Double-outline vehicle-mounted capacitor fixing structure

Abstract

This utility model relates to a dual-outlet vehicle-mounted capacitor fixing structure, including a film capacitor and an inverter brick housing. A plastic baffle is provided on the inverter brick housing. The film capacitor is encapsulated inside the inverter brick housing through the plastic baffle. The plastic baffle includes a first plastic baffle, a second plastic baffle, a third plastic baffle, and a fourth plastic baffle. The first and second plastic baffles are positioned between the film capacitor and the power module of the inverter brick. The third plastic baffle is connected to the inverter brick housing via a slot. The fourth plastic baffle is fixed to the inverter brick housing with mounting bolts. Compared with the prior art, this utility model achieves reduced space and weight while ensuring heat dissipation efficiency, solving the heat dissipation and space design problems of installing high-performance capacitors in a limited space.

Description

Technical Field

[0001] This utility model relates to the field of inverters for new energy vehicles, and in particular to a fixed structure for a dual-outlet vehicle-mounted capacitor. Background Technology

[0002] Currently, the technology of motor controllers for new energy vehicles is undergoing a profound transformation, with its core development trend increasingly leaning towards miniaturization, multi-functionality, and thinness to meet the vehicle's higher requirements for space utilization and improved energy conversion efficiency. This trend also compels the design and production of inverter components to keep pace, continuously moving towards miniaturization, thinness, high integration, and multi-functionality.

[0003] In the common-shell integrated module solution, the inverter's shell material is aluminum alloy. The metal shell has a significant advantage in capacitor heat dissipation due to its excellent thermal conductivity, effectively reducing the product's thermal resistance.

[0004] However, using metal for the entire inverter housing presents another problem. To meet the insulation gap and creepage distance requirements between the capacitor copper busbars and the metal housing under high power conditions, the required potting space for the capacitors would increase. However, due to the limited structural space of the inverter, this requirement is difficult to meet.

[0005] Metal casings not only increase the manufacturing cost and weight of the entire machine, but also make it difficult to minimize the volume in order to ensure safety clearances, which increases the amount of glue used, further increasing the cost and weight.

[0006] Using plastic components not only provides insulation but also reduces weight. For example, patent application CN116525302A discloses an automotive drive film capacitor. This automotive drive film capacitor improves the capacitor structure by directly attaching the positive and negative copper busbars to both sides of the capacitor core, allowing them to directly match the target interface. However, this automotive drive film capacitor cannot solve the problem of the relatively large required potting space for the capacitor and the limited structural space of the inverter under high power conditions. Utility Model Content

[0007] The purpose of this utility model is to overcome the defects of the existing technology and provide a dual-outlet vehicle-mounted capacitor fixing structure, which can stably connect the power module in the inverter brick, reduce space and weight while ensuring heat dissipation efficiency, and solve the heat dissipation and space design problems of installing high-performance capacitors in a limited space.

[0008] The objective of this utility model can be achieved through the following technical solutions:

[0009] A dual-outlet vehicle-mounted capacitor fixing structure includes a film capacitor and an inverter brick housing. A plastic baffle is provided on the inverter brick housing. The film capacitor is encapsulated inside the inverter brick housing through the plastic baffle. The plastic baffle includes a first plastic baffle, a second plastic baffle, a third plastic baffle, and a fourth plastic baffle. The first and second plastic baffles are disposed between the film capacitor and the power module of the inverter brick. The third plastic baffle is connected to the inverter brick housing through a slot provided on the inverter brick housing. The fourth plastic baffle is fixed to the inverter brick housing by mounting bolts.

[0010] Furthermore, the cross-section of the third plastic baffle is L-shaped, and the horizontal third plastic baffle adopts a jigsaw puzzle-style snap-fit ​​shape.

[0011] Furthermore, the thin-film capacitor includes a capacitor core, a negative copper busbar, a positive copper busbar, and insulating paper, wherein the capacitor core is connected to the negative copper busbar and the positive copper busbar by welding.

[0012] Furthermore, the widths of the capacitor's negative copper busbar and positive copper busbar match the dimensions of the capacitor core.

[0013] Furthermore, the capacitor cores are arranged in two regular vertical columns, and the top center of each capacitor core is a housing water channel, the direction of which is parallel to the arrangement direction of the capacitor cores.

[0014] Furthermore, the insulating paper includes a first insulating paper, a second insulating paper, a third insulating paper, a fourth insulating paper, and a fifth insulating paper, which are interlaced between the intersecting negative copper busbar and the positive copper busbar of the capacitor.

[0015] Furthermore, the capacitor negative copper busbar includes the capacitor input terminal negative terminal, the capacitor core welded copper busbar negative terminal, and the capacitor power module input terminal negative terminal.

[0016] Furthermore, the positive copper busbar of the capacitor includes the positive terminal of the capacitor input terminal, the positive terminal of the copper busbar welded to the capacitor core, and the positive terminal of the input terminal of the capacitor power module.

[0017] Furthermore, the negative terminal and the positive terminal of the capacitor power module input are C-shaped vertically bent structures.

[0018] Furthermore, the negative terminal of the capacitor power module input terminal and the positive terminal of the capacitor power module input terminal are arranged in a double-layer copper busbar distribution structure with vertical wiring.

[0019] Compared with the prior art, the present invention has the following beneficial effects:

[0020] 1. This utility model provides a plastic baffle on the inverter brick housing. The plastic baffle is installed on the inverter brick housing by bolts and by a slot, which is easy to install and can also achieve insulation and protect the capacitor. By combining the plastic baffle with the inverter brick housing, the film capacitor is encapsulated inside the inverter brick housing. This solves the problem that the encapsulation space of the capacitor increases under high power conditions and the structural space of the inverter is limited.

[0021] 2. This utility model arranges the positive copper busbar and negative copper plate of the capacitor on both sides of the thin-film capacitor, allowing the power module to be distributed in a stacked manner. This greatly reduces the problem of the power module occupying too much space due to the previous copper busbar wiring method. It ensures the feasibility of a compact water channel for heat dissipation of the power module and the capacitor body. Furthermore, by setting a shell water channel at the top center of the capacitor core, the capacitor is directly encapsulated with the shell, reducing the overall height of the capacitor, improving the heat dissipation efficiency and stability of the capacitor, and preventing the risk of thermal runaway due to heat accumulation. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of a dual-outlet vehicle-mounted capacitor fixing structure proposed in this utility model;

[0023] Figure 2 This is an exploded view of a dual-outlet vehicle-mounted capacitor fixing structure proposed in this utility model;

[0024] Figure 3 Here are schematic diagrams of the structure of the plastic baffles, where (3a) is a schematic diagram of the structure of the fourth plastic baffle, (3b) is a schematic diagram of the structure of the second plastic baffle, (3c) is a schematic diagram of the structure of the third plastic baffle, and (3d) is a schematic diagram of the structure of the first plastic baffle.

[0025] Figure 4 Here are schematic diagrams of a film capacitor, where (4a) is a structural schematic diagram of the film capacitor and (4b) is an exploded view of the film capacitor;

[0026] Figure 5 Here are schematic diagrams of the copper busbar of the capacitor negative electrode, where (5a) is a structural schematic diagram of the copper busbar of the capacitor negative electrode, and (5b) is an exploded view of the copper busbar of the capacitor negative electrode.

[0027] Figure 6 Here are schematic diagrams of the positive copper busbar of the capacitor, where (6a) is a structural schematic diagram of the positive copper busbar of the capacitor, and (6b) is an exploded view of the positive copper busbar of the capacitor.

[0028] Legend: 1. Fourth plastic baffle; 2. Second plastic baffle; 3. Third plastic baffle; 4. Film capacitor; 41. Capacitor core; 42. First insulating paper; 43. Second insulating paper; 44. Capacitor negative copper busbar; 441. Capacitor input terminal negative terminal; 442. Capacitor core welded copper busbar negative terminal; 443. Capacitor power module input terminal negative terminal; 45. Third insulating paper; 46. Fourth insulating paper; 47. Capacitor positive copper busbar; 471. Capacitor input terminal positive terminal; 472. Capacitor core welded copper busbar positive terminal; 473. Capacitor power module input terminal positive terminal; 48. Fifth insulating paper; 5. Inverter brick housing; 6. First plastic baffle; 7. Mounting bolts. Detailed Implementation

[0029] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. This embodiment is based on the technical solution of the present invention and provides detailed implementation methods and specific operating procedures; however, the scope of protection of the present invention is not limited to the following embodiments.

[0030] Example 1

[0031] This embodiment provides a dual-outlet vehicle-mounted capacitor fixing structure, such as... Figure 1 As shown, it includes a thin-film capacitor 4 and an inverter brick housing 5. A plastic baffle is provided on the inverter brick housing 5, and the thin-film capacitor 4 is encapsulated inside the inverter brick housing 5 through the plastic baffle.

[0032] To accommodate the installation of the film capacitor 4 and subsequent potting process, we applied a special frosting treatment to the inner surface of the inverter brick housing 5 to improve the bonding strength between the potting material and the housing. Furthermore, a plastic baffle was designed to assemble with the inverter brick housing 5 to form a closed potting space. The plastic baffle includes a first plastic baffle 6, a second plastic baffle 2, a third plastic baffle 3, and a fourth plastic baffle 1, as shown below. Figure 2 As shown, the first plastic baffle 6 and the second plastic baffle 2 are disposed between the film capacitor 4 and the power module of the inverter brick. The third plastic baffle 3 is connected to the inverter brick housing 5 via a slot on the housing 5. The fourth plastic baffle 1 is fixed to the inverter brick housing 5 by mounting bolts 7. The structure of the first plastic baffle 6 is as follows: Figure 3 As shown in (3a); the structure of the second plastic baffle 2 is as follows Figure 3 As shown in (3b); the structure of the third plastic baffle 3 is as follows Figure 3 As shown in (3c), the cross-section of the third plastic baffle 3 is L-shaped, and the horizontal third plastic baffle 3 adopts a jigsaw puzzle-style snap-fit ​​shape; the structure of the fourth plastic baffle 1 is as follows Figure 3 As shown in (3d).

[0033] Since the inverter brick contains dual power modules with an upper and lower structure, and considering that the capacitor terminals need to be connected to the power modules, the capacitor is designed to be installed on the side, taking into account the ease of installation and practicality of operation.

[0034] The plastic baffle used to separate the film capacitor 4 from the power module is installed using a pin-slot insertion method. The first plastic baffle 6 is inserted straight into the inverter brick housing 5. The third plastic baffle 3, inserted into the groove of the inverter brick housing 5, has a large, 3mm thick protrusion that fills the horizontal gap. A jigsaw puzzle-like snap-fit ​​design is used in the horizontal direction to ensure the plastic baffle is fixed and cannot be easily moved. The joint between the plastic baffle and the inverter brick housing 5 uses an L-shaped bend, with the plastic flange covering the inverter brick housing 5. This increases the overlap length, reduces the risk of glue leakage, and prevents glue overflow during application. Both the third plastic baffle 3 and the plastic baffle 4 use this design.

[0035] When potting the thin-film capacitor 4 into the inverter brick housing 5, since the third plastic baffle 3 only restricts horizontal movement, a longitudinal force needs to be applied to the baffle during potting to hold it in place. This force may be applied using an installation fixture during potting. After the potting compound cures, the plastic baffle is connected to the compound and fixed to the inverter brick housing 5.

[0036] like Figure 4 As shown in (4a), the film capacitor 4 includes a capacitor core 41, a negative copper busbar 44, a positive copper busbar 47, and insulating paper. The capacitor core 41 is connected to the negative copper busbar 44 and the positive copper busbar 47 by welding. The film capacitor 4 uses a top-and-bottom welding method for the copper busbars. The width of the negative copper busbar 44 and the positive copper busbar 47 matches the size of the capacitor core 41. For different capacitance requirements, the copper busbars can be appropriately widened to match the size of the capacitor core with the required capacitance value. A thin plate is used for the welding plate to reduce the overall height of the film capacitor 4.

[0037] like Figure 4As shown in (4b), the capacitor cores 41 are arranged in two regular vertical rows. The top center of the capacitor cores 41 is the housing water channel, and the direction of the housing water channel is parallel to the arrangement direction of the capacitor cores 41. The heat dissipation of the film capacitor 4 is achieved by the water flowing from the bottom of the capacitor through the water channel on the inverter brick housing 5. Since the film capacitor 4 is encapsulated on the inverter brick housing 5, the heat generated will be conducted away by the coolant through the potting compound. The film capacitor 4 is directly encapsulated with the housing, which reduces the overall height of the capacitor on the one hand, and makes the heat dissipation of the capacitor more uniform on the other hand, thereby improving the heat dissipation efficiency and stability of the capacitor and preventing the risk of thermal runaway due to heat accumulation. The capacitor cores 41 are evenly distributed below the water channel, which ensures uniform heat dissipation of the capacitor and achieves better cooling effect. Since it is encapsulated in the inverter brick housing 5, which is made of aluminum, the high thermal conductivity of the metal significantly reduces the thermal resistance of the capacitor. In addition, the metal is impermeable to water, which also improves the moisture resistance of the capacitor.

[0038] The insulating paper includes a first insulating paper 42, a second insulating paper 43, a third insulating paper 45, a fourth insulating paper 46, and a fifth insulating paper 48, which are interspersed between the intersecting negative copper busbar 44 and positive copper busbar 47 of the capacitor.

[0039] like Figure 5 As shown in (5a), the capacitor negative copper busbar 44 includes a capacitor input terminal negative terminal 441, a capacitor core soldered copper busbar negative terminal 442, and a capacitor power module input terminal negative terminal 443. An exploded view of the capacitor negative copper busbar 44 is shown below. Figure 5 As shown in (5b).

[0040] like Figure 6 As shown in (6a), the capacitor positive copper busbar 47 includes a capacitor input terminal positive terminal 471, a capacitor core soldered copper busbar positive terminal 472, and a capacitor power module input terminal positive terminal 473. An exploded view of the capacitor positive copper busbar 47 is shown below. Figure 6 As shown in (6b).

[0041] The negative terminal 443 and the positive terminal 473 of the capacitor power module input terminals are a double-layer copper busbar distribution structure with top and bottom traces.

[0042] The negative terminal 443 and the positive terminal 473 of the capacitor power module input terminals have a C-shaped up-and-down bending structure, which is low-cost and easy to install.

[0043] Since the power module in this embodiment has a top-to-bottom layout, the copper busbar terminals of the film capacitor 4 are also distributed top-to-bottom. Considering the fixation of the current output terminals and the power module, a floating connection component is specially designed. The floating connection component has two parts: a first part to fix the upper power module and the upper current output terminal of the capacitor; and a second part to fix the lower power module and the lower current output terminal of the capacitor.

[0044] The installation steps for the dual-outlet vehicle-mounted capacitor fixing structure are as follows: Both the positive copper busbar 47 and the negative copper busbar 44 of the capacitor are welded together. Copper busbars of different thicknesses are bent and welded together, and then installed according to... Figure 2 The components are stacked sequentially in the inverter brick housing 5. The third plastic baffle 3 and the fixing parts between the film capacitor 4 and the power module need to be placed on the inverter brick housing 5 in advance. Then, the other three plastic baffles are installed using the installation tool, and the mounting bolts 7 of the fourth plastic baffle 4 are installed. Finally, the assembled components are subjected to the capacitor encapsulation step. After curing, the installation tool is removed to produce the dual-outlet vehicle-mounted capacitor fixing structure described in this embodiment.

[0045] The preferred embodiments of this utility model have been described in detail above. It should be understood that those skilled in the art can make numerous modifications and variations based on the concept of this utility model without creative effort. Therefore, all technical solutions that can be obtained by those skilled in the art based on the concept of this utility model through logical analysis, reasoning, or limited experimentation on the basis of existing technology should be within the scope of protection defined by the claims.

Claims

1. A dual-outlet vehicle-mounted capacitor fixing structure, characterized in that, The device includes a thin-film capacitor (4) and an inverter brick housing (5). A plastic baffle is provided on the inverter brick housing (5). The thin-film capacitor (4) is encapsulated inside the inverter brick housing (5) through the plastic baffle. The plastic baffle includes a first plastic baffle (6), a second plastic baffle (2), a third plastic baffle (3), and a fourth plastic baffle (1). The first plastic baffle (6) and the second plastic baffle (2) are disposed between the thin-film capacitor (4) and the power module of the inverter brick. The third plastic baffle (3) is connected to the inverter brick housing (5) through a slot provided on the inverter brick housing (5). The fourth plastic baffle (1) is fixed to the inverter brick housing (5) by mounting bolts (7).

2. The dual-outlet vehicle-mounted capacitor fixing structure according to claim 1, characterized in that, The cross-section of the third plastic baffle (3) is L-shaped, and the third plastic baffle (3) in the horizontal direction adopts a jigsaw puzzle-style snap-fit ​​shape.

3. The dual-outlet vehicle-mounted capacitor fixing structure according to claim 1, characterized in that, The thin-film capacitor (4) includes a capacitor core (41), a negative copper busbar (44), a positive copper busbar (47), and insulating paper. The capacitor core (41) is connected to the negative copper busbar (44) and the positive copper busbar (47) by welding.

4. The dual-outlet vehicle-mounted capacitor fixing structure according to claim 3, characterized in that, The widths of the capacitor negative copper busbar (44) and the capacitor positive copper busbar (47) are matched with the dimensions of the capacitor core (41).

5. The dual-outlet vehicle-mounted capacitor fixing structure according to claim 3, characterized in that, The capacitor core (41) is arranged in two regular vertical columns. The top center of the capacitor core (41) is a shell water channel, and the direction of the shell water channel is parallel to the arrangement direction of the capacitor core (41).

6. The dual-outlet vehicle-mounted capacitor fixing structure according to claim 3, characterized in that, The insulating paper includes a first insulating paper (42), a second insulating paper (43), a third insulating paper (45), a fourth insulating paper (46), and a fifth insulating paper (48), which are interspersed between the intersecting negative copper busbar (44) and positive copper busbar (47) of the capacitor.

7. The dual-outlet vehicle-mounted capacitor fixing structure according to claim 3, characterized in that, The capacitor negative copper busbar (44) includes a capacitor input terminal negative terminal (441), a capacitor core welding copper busbar negative terminal (442), and a capacitor power module input terminal negative terminal (443).

8. The dual-outlet vehicle-mounted capacitor fixing structure according to claim 7, characterized in that, The capacitor positive copper busbar (47) includes the capacitor input terminal positive terminal (471), the capacitor core welding copper busbar positive terminal (472), and the capacitor power module input terminal positive terminal (473).

9. The dual-outlet vehicle-mounted capacitor fixing structure according to claim 8, characterized in that, The negative terminal (443) and positive terminal (473) of the capacitor power module input terminal are C-shaped with up and down bends.

10. The dual-outlet vehicle-mounted capacitor fixing structure according to claim 8, characterized in that, The negative terminal (443) and positive terminal (473) of the capacitor power module input terminal are a double-layer copper busbar distribution structure with vertical wiring.

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