Power module structure

Abstract

A power module structure includes: a top cover having an opening; a bracket fixed to the top cover, the bracket having a threaded groove, a first handle and a second handle; a gasket set located between the bracket and the top cover, and an inner diameter of the opening is smaller than an outer diameter of the gasket set; and a screw threaded through the gasket set and the threaded groove.

Description

Technical Field

[0001] This application relates to a power module, and more particularly to a power module structure that prevents screws from falling off. Background Technology

[0002] The grounding cable terminals of power module products are secured to the terminal block with screws. However, existing screws are prone to loosening and falling off, and the grounding cable lacks directional control during insertion and removal. Furthermore, current power modules are relatively large. To achieve space efficiency and meet the demands of high density and high wattage, a smaller power module design is needed. This results in a more compact internal component configuration, potentially causing interference with other components if the grounding cable is inserted incorrectly. Additionally, loose screws that fall into the module are difficult to remove. Therefore, a new power module structural design is required to address these issues. Utility Model Content

[0003] To address the problems of the aforementioned prior art, the purpose of this application is to provide a power module structure that can effectively solve the problems of screws falling off and grounding cables being inserted incorrectly in the prior art.

[0004] To achieve the above objectives, this application provides a power module structure, comprising: a top cover having an opening; a bracket fixed to the top cover and having a threaded groove, a first handle and a second handle; a gasket assembly located between the bracket and the top cover and having an inner diameter of the opening smaller than the outer diameter of the gasket assembly; and a screw passing through the gasket assembly and the threaded groove.

[0005] In one embodiment of this application, the screw has a head and a stud, the stud being adapted to engage with the threaded groove, the stud having a threadless area and a threaded area, the threadless area being located between the head and the threaded area.

[0006] In one embodiment of this application, the thickness of the gasket group plus the length of the threaded area is greater than the distance between the top cover and the bracket.

[0007] In one embodiment of this application, the length of the threaded area plus the length of the unthreaded area equals the thickness of the gasket set plus the thickness of the terminal lug of a grounding cable and the depth of the threaded groove.

[0008] In one embodiment of this application, the outer diameter of the plug head is smaller than the inner diameter of the opening.

[0009] In one embodiment of this application, the bracket has a connecting portion that connects the first handle and the second handle and provides the threaded groove, and there is an acute angle between the normal direction of the surface of the connecting portion and the normal direction of the surface of the top cover.

[0010] In one embodiment of this application, the bracket further includes a nut fixed to the connecting portion to form the threaded groove.

[0011] In one embodiment of this application, the bracket further includes a protrusion located on the first handle and a notch located on the second handle.

[0012] In one embodiment of this application, the power module structure is adapted to fix a grounding cable, the grounding cable having a terminal lug adapted to be inserted into the power module structure and the terminal lug being clamped between the washer set and the bracket by the screw, the terminal lug having a folded edge configured to be inserted into the notch.

[0013] In one embodiment of this application, the terminal lug is configured such that when the terminal lug is inserted into the power module structure in the reverse direction, the folded edge interferes with the protrusion.

[0014] In one embodiment of this application, the gasket assembly includes a flat washer and a toothed washer.

[0015] Compared to prior art, the inner diameter of the opening in this application is smaller than the outer diameter of the washer assembly, thus avoiding the problem of screws falling out in prior art. The stud in this application has a threadless area and a threaded area, with the threadless area located between the stud head and the threaded area, providing better screw prevention. The bracket in this application also includes a protrusion on the first handle and a notch on the second handle. The terminal lug of the grounding cable has a folded edge configured to insert into the notch, so that when the terminal lug is inserted backwards into the power module structure, the folded edge interferes with the protrusion, thus avoiding the problem of reverse insertion of the grounding cable. Attached Figure Description

[0016] Figure 1 This is a three-dimensional structural schematic diagram of a power module structure according to one embodiment of the present application;

[0017] Figure 2 Show Figure 1 A partial exploded view of the power module structure in the diagram;

[0018] Figure 3 Show Figure 1 A top view of the power module structure after the grounding cable has been connected;

[0019] Figure 4 Show Figure 3 A cross-sectional view of the power module structure along line AA.

[0020] Figure 5 Show Figure 4 A magnified view of the area within the dashed box;

[0021] Figure 6Show Figure 5 A magnified view of the power module structure after the screws have been loosened;

[0022] Figure 7 This is a three-dimensional structural diagram of the bracket and grounding cable according to one embodiment of the present application;

[0023] Figure 8 Show Figure 1 A side view and a partially enlarged view of the power module structure after it has been connected to the grounding cable;

[0024] Figure 9 Show Figure 4 A magnified view of the area within the dashed box;

[0025] Figure 10 This diagram illustrates an application schematic of a power module structure according to one embodiment of the present application.

[0026] Figure 11 Show Figure 10 A schematic diagram illustrating the application of loosening screws in the middle;

[0027] Figure 12 This diagram illustrates the correct insertion of the terminal lugs of the grounding cable into the bracket according to one embodiment of this application.

[0028] Figure 13 A schematic diagram showing the reverse insertion of the terminal lugs of the grounding cable into the bracket according to one embodiment of this application;

[0029] Figure 14 The diagram shows top and side or cross-sectional views of a gasket assembly according to one embodiment of the present application.

[0030] Explanation of reference numerals in the attached figures

[0031] 1: Power module structure,

[0032] 10: Top cover

[0033] 11: Opening,

[0034] 20: Bracket,

[0035] 21: Threaded groove,

[0036] 22: First handle,

[0037] 221: Protrusion,

[0038] 23: Second handle

[0039] 231: Notch

[0040] 24: Connecting parts,

[0041] 30: Gasket set

[0042] 31: Flat washer,

[0043] 32: Perforated washer,

[0044] 40: Screws

[0045] 41: Bolt head,

[0046] 42: Stud,

[0047] 42n: Unpatterned area

[0048] 42t: Threaded area

[0049] 50: Grounding cable

[0050] 51: Terminal lug,

[0051] 511: Folded edge,

[0052] 60: Nuts

[0053] a1: acute angle

[0054] d1, d2, d3: distance,

[0055] dn1, dn2: Normal direction

[0056] lt, ln: length,

[0057] p1: Depth

[0058] r1: inner diameter,

[0059] r2, r3: outer diameter,

[0060] t1, t2: thickness. Detailed Implementation

[0061] To make the above and other objects, features, and advantages of this application more apparent and understandable, preferred embodiments of this application will be described in detail below with reference to the accompanying drawings. Furthermore, in the drawings, structurally similar units are denoted by the same reference numerals.

[0062] Reference Figure 1 and Figure 2 , Figure 1 A three-dimensional structural diagram of a power module structure according to one embodiment of this application is shown. Figure 2 Show Figure 1 A partially exploded view of the power module structure. This application provides a power module structure 1, including a top cover 10, a bracket 20, a gasket assembly 30, and a screw 40. The top cover 10 has an opening 11. (Refer to...) Figures 2 to 4 , Figure 3Show Figure 1 A top view of the power module structure after the grounding cable has been connected. Figure 4 Show Figure 3 The diagram shows a cross-sectional view of the power module structure along line AA. The bracket 20 is fixed to the upper cover 10 and has a threaded groove 21, a first handle 22, and a second handle 23. (Refer to...) Figures 4 to 6 , Figure 5 Show Figure 4 A magnified view of the area within the dashed box. Figure 6 Show Figure 5 The diagram shows a partially enlarged view of the power module structure after the screws have been loosened. The washer assembly 30 is located between the bracket 20 and the top cover 10, and the inner diameter r1 of the opening 11 is smaller than the outer diameter r2 of the washer assembly 30. The screw 40 passes through the washer assembly 30 and the threaded groove 21.

[0063] Specifically, since the inner diameter r1 of the opening 11 is smaller than the outer diameter r2 of the washer group 30, when the user loosens the screw 40, as long as the screw 40 has not been screwed out of the washer group 30, the interference between the washer group 30 and the opening 11 can ensure that the screw 40 will not fall out of the top cover 10.

[0064] Specifically, the power module structure 1 is designed such that after the bracket 20 and the top cover 10 are joined (riveted, locked, or welded), the gasket assembly 30 is placed in the space between the bracket 20 and the top cover 10, and the screw 40 passes through the opening 11 from top to bottom through the gasket assembly 30 and locks into the threaded groove 21. This facilitates the production of the power module structure 1 and avoids overly complex designs that would increase the difficulty of producing the power module structure 1.

[0065] Reference Figure 5 In one embodiment of this application, the screw 40 has a head 41 and a stud 42, the stud 42 being adapted to engage with the threaded groove 21. The stud 42 has a threadless region 42n and a threaded region 42t, with the threadless region 42n located between the head 41 and the threaded region 42t. The outer diameter r3 of the head 41 is smaller than the inner diameter r1 of the opening 11.

[0066] Specifically, the stud 42 is provided with a threadless area 42n and a threaded area 42t, with the threadless area 42n located between the stud head 41 and the threaded area 42t. This allows the washer assembly 30 to easily interfere with the threaded area 42t and remain in the position of the threadless area 42n when the user unscrews the screw 40. This means that if the user attempts to further loosen the screw 40, the threaded area 42t will push the washer assembly 30 to interfere with the opening 11, preventing the screw 40 from being unscrewed. Furthermore, the user will feel an interfering force making the screw 40 difficult to turn, thus reminding the user not to turn the screw 40 further. In one embodiment of this application, the length lt of the threaded area 42t plus the length ln of the threadless area 42n is equal to the thickness t1 of the washer assembly 30 plus the thickness t2 of the terminal lug 51 of the grounding cable 50 and the depth p1 of the threaded groove 21.

[0067] Specifically, the above design ensures that when the screw 40 engages and tightens the terminal lug 51 of the grounding cable 50, the lower edge of the screw 40 will not protrude beyond the nut 60. This is to prevent the screw 40 from interfering with or damaging other components when tightened.

[0068] Reference Figure 6 In one embodiment of this application, the thickness t1 of the gasket group 30 plus the length lt of the threaded area 42t is greater than the distance d1 between the top cover 10 and the bracket 20. This design ensures that when the threaded area 42t pushes the gasket group 30 to interfere with the opening 11 during the process of the user unscrewing the screw 40, a portion of the threaded area 42t still engages with the threaded groove 21, preventing the screw 40 from easily falling out of the opening 11.

[0069] Refer to together Figure 10 and Figure 11 . Figure 10 A schematic diagram illustrating the application of a power module structure according to one embodiment of this application is shown. Figure 11 Show Figure 10 A schematic diagram illustrating the application of loosening screws. (Example) Figure 10 As shown, when applying power module structure 1, reducing the size of the power module to meet space efficiency and high-density, high-wattage requirements will lead to the problem of interference between screw 40 and other components due to the compact internal component configuration. Figure 10 In the design, the bottom of the screw 40 is spaced d2 away from other components to avoid interference when the screw 40 is tightened. In one embodiment, d2 is greater than 2mm to meet the electrical insulation requirements of the power module structure.

[0070] Reference Figure 7 , Figure 7A perspective view of the bracket and grounding cable according to one embodiment of this application is shown. In one embodiment of this application, the bracket 20 has a connecting portion 24 connecting the first handle 22 and the second handle 23 and providing the threaded groove 21.

[0071] Reference Figures 8 to 9 . Figure 8 Show Figure 1 The diagram shows a side view and a partially enlarged view of the power module structure after it has been connected to the grounding cable. Figure 9 Show Figure 4 A partially enlarged schematic diagram of the area within the dashed box. In one embodiment of this application, an acute angle α1 exists between the normal direction dn1 of the surface of the connecting portion 24 and the normal direction dn2 of the surface of the upper cover 10.

[0072] Specifically, the surface of the connecting portion 24 is typically set to be parallel to the upper surface of the screw 40 when it is tightened. Therefore, the normal direction dn1 of the surface of the connecting portion 24 is also the normal direction of the upper surface of the screw 40. Specifically, the upper cover 10 is only designed to be inclined relative to the surface of the connecting portion 24 near the opening 11. The design intention of having an acute angle a1 between the normal direction dn1 of the surface of the connecting portion 24 and the normal direction dn2 of the surface of the upper cover 10 is to ensure that when the user unscrews the screw 40, the threaded area 42t will push the washer assembly 30 to interfere with the upper cover 10, causing the washer assembly 30 to tilt. This will reduce the cross-sectional size of the opening of the washer assembly 30 relative to the cross-section of the stud 42. The screw 40 will be less likely to be unscrewed from the washer assembly 30, giving the washer assembly 30 a higher chance of remaining in the unthreaded area 42n of the stud 42 and preventing it from falling out of the opening 11.

[0073] Reference Figure 4 and Figure 7 In one embodiment of this application, the bracket 20 further includes a nut 60 fixed to the connecting portion 24 to form the threaded groove 21.

[0074] Specifically, the threaded groove 21 can be directly formed in the connecting portion 24 of the bracket 20. However, the thickness of the connecting portion 24 is usually not large, which may result in insufficient depth of the threaded groove 21, making it impossible for the screw 40 to be tightened. Therefore, in one embodiment, a nut 60 can be fixed (riveted or welded) to the connecting portion 24 to form the threaded groove 21.

[0075] Reference Figure 7 In one embodiment of this application, the bracket 20 further includes a protrusion 221 located on the first handle 22 and a notch 231 located on the second handle 23.

[0076] Figure 12This diagram illustrates the correct insertion of the terminal lugs of the grounding cable into the bracket according to one embodiment of this application, with reference to... Figure 4 , Figure 7 and Figure 12 In one embodiment of this application, the power module structure 1 is adapted to fix a grounding cable 50, the grounding cable 50 having a terminal lug 51 adapted to be inserted into the power module structure 1 and the terminal lug 51 being clamped between the washer group 30 and the bracket 20 by the screw 40, the terminal lug 51 having a folded edge 511 configured to be inserted into the notch 231.

[0077] Specifically, the folded edge 511 of the terminal lug 51 cooperates with the notch 231 to prevent the terminal lug 51 from being inserted backwards, which is a foolproof design.

[0078] Specifically, refer to Figure 13 , Figure 13 This diagram illustrates a grounding cable terminal lug inserted into a bracket in reverse according to one embodiment of the present application. In one embodiment, the terminal lug 51 is configured such that when the terminal lug 51 is inserted in reverse into the power module structure 1, the folded edge 511 interferes with the protrusion 221.

[0079] Specifically, by Figure 13 As can be seen, due to the interference between the folded edge 511 and the protrusion 221, the terminal lug 51 cannot be inserted into the threaded groove 21. Because of this interference, when the user attempts to insert the terminal lug 51 between the bracket 20 and the top cover 10, not only can the terminal lug 51 not be inserted, but it also tilts and cannot be placed flat. This serves as a foolproof design to remind the user to pay attention to the insertion direction.

[0080] For details, please refer to the following: Figure 10 When applying power module structure 1, reducing the size of the power module to meet space efficiency and high-density, high-wattage requirements presents a problem: the compact internal component configuration can lead to interference between the grounding cable and other components when the cable is inserted incorrectly. For example... Figure 10 As shown, the distance d3 between the correctly inserted terminal lug 51 and the component below is very small. If the terminal lug 51 is inserted in reverse, it will damage the component below.

[0081] Figure 14 The diagram shows top and side or cross-sectional views of a gasket assembly according to one embodiment of this application, with reference to... Figure 5 and Figure 14In one embodiment of this application, the gasket assembly 30 includes a flat washer 31 and a toothed washer 32. Specifically, the toothed washer 32 provides a positive force for tightening the screw 40 and ensures electrical continuity of the grounding cable. The flat washer 31 provides a larger contact area and generates greater friction, preventing the screw 40 from loosening.

[0082] Compared to prior art, the inner diameter of the opening in this application is smaller than the outer diameter of the washer assembly, thus avoiding the problem of screws falling out in prior art. The stud in this application has a threadless area and a threaded area, with the threadless area located between the stud head and the threaded area, providing better screw prevention. The bracket in this application also includes a protrusion on the first handle and a notch on the second handle. The terminal lug of the grounding cable has a folded edge configured to insert into the notch, so that when the terminal lug is inserted backwards into the power module structure, the folded edge interferes with the protrusion, thus avoiding the problem of reverse insertion of the grounding cable.

[0083] The above description of preferred embodiments illustrates the features of this application. Its purpose is to enable those skilled in the art to understand the content of this application and implement it accordingly, rather than to limit the patent scope of this application. Therefore, any equivalent modifications or alterations made without departing from the technical concept shown in this application should still be included in the patent scope described below.

Claims

1. A power module structure, characterized in that, Include: The top cover has an opening; A bracket is fixed to the top cover and the bracket has a threaded groove, a first handle and a second handle; A gasket assembly, located between the bracket and the top cover, wherein the inner diameter of the opening is smaller than the outer diameter of the gasket assembly; and A screw is inserted into the washer assembly and the threaded groove.

2. The power module structure according to claim 1, characterized in that, The screw has a head and a stud, the stud being adapted to engage with the threaded groove, the stud having a threadless area and a threaded area, the threadless area being located between the head and the threaded area.

3. The power module structure according to claim 2, characterized in that, The thickness of the gasket assembly plus the length of the threaded area is greater than the distance between the top cover and the bracket.

4. The power module structure according to claim 2, characterized in that, The length of the threaded area plus the length of the unthreaded area equals the thickness of the gasket set plus the thickness of the terminal lug of a grounding cable and the depth of the threaded groove.

5. The power module structure according to claim 2, characterized in that, The outer diameter of the plug head is smaller than the inner diameter of the opening.

6. The power module structure according to claim 1, characterized in that, The bracket has a connecting portion that connects the first handle and the second handle and provides the threaded groove. The normal direction of the surface of the connecting portion has an acute angle with the normal direction of the surface of the top cover.

7. The power module structure according to claim 6, characterized in that, The bracket also includes a nut that is fixed to the connection to form the threaded groove.

8. The power module structure according to claim 1, characterized in that, The bracket also includes a protrusion located on the first handle and a notch located on the second handle.

9. The power module structure according to claim 8, characterized in that, Suitable for fixing a grounding cable, the grounding cable having a terminal lug adapted to be inserted into the power module structure and the terminal lug being clamped between the washer set and the bracket by the screw, the terminal lug having a folded edge configured to be inserted into the notch.

10. The power module structure according to claim 9, characterized in that, The terminal lug is configured such that when the terminal lug is inserted into the power module structure in the reverse direction, the folded edge interferes with the protrusion.

11. The power module structure according to claim 1, characterized in that, The gasket assembly includes a flat washer and a toothed washer.

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