A power module, inverter and vehicle
By introducing flexible metal connectors into the copper busbars, the problem of poor flexibility of the copper busbars is solved, enabling flexible connection and wide application of the copper busbars, reducing development costs, and improving the connection stability of the ceramic substrate.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- VITESCO AUTOMOTIVE (TIANJIN) CO LTD
- Filing Date
- 2025-03-28
- Publication Date
- 2026-06-09
AI Technical Summary
Existing rigid copper busbars have poor flexibility and cannot be bent, resulting in a single lead-out direction for the copper busbars, which limits the application range of power modules and leads to high development and testing costs and long cycles.
The flexible metal connector is formed by stacking multiple layers of copper foil, combined with rigid first and second metal connectors, to achieve the flexibility and ductility of the copper busbar, which can be bent to change the connection direction.
It enables flexible connection of copper busbars, has a wide range of applications, reduces development costs and time, and improves the connection stability of ceramic substrates, thus avoiding damage to the ceramic substrates.
Smart Images
Figure CN224342552U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of vehicle technology, and in particular to a power module inverter and a vehicle. Background Technology
[0002] Copper busbars have excellent electrical conductivity, good mechanical properties and corrosion resistance, and can withstand high current loads, making them widely used.
[0003] In new energy vehicles, power modules typically consist of power semiconductor devices, control circuits, and heat dissipation devices. The power module receives commands from the control unit and adjusts the magnitude and direction of the current to control the motor's speed and torque. Currently, commercially available copper busbars are made of rigid metal. Due to their high rigidity and poor flexibility, they cannot be bent or have their lead-out direction changed. This limited lead-out direction restricts their application range. For example, limitations imposed by the direction of the copper busbar connection result in inflexible power module applications. Different power modules need to be developed for different copper busbar lead-out directions, leading to high development and testing costs and long development cycles. Utility Model Content
[0004] The purpose of this invention is to solve the technical problem of poor flexibility in existing copper busbars. This invention provides a power module whose wiring copper busbars have good flexibility, can be bent to change the connection direction of the copper busbars, thereby meeting the needs of different copper busbar lead-out directions and having a wide range of applications.
[0005] To solve the above-mentioned technical problems, an embodiment of this utility model discloses a wiring copper busbar, comprising:
[0006] The first metal connector is used to be mounted on the power module;
[0007] A second metal connection portion is connected to the first metal connection portion, and the second metal connection portion is used to connect to a battery pack or a motor.
[0008] A flexible metal connector is disposed between the first metal connector and the second metal connector.
[0009] The above technical solution provides a flexible metal connection between the first metal connection and the second metal connection. The flexible metal connection has good flexibility and ductility, and can be bent to change the connection direction of the second metal connection (e.g., horizontal, vertical, inclined, etc.), which can meet the needs of different copper busbar lead-out directions and has a wide range of applications.
[0010] According to another specific embodiment of the present invention, an embodiment of the present invention discloses a wiring copper busbar, wherein the multi-layer copper foil is stacked to form the flexible metal connection part.
[0011] By adopting the above technical solution, a flexible metal connector is formed by stacking multiple layers of copper foil, which can ensure that the flexible metal connector has good conductivity and also has good flexibility and ductility at a lower cost.
[0012] According to another specific embodiment of the present invention, an embodiment of the present invention discloses a wiring copper busbar, wherein the thickness of each layer of copper foil is 0.08mm to 0.12mm.
[0013] The present invention also discloses a power module, which includes at least the wiring copper busbar in any of the above embodiments.
[0014] According to another specific embodiment of the present invention, a power module is disclosed, including a ceramic substrate, wherein a first metal connection portion is connected to the ceramic substrate.
[0015] Using the above technical solution, the first metal connector is connected to the ceramic substrate. When the second metal connector is used to connect to a battery pack or motor, due to dimensional tolerances, the second metal connector will be subjected to stress in different directions. Furthermore, without a flexible metal connector, this stress will be directly transmitted to the first metal connector, causing the connection between the first metal connector and the ceramic substrate to fail. Simultaneously, since the ceramic substrate itself is fragile, the failure of the connection between the first metal connector and the ceramic substrate is often accompanied by damage to the ceramic substrate. In the technical solution provided in this application, because a flexible metal connector is provided, the stress on the second metal connector will cause the flexible metal connector to move in the direction of the force, thereby preventing the stress from being transmitted to the first metal connector. This improves the stability of the connection between the first metal connector and the ceramic substrate, providing better protection for the ceramic substrate.
[0016] The present invention also discloses an inverter, wherein the power module includes at least the power module described in any of the above embodiments.
[0017] According to another specific embodiment of the present invention, an inverter is disclosed, comprising multiple power modules, each power module comprising:
[0018] The DC input terminal is provided with a plurality of copper busbars, and the second metal connection portion of each copper busbar is used to connect to the battery pack.
[0019] The AC output terminal is provided with the DC input terminal and the AC output terminal spaced apart. The AC output terminal is provided with at least one of the copper busbars, and the second metal connection part of the copper busbar is used to connect to the motor.
[0020] The present invention also discloses a vehicle in which the power module includes at least the inverter described in the above embodiments.
[0021] According to another specific embodiment of the present invention, an embodiment of the present invention discloses a vehicle including a battery pack and a motor, wherein the second metal connection portion of each of the copper busbars at the DC input terminal is connected to the battery pack, and the second metal connection portion of the copper busbars at the AC output terminal is connected to the motor. Attached Figure Description
[0022] Figure 1 A simplified schematic diagram of a vehicle provided in an embodiment of this application is shown.
[0023] Figure 2 A schematic diagram of a power module including a wiring copper busbar is shown in an embodiment of this application.
[0024] Figure 3 A perspective view of a power module including a wiring busbar is shown in some embodiments.
[0025] Figure 3a A schematic diagram of a wiring busbar is shown in some embodiments.
[0026] Figure 3b A schematic diagram of a wiring busbar for connecting to a motor or battery pack is shown in some embodiments.
[0027] Figure 4 A perspective view of a wiring copper busbar including a flexible metal connection portion provided in an embodiment of this application is shown.
[0028] Figure 5 A color perspective view of a power module including a flexible metal connector copper busbar provided in an embodiment of this application is shown.
[0029] Figure 6 A wireframe perspective view of a power module including a flexible metal connector copper busbar provided in an embodiment of this application is shown.
[0030] Figure 7 Another perspective view of a power module of a wiring busbar including a flexible metal connection portion, provided in an embodiment of this application, is shown.
[0031] Figure 8 A schematic diagram of the copper foil of the flexible metal connection portion of the wiring copper bus provided in an embodiment of this application is shown. Detailed Implementation
[0032] The following specific embodiments illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification. Although the description of this utility model will be presented in conjunction with preferred embodiments, this does not mean that the features of this utility model are limited to this embodiment. On the contrary, the purpose of describing the utility model in conjunction with the embodiments is to cover other options or modifications that may be derived based on the claims of this utility model. To provide a deep understanding of this utility model, many specific details will be included in the following description. This utility model may also be implemented without using these details. Furthermore, to avoid confusion or obscuring the focus of this utility model, some specific details will be omitted in the description. It should be noted that, without conflict, the embodiments and features in the embodiments of this utility model can be combined with each other.
[0033] It should be noted that in this specification, similar reference numerals and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.
[0034] In the description of this embodiment, it should be noted that the terms "upper", "lower", "inner", "bottom", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship that the utility model product is usually placed in during use. They are only for the convenience of describing the utility model and 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 the utility model.
[0035] The terms “first”, “second”, etc., are used only to distinguish descriptions and should not be interpreted as indicating or implying relative importance.
[0036] In the description of this embodiment, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set up," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this embodiment based on the specific circumstances.
[0037] To make the objectives, technical solutions, and advantages of this utility model clearer, the embodiments of this utility model will be described in further detail below with reference to the accompanying drawings.
[0038] Copper busbars, also known as copper busbars or copper busbars, are long conductors made of copper with a rectangular or chamfered (rounded) rectangular cross-section. The use of rounded corners on copper busbars can prevent the generation of point discharge. Copper busbars play the role of transmitting current and connecting electrical equipment in circuits and have a wide range of applications.
[0039] See Figure 1 , Figure 2 This application provides a vehicle including an inverter, a battery pack, and a motor. The inverter includes multiple power modules 10, each power module 10 including a DC input terminal 101 and an AC output terminal 102, which are spaced apart. The DC input terminal 101 is connected to the battery pack, and the AC output terminal 102 is connected to the motor.
[0040] In some embodiments, see Figure 2 , Figure 3 , Figure 3a Each power module 10 includes a copper busbar 11 and a ceramic substrate (not shown in the figure). Exemplarily, the copper busbar 11 includes a first metal connection portion 111 and a second metal connection portion 112, and the first metal connection portion 111 is connected to the ceramic substrate (e.g., soldered).
[0041] For example, both the first metal connection 111 and the second metal connection 112 are rigid connections. Rigidity can be understood as having high hardness and rigidity, and almost no bendability. For example, the first metal connection 111 and the second metal connection 112 can be formed by stamping copper material.
[0042] In essence, a ceramic substrate refers to a special type of board where copper foil is directly bonded to the surface (single-sided or double-sided) of an alumina (Al2O3) or aluminum nitride (AlN) ceramic substrate at high temperatures. It possesses excellent electrical insulation properties, high thermal conductivity, superior solderability, and high adhesion strength. Like a PCB board, it can be etched with various patterns and has a large current-carrying capacity. Ceramic substrates exhibit the property of fracturing and breaking under external forces (such as tension or impact) with only minimal deformation.
[0043] In some embodiments, see Figure 2 , Figure 3 , Figure 3a and combined Figure 1The first metal connector 111 is connected to the ceramic substrate. The first metal connector 111 and the second metal connector 112 are directly connected. There is no flexible metal connector 113 between the first metal connector 111 and the second metal connector 112. When the second metal connector 112 is used to connect to the battery pack or motor, due to dimensional tolerances, the second metal connector 112 will be subjected to stress in different directions. Furthermore, without a flexible metal connector, this stress will be directly transmitted to the first metal connector 111, causing the connection between the first metal connector 111 and the ceramic substrate to fail. At the same time, since the ceramic substrate itself is easily broken, the failure of the connection between the first metal connector 111 and the ceramic substrate is often accompanied by damage to the ceramic substrate.
[0044] In some embodiments, see Figure 2 , Figure 3a , Figure 3b and combined Figure 1 The first metal connection portion 111 includes a first threaded hole 1111, and the second metal connection portion 112 includes a second threaded hole 1121. Both the first threaded hole 1111 and the second threaded hole 1121 are used for inserting a connector (e.g., a bolt) to achieve connection with other components (e.g., a battery pack or a motor).
[0045] For example, Figure 3b This diagram illustrates the connection between the wiring busbar 11 and the connecting busbar 20 for the motor or battery pack, as provided in an embodiment of this application. In mechanical design and manufacturing processes, dimensional tolerances are unavoidable; therefore, as... Figure 3b As shown, there is a gap 21 between the wiring copper busbar 11 and the connecting copper busbar 20. When bolts or other connecting parts are inserted into the threaded holes of the connecting copper busbar 20 and the threaded holes of the wiring copper busbar 11 (e.g., the first threaded hole 1111 or the second threaded hole 1121) in sequence and are in a tightened state, the wiring copper busbar 11 will be subjected to stress in the vertical direction X. If this stress is directly transmitted to the first metal connection part 111, the connection between the first metal connection part 111 and the ceramic substrate will fail.
[0046] Based on this, see Figure 4 , Figure 5 , Figure 6 and combined Figure 1 This application provides a wiring copper busbar 11, including a first metal connection portion 111, a second metal connection portion 112, and a flexible metal connection portion 113. The flexible metal connection portion 113 is disposed between the first metal connection portion 111 and the second metal connection portion 112. The first metal connection portion 111, the flexible metal connection portion 113, and the second metal connection portion 112 are connected sequentially. The first metal connection portion 111 is connected to a ceramic substrate, and the second metal connection portion 112 is used to connect to a battery pack or a motor.
[0047] The above technical solution provides a flexible metal connection 113 between the first metal connection 111 and the second metal connection 112. The flexible metal connection 113 has good flexibility and extensibility and can be bent to change the connection direction of the second metal connection 112 (e.g., horizontal Y, vertical X, inclined Z, etc.), which can meet the needs of different lead-out directions of the wiring copper busbar 11 and has a wide range of applications.
[0048] For example, see Figure 4 , Figure 5 , Figure 6 and combined Figure 1 The power module 10 has a DC input terminal 101 with multiple first copper busbars 1101, and the second metal connection portion 112 of each first copper busbar 1101 is used to connect to the battery pack. The power module 10 has an AC output terminal 102 with at least one second copper busbar 1102, and the second metal connection portion 112 of the second copper busbar 1102 is used to connect to the motor. Figure 6 As can be seen, the power module 10 extends along the horizontal direction Y, and the flexible metal connection part 113 of the second wiring copper busbar 1102 can be bent perpendicular to the horizontal direction Y, thereby changing the connection direction of the second metal connection part 112, thus meeting the needs of different lead-out directions of the wiring copper busbar 11 and having a wide range of applications.
[0049] Understandably, this application does not limit the bending direction of the flexible metal connector 113, and it also does not limit the connection direction of the first copper busbar 1101 or the second copper busbar 1102 in the power module 10, for example... Figure 7 As shown, the flexible metal connection part 113 of the first wiring copper busbar 1101 can also be bent perpendicular to the horizontal direction Y.
[0050] In some embodiments, see Figure 4 , Figure 5 , Figure 6 and combined Figure 1 The inverter includes three power modules 10, which output three-phase AC power, for example, the three power modules 10 output phase A, phase B, and phase C AC power respectively. Each power module 10 has three spaced-apart first copper busbars 1101 at its DC input terminal 101, where any two first copper busbars 1101 are positive and the other is negative, used to input the DC power from the battery pack into the power module 10. Each power module 10 has one second copper busbar 1102 at its DC output terminal, used to output the AC power generated by the power module 10 to the motor.
[0051] In some embodiments, see Figure 4 , Figure 5 , Figure 8 and combined Figure 1 The copper busbar 11 includes multiple layers of copper foil 1131, which are stacked to form a flexible metal connection portion 113. Exemplarily, the copper busbar 11 is formed by stacking multiple layers of copper foil 1131, and rigid first metal connection portions 111 and second metal connection portions 112 are formed by stamping at both ends of the copper foil 1131. Exemplarily, the thickness of each layer of copper foil 1131 is 0.08 mm to 0.12 mm. It is understood that the embodiments of this application do not limit the thickness of each layer of copper foil 1131, for example, it can be 0.08 mm, 0.09 mm, 0.10 mm, 0.12 mm, etc.
[0052] Although the present invention has been illustrated and described with reference to certain preferred embodiments, those skilled in the art should understand that the above description is a further detailed explanation of the present invention in conjunction with specific embodiments, and should not be construed as limiting the specific implementation of the present invention to these descriptions. Those skilled in the art can make various changes in form and detail, including some simple deductions or substitutions, without departing from the spirit and scope of the present invention.
Claims
1. A power module, characterized in that, The system includes a copper busbar and a ceramic substrate, wherein the copper busbar includes: A first metal connection portion is provided on the power module, and the first metal connection portion is connected to the ceramic substrate; A second metal connection portion is connected to the first metal connection portion, and the second metal connection portion is used to connect to a battery pack or a motor. A flexible metal connector is disposed between the first metal connector and the second metal connector.
2. The power module as described in claim 1, characterized in that, It includes multiple layers of copper foil, which are stacked to form the flexible metal connection.
3. The power module as described in claim 2, characterized in that, The thickness of each layer of copper foil is from 0.08 mm to 0.12 mm.
4. An inverter, characterized in that, Includes the power module as described in any one of claims 1 to 3.
5. The inverter as described in claim 4, characterized in that, It includes multiple power modules, each of which includes: The DC input terminal is provided with a plurality of copper busbars, and the second metal connection portion of each copper busbar is used to connect to the battery pack. The AC output terminal is provided with the DC input terminal and the AC output terminal spaced apart. The AC output terminal is provided with at least one of the copper busbars, and the second metal connection part of the copper busbar is used to connect to the motor.
6. A vehicle, characterized in that, Including the inverter as described in claim 5.
7. The vehicle as described in claim 6, characterized in that, The device includes a battery pack and a motor. The second metal connection portion of each of the copper busbars at the DC input terminal is connected to the battery pack, and the second metal connection portion of the copper busbars at the AC output terminal is connected to the motor.