), and the drive and control integrated board (2), the power module (3) and the upper surface of the heat sink (5); characterized in that: The integrated thin-film capacitor module (1) adopts the integrated thin-film capacitor module as described in any one of claims 1 to 4, wherein the adapter copper busbar (12) of the integrated thin-film capacitor module passes through the copper busbar clearance hole and is located above the heat sink (5).

6. An electric machine controller comprising an electric control housing (6) and a power brick assembly (7) mounted on the electric control housing (6), characterized in that: The power brick assembly (7) adopts the power brick assembly as described in claim 5. The motor controller further includes a water pipe connector (8) with one end pressed into the power brick water channel interface (51) and the other end pressed into the water channel interface of the drive motor housing. The water pipe connector (8) is composed of a connecting pipe (81) and a rubber sleeve (82). The rubber sleeve (82) is vulcanized and fixed to the outer wall of the connecting pipe (81).

7. The motor controller of claim 6, wherein: Both ends of the rubber sleeve (82) are frustoconical, with the small end face of the frustoconical flush with the end face of the connecting pipe (81).

8. The motor controller of claim 7, wherein: The rubber sleeve (82) has multiple rings of protrusions (821) arranged axially on the outer sides of both ends.

9. The motor controller of claim 7, wherein: The rubber sleeve (82) has four rings of protrusions (821) on each of its two outer ends along the axial direction.

10. A vehicle characterized by: Including the motor controller as described in any one of claims 6 to 9.

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