A power module, motor controller, electric drive assembly, and vehicle

Abstract

The utility model discloses an embodiment of a kind of power module, motor controller, electric drive assembly and vehicle. Power module includes: sub-power module;Heat dissipation plate, cooling liquid flow channel for cooling sub-power module is formed in heat dissipation plate;Heat dissipation plate includes non-contact surface and the contact surface with sub-power module;Non-contact surface is non-metal surface.The power module, motor controller, electric drive assembly and vehicle provided in the utility model embodiment, can guarantee the electromagnetic compatibility performance of electric drive assembly meets the requirement, while, the problem of the filter volume increasing due to the order of promotion filter is solved.

Description

Technical Field

[0001] This utility model relates to electric drive technology, and more particularly to a power module, a motor controller, an electric drive assembly, and a vehicle. Background Technology

[0002] With the application of silicon carbide power devices in power modules, power modules are developing towards higher voltage, higher switching frequency, higher turn-on speed, and smaller size, making electromagnetic compatibility issues increasingly prominent.

[0003] Currently, existing power modules typically reduce noise by increasing the filter order to improve the high-frequency insertion loss of the filter. However, increasing the filter order leads to an increase in the filter size. Utility Model Content

[0004] This utility model provides a power module, a motor controller, an electric drive assembly, and a vehicle, which ensures that the electromagnetic compatibility performance of the power module meets the requirements while solving the problem of increased filter size caused by increasing the order of the filter.

[0005] In a first aspect, embodiments of the present invention provide a power module, comprising:

[0006] Sub-power module;

[0007] A heat sink, wherein a coolant flow channel for cooling the sub-power module is formed within the heat sink;

[0008] The heat sink includes a non-contact surface and a contact surface that contacts the sub-power module;

[0009] The non-contact surface is a non-metallic surface.

[0010] Optionally, the non-metallic surface is an engineering plastic surface.

[0011] Optionally, the heat sink has multiple non-contact surfaces with the sub-power module.

[0012] Optionally, both the contact surface and the non-contact surface between the heat sink and the sub-power module are sealed surfaces.

[0013] Optionally, the contact surface between the heat sink and the sub-power module is a metal surface.

[0014] Optionally, the material of the metal surface may include copper.

[0015] Optionally, the number of contact surfaces between the heat sink and the sub-power module is 1.

[0016] Optionally, the material of the non-metallic surface includes at least one of polyetheretherketone, polytetrafluoroethylene, polyethersulfone, polycarbonate, polyoxymethylene, polyolamine, polyethylene terephthalate, and acrylonitrile styrene.

[0017] Optionally, the capacitance to ground of the sub-power module ranges from 1pF to 10pF.

[0018] Secondly, embodiments of the present invention provide a motor controller, including a sub-power module as described in the first aspect.

[0019] Thirdly, embodiments of the present invention provide an electric drive assembly, including a motor controller as described in the second aspect.

[0020] Fourthly, embodiments of the present invention provide a vehicle including the electric drive assembly as described in the third aspect.

[0021] The present invention provides a power module, a motor controller, an electric drive assembly, and a vehicle. The power module includes a sub-power module and a heat sink with coolant channels for cooling the sub-power module. The heat sink includes a non-contact surface and a contact surface that contacts the sub-power module. The non-contact surface is non-metallic. In the power module, motor controller, electric drive assembly, and vehicle provided by the present invention, the non-contact surface between the heat sink and the sub-power module is non-metallic. Compared to a metallic non-contact surface, this effectively reduces the parasitic capacitance of the sub-power module's phase line to ground. When the switching devices in the sub-power module have high oscillation output, resulting in high-frequency noise, the high-frequency internal resistance of the noise source in the power module is increased, thereby reducing the high-frequency noise of the power module. This ensures that the electromagnetic compatibility performance of the power module meets requirements, eliminating the need to increase the filter order to reduce noise and solving the problem of increased filter size caused by increasing the filter order. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the structure of a power module provided in an embodiment of this utility model;

[0023] Figure 2 This is a schematic diagram of another power module provided in an embodiment of the present invention;

[0024] Figure 3 This is a schematic diagram of an interference source circuit provided in an embodiment of the present invention;

[0025] Figure 4 This is a schematic diagram of noise variation provided by an embodiment of the present invention. Detailed Implementation

[0026] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, not the entire structure.

[0027] Figure 1 This is a schematic diagram of the structure of a power module provided in an embodiment of the present invention. Figure 2 This is a schematic diagram of another power module provided in an embodiment of this utility model. (Reference) Figure 1 and Figure 2 The power module includes a sub-power module 10 and a heat sink 20. The heat sink 20 has a coolant flow channel for cooling the sub-power module 10. The heat sink 20 includes a non-contact surface and a contact surface A that contacts the sub-power module 10. The non-contact surface A is a non-metallic surface.

[0028] The heat generated by the sub-power module 10 during operation can be dissipated through the coolant channels formed within the heat sink 20. Furthermore, the heat sink 20 includes multiple sides, many of which do not contact the sub-power module 10. These non-contact sides (the sides of the heat sink 20), i.e., non-contact surface A, are non-metallic. Compared to a metallic surface, non-contact surface A effectively reduces the parasitic capacitance of the power module's phase line to ground. This allows for increased high-frequency (20MHz-40MHz) internal resistance of the power module's noise source when the switching devices in the power module have high oscillation output resulting in significant high-frequency noise. This reduces the high-frequency noise of the power module, ensuring its electromagnetic compatibility performance meets requirements. Noise reduction is achieved without increasing the filter order, solving the problem of increased filter size caused by increasing the filter order and saving filter design space, resulting in a 20% reduction in filter volume.

[0029] For example, Figure 3 This is a schematic diagram of an interference source circuit provided in an embodiment of this utility model. Figure 4 This is a schematic diagram illustrating a noise variation according to an embodiment of the present invention. (Reference) Figure 3 and Figure 4 V represents the interference source, i.e., the noise source, including the switching devices in the power module. Rs is the internal resistance of the interference source. Z1 and Z2 are the impedances in the transmission path, which attenuate the noise (conduction and shielding). R1 ​​is the receiver. The non-contact surface A between the water channel 20 and the power module 10 is a non-metallic surface, which can increase the internal resistance Rs of the interference source and reduce noise. Figure 4 As shown, the green and blue curves represent the noise reduction before and after the noise reduction, respectively. It can be seen that the noise is significantly reduced in the high-frequency region of 20MHz-40MHz.

[0030] The power module provided in this embodiment has a non-metallic surface between the heat sink and the sub-power module. Compared to a metallic surface, this effectively reduces the parasitic capacitance of the power module's phase line to ground. When the switching devices in the power module have high oscillation output, resulting in high-frequency noise, the high-frequency internal resistance of the noise source in the power module is increased, thereby reducing the high-frequency noise of the power module. This ensures that the electromagnetic compatibility performance of the power module meets the requirements, eliminating the need to reduce noise by increasing the order of the filter and solving the problem of increased filter size caused by increasing the order of the filter.

[0031] Optionally, the non-metallic side is an engineering plastic side.

[0032] Specifically, engineering plastics possess excellent light transmittance and protective properties, are easy to process and have high production efficiency. They also exhibit good corrosion resistance, resisting the erosion of chemicals such as acids and alkalis. Furthermore, they possess good wear resistance and lubrication properties; the coefficient of friction can be reduced and wear resistance improved by adding solid lubricants. Engineering plastics have excellent comprehensive properties, including high rigidity, low creep, high mechanical strength, good heat resistance, and good electrical insulation. Therefore, engineering plastics are used on the non-contact surfaces of the heat sink and the sub-power module to reduce the parasitic capacitance of the power module's phase lines to ground while ensuring the reliability of the heat sink.

[0033] Optionally, the heat sink 20 may have multiple non-contact surfaces B with the sub-power module 10.

[0034] Specifically, the heat sink 20 has multiple sides, and several sides B1, B2, and B3 are not in contact with the sub-power module 10. Each non-contact surface B is made of engineering plastic, which, compared to surfaces made of metal, effectively reduces the parasitic capacitance of the power module's phase lines to ground. Furthermore, multiple non-contact surfaces allow for more efficient heat conduction and more even dissipation from the sub-power module, maintaining overall temperature balance. The sub-power module generates an electromagnetic field during operation, and the flow of coolant in the channels can affect this field; conversely, the electromagnetic field can also affect the flow of coolant and heat dissipation. Multiple non-contact surfaces reduce this mutual interference, enabling the sub-power module to operate more stably. They also increase the insulation distance and reliability between the sub-power module and the heat sink, reducing the risk of electrical failures. The sub-power module and heat sink may undergo dimensional changes due to thermal expansion and contraction during operation. Multiple non-contact surfaces provide space for these deformations, reducing structural stress and improving structural stability.

[0035] Optionally, both the contact surface A and the non-contact surface B between the heat sink 20 and the sub-power module 10 are sealed surfaces. This configuration ensures that all sides of the heat sink 20 are sealed, preventing liquid leakage from the heat sink 20 from affecting the normal operation of the sub-power module 10 and other components in the electric drive assembly, as well as preventing electrical short circuits, leakage, and other safety issues. It effectively prevents liquid from contacting electrical components, reducing electrical safety hazards and ensuring safety. Furthermore, the sealed surfaces ensure that the liquid flows along the designed path within the coolant channels, preventing leakage and ensuring sufficient heat exchange between the liquid and contact surface A. This improves heat dissipation efficiency, maintains stable heat transfer between the power module and the liquid, reduces the increase in thermal resistance caused by liquid leakage, and ensures that heat can be quickly and effectively transferred from the sub-power module to the liquid, keeping the sub-power module operating at a lower temperature. Moreover, the sealed surfaces not only prevent liquid leakage but also prevent external dust and impurities from entering the gap between the heat sink and the sub-power module, avoiding these impurities from hindering heat transfer or causing wear and corrosion to components. When subjected to external forces such as vibration and impact, the sealing surface can provide good sealing and buffering, making the connection between the heat sink and the sub-power module more stable, better resisting external forces, and avoiding sealing failure and component damage caused by vibration and impact.

[0036] Optionally, the contact surface A between the sub-power module 10 and the heat sink 20 is a metal surface.

[0037] Specifically, metal possesses excellent thermal conductivity, enabling rapid transfer of heat generated by the sub-power module to the coolant channels. This ensures timely heat dissipation even under high loads, preventing overheating. The metal surface allows for more even heat distribution on the contact surface, facilitating heat transfer to the coolant channels, reducing localized overheating, improving overall heat dissipation, and extending the lifespan of electronic components within the sub-power module. Metal's high strength and hardness allow it to withstand the pressure and stress generated when the sub-power module connects to the heat sink, ensuring a tight and stable connection that is resistant to loosening or deformation due to external forces, vibrations, or thermal expansion. While there may be slight relative movement or friction between the sub-power module and the heat sink, the metal surface's good wear resistance prevents wear, scratches, and other damage, maintaining good contact and stable heat dissipation performance. Finally, metal's excellent electrical conductivity ensures stable electrical signal transmission between the sub-power module and other components and allows for rapid static electricity conduction, preventing static buildup between the sub-power module and the heat sink. This avoids electrostatic discharge damage to electronic components, improving safety and stability. Many metals exhibit good chemical stability in common working environments, making them resistant to chemical reactions with liquids in coolant channels or substances in the surrounding environment. This ensures that the performance and structure of the contact surfaces remain unaffected during long-term use, maintaining good heat dissipation and connection performance. Metals generally have good compatibility with other materials commonly used in power modules and heat sinks, such as plastics, and will not suffer adverse effects due to material interactions. Metal materials can be easily processed into contact surfaces of various shapes and sizes through various processing techniques, such as casting, forging, stamping, and machining, to meet the design requirements of different power modules and heat sinks. High-precision machining can be achieved, ensuring that parameters such as flatness and roughness of the contact surfaces meet requirements, improving heat transfer efficiency and connection performance. Metal surfaces can undergo various treatments, such as electroplating, oxidation, and spraying, to further improve their performance, such as enhancing corrosion resistance, increasing surface hardness, and improving thermal radiation performance, thereby meeting the requirements of different working environments and applications.

[0038] Optional materials for the metal surface include copper.

[0039] Specifically, copper's thermal conductivity is among the highest of common metals, allowing copper-containing metal surfaces to transfer heat generated by the sub-power module to the coolant channels within the heat sink more quickly. This effectively reduces the operating temperature of the sub-power module, ensuring it remains within a safe temperature range even under high loads, thereby improving equipment performance and stability. Copper's high thermal conductivity also facilitates more uniform heat transfer at the contact area between the metal surface, the sub-power module, and the heat sink, rapidly dissipating heat from the sub-power module and preventing localized overheating. This results in a more balanced temperature distribution within the sub-power module, extending the lifespan of its electronic components and reducing the risk of failures due to uneven temperature distribution. Furthermore, copper has extremely low resistivity. During the operation of the sub-power module, situations may require electrical conduction through the metal surface, such as grounding and signal transmission. Copper's low resistance ensures minimal energy loss during current transmission within the metal surface, resulting in stable and accurate signal transmission. This reduces heat generation and signal distortion caused by resistance, improving the electrical performance and efficiency of the sub-power module. Copper's excellent electrical conductivity facilitates electromagnetic shielding and electrostatic discharge. Copper-containing metal surfaces can serve as effective electromagnetic shielding layers, reducing the propagation of electromagnetic interference generated within the power module and preventing external electromagnetic interference from affecting the power module. Copper possesses moderate strength and good toughness, making it easy to process and shape. As a recyclable metal, it can be recycled and refined to produce new copper products or alloys. This not only helps conserve resources and reduce dependence on primary copper ore but also minimizes the environmental impact of waste, aligning with the principles of sustainable development.

[0040] It should be noted that the material of the metal surface can also include metals other than copper, which can be determined according to the actual design requirements of the metal surface, and is not limited here.

[0041] Optionally, the number of contact surfaces A between the heat sink 20 and the sub-power module 10 is 1.

[0042] Specifically, a single contact surface A allows for more concentrated and efficient heat transfer. Heat can be transferred more efficiently from the sub-power module to the heat sink compared to the potential heat dispersion associated with multiple contact surfaces. A single contact surface A has a higher heat flux density, effectively removing heat generated by the sub-power module. This helps maintain the power module at a lower temperature, improving its performance and stability, and reducing the risk of failure due to overheating. Furthermore, a single contact surface facilitates more uniform heat dissipation. The single contact surface between the heat sink and the sub-power module ensures relatively even heat transfer, preventing localized overheating or undercooling. This results in a more uniform temperature distribution across the sub-power module, extending its lifespan and improving its reliability. From a structural design perspective, a single contact surface between the heat sink and the sub-power module simplifies the design, reducing the complexity and layout requirements associated with multiple contact surfaces. This lowers design difficulty and cost, and facilitates thermal simulation and optimization, allowing for accurate calculation and prediction of heat transfer, thus simplifying the overall design process. In the manufacturing process, a single-contact surface structure is easier to process and assemble. Compared to multiple contact surfaces, which require precise control of the dimensions, flatness, and sealing of multiple contact points, the manufacturing process of a single contact surface is easier to implement, improving production efficiency, reducing errors and defects in the manufacturing process, and lowering manufacturing costs and quality risks. Compared to multiple contact surfaces, it is easier to seal, requiring only one contact surface for sealing treatment, greatly reducing the difficulty and complexity of sealing, reducing the risk of leakage at the sealing point, improving sealing performance and reliability, and reducing the possibility of failures and damage caused by liquid leakage in the water channel. The flow of liquid in the coolant channel is affected by factors such as the shape and number of contact surfaces. When the number of contact surfaces is one, the liquid flow pattern is relatively simple, and complex eddies or turbulence are not generated due to interference from multiple contact surfaces, thereby reducing flow resistance, improving efficiency, and reducing energy consumption. A single contact surface helps to more accurately control the flow distribution of liquid in the coolant channel. Based on the heating characteristics of the sub-power module, the shape and size of the water channel can be designed more rationally, allowing the liquid in the coolant channel to be distributed more evenly, ensuring that the sub-power module is effectively cooled, and further improving the heat dissipation effect.

[0043] refer to Figure 1 Optionally, the power module also includes a housing 30, with the sub-power module 10 located inside the housing 30.

[0044] The outer casing 30 can be made of metal or other materials with high hardness, which protects the internal components of the power module, such as the sub-power module 10, and prevents external environmental factors such as dust and external forces from affecting the normal operation of the electric drive assembly.

[0045] Optionally, the material for the non-metallic surface includes at least one of polyetheretherketone, polytetrafluoroethylene, polyethersulfone, polycarbonate, polyoxymethylene, polyolamine, polyethylene terephthalate, and acrylonitrile styrene.

[0046] Polyetheretherketone (PEEK) is a high-performance special engineering plastic characterized by high temperature resistance, a low coefficient of thermal expansion, good dimensional stability, and minimal impact from changes in environmental conditions such as temperature and humidity. Its relatively low density allows for lightweight design in practical applications, reducing overall weight. It boasts high tensile strength, with reinforced versions exhibiting even higher tensile strength, enabling it to withstand significant external forces. High flexural and compressive strength make it suitable for load-bearing components requiring structural stability. It possesses excellent toughness, impact resistance, and fatigue resistance. It exhibits outstanding tribological properties, possessing some self-lubricating properties, a low coefficient of friction, extremely low wear rate, and excellent resistance to sliding wear and fretting wear. It demonstrates excellent resistance to various organic solvents, oils, weak acids, and weak alkalis, with corrosion resistance similar to nickel steel. It is hydrolytically resistant, maintaining a very low saturated water absorption rate over a wide temperature range, and can withstand... Chemical damage from seawater or high-pressure steam; radiation resistant, able to withstand large radiation doses without loss of performance, and resistant to gamma rays and electron beams, suitable for applications requiring radiation resistance; excellent insulation: possessing high volume resistivity and surface resistivity, maintaining good insulation performance over a wide temperature range and environmental changes, making it an ideal electrical insulation material; dielectrically stable, with stable electrical properties over a wide frequency and temperature range; versatile molding methods: due to its good high-temperature fluidity and high thermal decomposition temperature, it can be processed using various methods such as injection molding, extrusion molding, compression molding, blow molding, melt spinning, rotational molding, and powder coating, suitable for producing parts with complex geometries; high processing precision: dimensional accuracy is easily controlled, meeting the processing requirements of high-precision parts, with good repeatability and consistency of products; non-toxic, suitable for non-metallic surfaces of heat sinks.

[0047] Polytetrafluoroethylene (PTFE), commonly known as the "King of Plastics," is characterized by its resistance to high and low temperatures. It can be used long-term in a temperature range of -196℃ to 260℃, with short-term operating temperatures up to 300℃. It maintains a certain degree of flexibility at low temperatures and is not easily deformed or decomposed at high temperatures. It has extremely low surface tension, is almost unwettable, and possesses excellent non-stick properties. It has a white, waxy, translucent to opaque appearance and good optical properties. It has a low dielectric constant: maintaining a dielectric constant of around 2.0 over a wide frequency range, making it an excellent electrical insulating material. It also exhibits extremely excellent chemical stability and good weather resistance; it is resistant to various environmental factors in the atmosphere. It exhibits strong resistance to ultraviolet light, oxygen, and moisture, making it resistant to aging, cracking, or fading, resulting in a long service life. Its extremely low coefficient of friction provides excellent self-lubrication, reducing wear and energy loss between mechanical parts. It boasts high flexibility and tensile strength, allowing it to withstand external forces to a certain extent without breaking. It is suitable for secondary processing; molded PTFE products can undergo turning, drilling, milling, and other secondary processing to meet different usage requirements. It is non-flammable, possessing good flame retardancy, a high limiting oxygen index, and is not easily combustible, providing a certain level of safety in hazardous environments such as fires. It is non-toxic and suitable for the non-metallic surfaces of heat sinks.

[0048] Polyethersulfone (PES) is a high-performance thermoplastic engineering plastic, typically a transparent to translucent amber solid with good optical properties. Compared to other engineering plastics, it has a medium density, neither too heavy nor too light, ensuring sufficient structural strength. It exhibits good thermal stability, maintaining stable performance at high temperatures. Its low coefficient of thermal expansion results in minimal dimensional change across different temperatures, allowing it to maintain precise dimensions over a wide temperature range. It boasts high strength and rigidity: high tensile and flexural strength, enabling it to withstand significant external forces and pressures, providing reliable support and load-bearing capacity in structural components. It exhibits good impact resistance: good toughness, able to withstand a certain degree of impact load without easily cracking or breaking under impact. It demonstrates good fatigue resistance: under repeated stress, it exhibits good fatigue resistance, able to withstand multiple cyclic loads without premature fatigue failure. It also demonstrates good chemical resistance: good resistance to most organic solvents, acids, alkalis, and other chemicals. Furthermore, it exhibits good hydrolysis resistance: in high-temperature and high-humidity environments, it maintains good... It exhibits excellent hydrolysis resistance, is not prone to hydrolysis reactions that lead to performance degradation, and can be used for extended periods in humid or moisture-containing environments; excellent insulation properties: it possesses high volume resistivity and surface resistivity, resulting in superior insulation performance, making it a suitable insulating material in electrical equipment; dielectric stability: its dielectric constant remains stable over a wide frequency and temperature range, with low dielectric loss; good processability: it can be molded using various common plastic processing methods such as injection molding, extrusion molding, and compression molding, enabling the manufacture of various complex-shaped parts with high production efficiency, meeting the needs of large-scale production; high machinability: dimensional accuracy is easily controlled during processing, achieving high machining precision to meet the precision requirements of parts in different application fields; good compatibility with other materials: it can be blended or compounded with glass fiber, carbon fiber, and other plastic reinforcing materials to further improve its performance and meet different application requirements. It can also be connected or compounded with metals and other materials through appropriate processes to expand its application range. Flame retardancy: It has good flame retardant properties and can effectively slow down the burning rate and reduce the risk of fire in the event of a fire; Environmental friendliness: Polyethersulfone material itself is non-toxic and does not release harmful substances during use, which meets environmental protection requirements and can be recycled, which is conducive to environmental protection and resource conservation.

[0049] Polycarbonate is a high-performance thermoplastic engineering plastic with high transparency and good weather resistance: it has good resistance to ultraviolet radiation and does not easily yellow or age during long-term outdoor use, maintaining a good appearance and performance; its moderate density facilitates processing, transportation, and installation, while also providing a certain degree of stability, making it advantageous in applications requiring weight reduction but also strength; and it boasts high strength and toughness: it has high tensile and impact strength, making it resistant to breakage under external impact and able to withstand significant deformation without fracturing, thus suitable for manufacturing materials that require high strength and durability. Forced components; high surface hardness, good wear resistance, able to resist a certain degree of friction and scratching, maintaining surface smoothness and integrity, extending product lifespan; dimensional stability: minimal dimensional changes under different temperature and humidity environments, maintaining precise dimensions and shape; chemical corrosion resistance: good resistance to common acids, alkalis, salt solutions, and various organic solvents, maintaining stable performance in most everyday chemical environments; hydrolysis resistance: good hydrolysis resistance at room temperature, but under extreme conditions of high temperature and high humidity, it can be further improved by adding stabilizers and other measures. Its hydrolysis resistance expands its application range; it possesses high resistivity and low dielectric constant, exhibiting excellent electrical insulation properties, effectively preventing current flow. In the electrical and electronic fields, it serves as a superior insulating material, ensuring the safe operation of electrical equipment. Its dielectric stability remains stable over a wide frequency and temperature range, with low dielectric loss, maintaining good electrical performance under various electrical environments, meeting the application requirements of complex electrical conditions such as high frequency and high voltage. It also boasts good processability: it can be processed through various methods such as injection molding, extrusion molding, and blow molding, enabling the manufacture of various complex shapes and precise dimensions. The product boasts high production efficiency, enabling large-scale industrial production and widespread application in plastic product manufacturing across various fields. It is also capable of secondary processing: molded polycarbonate products can undergo cutting, drilling, milling, and welding, facilitating assembly and further processing to meet diverse usage requirements. For instance, multiple polycarbonate components can be welded together to form a complex structure. Furthermore, polycarbonate itself possesses flame-retardant properties, slowing the combustion process and reducing smoke and toxic gas production during fires, thus enhancing safety. Finally, it is non-toxic and suitable for non-metallic surfaces of heat sinks.

[0050] Polyoxymethylene (POM) is a high-performance engineering plastic, typically found in white or pale yellow granules or powder with a smooth surface, resulting in products with good gloss. Its density is medium to high among engineering plastics, giving it a certain weight and texture while maintaining structural strength. It has high crystallinity, which contributes to its good dimensional stability and mechanical properties. It also exhibits good heat resistance among engineering plastics. High strength: It possesses high tensile strength, capable of withstanding significant tensile and compressive forces, making it suitable for manufacturing components that need to withstand substantial external forces. High rigidity: Its high flexural modulus gives the material good rigidity and makes it resistant to... It exhibits bending deformation, making it suitable for manufacturing components requiring high structural stability; It possesses excellent wear resistance with a low and stable coefficient of friction, surpassing metals and other plastics in wear resistance, effectively reducing frictional loss and extending service life; It demonstrates good fatigue resistance under repeated stress, withstanding multiple cyclic loads without premature fatigue failure, making it suitable for manufacturing parts subjected to long-term use and dynamic loads; It exhibits good resistance to chemical corrosion, organic solvents, greases, weak acids, and weak alkalis; It demonstrates good hydrolysis resistance at room temperature and under high temperature and high humidity conditions. Under certain environmental conditions, its hydrolysis resistance can be improved by adding additives or using special processing techniques; good insulation properties: it has high volume resistivity and surface resistivity, excellent insulation performance, and can effectively prevent current from passing through, making it a good insulating material for use in electrical equipment to ensure the safe operation of the equipment; dielectric stability: its dielectric constant remains relatively stable over a wide frequency and temperature range, and its dielectric loss is low, making it suitable for manufacturing products with high electrical performance requirements; good moldability: it has good flowability and is easy to mold and process, and can be processed using various methods such as injection molding, extrusion molding, and blow molding, enabling the manufacture of various complex shapes and sizes. High-precision components offer high production efficiency, meeting the demands of large-scale production; rapid prototyping: short molding cycle, rapid cooling during injection molding, and quick demolding improve production efficiency and reduce production costs, making it suitable for large-scale industrial production; self-lubricating properties: excellent self-lubricating properties reduce wear and energy loss during friction without the need for additional lubricants, making it suitable for manufacturing components requiring low friction and high smoothness; aging resistance: under normal operating conditions, it exhibits good aging resistance and is not easily affected by factors such as ultraviolet light, oxygen, and moisture, maintaining stable performance over a long period.

[0051] Polyamide, commonly known as nylon, is usually a white to pale yellow solid, available in various forms such as granules and flakes. Depending on the production process, it can also exhibit other colors. It has a moderate density: much lighter than common metals such as iron and copper, which helps reduce product weight. It also has good heat resistance: possessing a certain degree of heat resistance, although different types of polyamide have different heat distortion temperatures. Some specially modified polyamides have even higher heat resistance and can maintain stable performance at higher temperatures. Furthermore, it exhibits high strength and high toughness: possessing excellent tensile strength and impact resistance, with reinforced polyamides showing even higher tensile strength. Meanwhile, it possesses good toughness, making it resistant to breakage under impact and able to withstand significant external forces; excellent wear resistance: polyamide has a low coefficient of friction and self-lubricating properties, resulting in superior wear resistance. It can be used to manufacture mechanical parts requiring long-term frictional movement, such as gears, bearings, and pulleys, effectively reducing wear and extending service life; high rigidity, maintaining shape stability and resisting deformation under pressure and external forces, making it suitable for manufacturing parts requiring high structural strength and stability; chemical corrosion resistance: it exhibits good resistance to chemical substances, resisting the erosion of common acids, alkalis, salt solutions, and organic solvents; water resistance: with relatively high water absorption, it maintains good chemical stability and mechanical properties even under normal humidity conditions; and good insulation. Properties: It has high volume resistivity and surface resistivity, making it an excellent insulating material; Stable dielectric properties: The dielectric constant remains relatively stable over a wide frequency and temperature range, with low dielectric loss, effectively reducing energy loss and interference during signal transmission in electrical and electronic fields; Good processability: It has good flowability and is easily processed by various methods such as injection molding, extrusion molding, and blow molding, allowing it to be made into products of various complex shapes with high production efficiency, meeting the needs of large-scale industrial production; High modifiability: Its properties can be customized by adding reinforcing materials such as glass fiber, carbon fiber, and minerals, as well as functional additives such as toughening agents and flame retardants, to meet the special requirements of different application scenarios.

[0052] Polyethylene terephthalate (PET) is a milky white or light yellow highly crystalline polymer with a smooth, glossy surface. Films or sheets made from it exhibit good transparency. It has a medium density among commonly used plastics, allowing it to maintain good strength and rigidity while ensuring a certain level of quality. It also has good heat resistance, meeting the requirements of applications demanding high heat resistance. High strength: It possesses high tensile strength, which can be significantly improved after reinforcement with glass fiber, making it suitable for manufacturing components that need to withstand large tensile forces. High rigidity: Its high flexural modulus makes it resistant to bending deformation, suitable for manufacturing products requiring high dimensional stability and structural strength. Fatigue resistance: It exhibits good fatigue resistance under repeated stress, able to withstand multiple cyclic loads without premature fatigue failure, making it suitable for manufacturing parts that are used for long periods and subjected to dynamic loads. Chemical resistance: It has good resistance to most organic solvents, weak acids, and weak alkalis, maintaining stable performance in general chemical environments. Water resistance: It has good water resistance, with low water absorption at room temperature, and moisture has minimal impact on its properties. It has low noise and maintains good physical and mechanical properties in humid environments; good insulation: it has high volume resistivity and surface resistivity, excellent insulation performance, and can effectively prevent current from passing through, making it a good insulating material for electrical equipment; dielectric stability: the dielectric constant remains relatively stable over a wide frequency and temperature range, and the dielectric loss is low, making it suitable for manufacturing high-frequency electronic components, insulation layers for wires and cables, and other products with high electrical performance requirements; good processability: it has good flowability and is easy to process through various processing methods such as injection molding, extrusion molding, and blow molding, enabling the manufacture of products with various complex shapes and high dimensional accuracy, resulting in high production efficiency and meeting the needs of large-scale production; good recyclability: after recycling, it can be regenerated through physical or chemical methods and reused in the production of various plastic products or fibers, which is beneficial to environmental protection and resource recycling; barrier properties: it has good barrier properties against oxygen, carbon dioxide, and water vapor; optical properties: the films and sheets made from it have good optical properties, such as high transparency, low haze, and good gloss.

[0053] Acrylonitrile styrene is typically colorless, transparent, or translucent granular material with a smooth, glossy surface. Compared to other common thermoplastics, it has a medium density, giving it advantages in terms of weight and volume, making it easy to process and use. It possesses high transparency, approaching that of glass, while exhibiting low haze. It has good tensile strength, capable of withstanding certain tensile and compressive forces without easily breaking or deforming, making it suitable for manufacturing structural components and parts requiring a certain strength. It has high hardness, resulting in good surface wear resistance, making it less prone to scratches and maintaining the integrity and smoothness of the product's appearance, thus extending its service life. It also has good rigidity, with a high flexural modulus, exhibiting good shape stability under external forces and resisting bending or torsional deformation, making it suitable for manufacturing products with high dimensional accuracy and stability requirements. Furthermore, it is resistant to chemical corrosion. Properties: It exhibits good resistance to common acid, alkali, and salt solutions, and will not undergo significant chemical reactions or corrosion within a certain concentration and temperature range; it has good water resistance with low water absorption, maintaining good physical and mechanical properties even in humid environments or in contact with water, and its performance is not easily degraded due to water absorption; excellent insulation: It has high volume resistivity and surface resistivity, effectively preventing current flow, making it an excellent insulating material; dielectric stability: Its dielectric constant remains relatively stable over a wide frequency and temperature range, with low dielectric loss, providing good electrical performance in high-frequency circuits and electronic equipment; during processing, it has good flowability, easily processed by various methods such as injection molding, extrusion molding, and blow molding, enabling the manufacture of products with complex shapes and high dimensional accuracy, resulting in high production efficiency and meeting the needs of large-scale production. The low and stable molding shrinkage rate results in high dimensional accuracy of the molded product, reducing the likelihood of significant dimensional deviations and deformation, thus ensuring product quality and assembly precision. It also exhibits good thermal stability, resisting thermal decomposition or degradation within the processing temperature range, maintaining good processing performance at higher temperatures, and improving processing speed and efficiency to some extent. Furthermore, it possesses good weather resistance, resisting the effects of ultraviolet radiation, rain, temperature changes, and other natural factors, and is less prone to significant aging, discoloration, and embrittlement. Finally, it is non-toxic, making it suitable for the non-metallic surfaces of heat sinks.

[0054] It should be noted that the specific type of engineering plastic used for the non-metallic surface can be determined according to the actual design requirements of the non-metallic surface, and is not limited here.

[0055] Optionally, the capacitance to ground of the sub-power module is less than 40pF. In this embodiment, the non-contact surface between the heat sink 20 and the sub-power module is a metal surface, which can effectively reduce the capacitance to ground of the sub-power module. For example, it can reduce the capacitance to ground of the sub-power module from 400pF to below 40pF, such as 10pF. This is to increase the high-frequency internal resistance of the noise source in the power module when the switching devices in the power module have high oscillation output and high high-frequency noise, thereby reducing the high-frequency noise of the power module.

[0056] This embodiment also provides a motor controller, including the power module as described in any embodiment of this utility model.

[0057] This embodiment also provides an electric drive assembly, including a motor controller as described in any embodiment of this utility model.

[0058] This embodiment also provides a vehicle including the electric drive assembly as described in any embodiment of the present invention.

[0059] The motor controller, electric drive assembly, and vehicle provided in this embodiment belong to the same inventive concept as the power module provided in any embodiment of this utility model, and have corresponding beneficial effects. For technical details not covered in this embodiment, please refer to the power module provided in any embodiment of this utility model.

[0060] Note that the above description is merely a preferred embodiment of the present invention and the technical principles employed. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and various obvious changes, readjustments, combinations, and substitutions can be made without departing from the scope of protection of the present invention. Therefore, although the present invention has been described in detail through the above embodiments, the present invention is not limited to the above embodiments, and may include many other equivalent embodiments without departing from the concept of the present invention. The scope of the present invention is determined by the scope of the appended claims.

Claims

1. A power module, characterized in that, include: Sub-power module; A heat sink, wherein a coolant flow channel for cooling the sub-power module is formed within the heat sink; The heat sink includes a non-contact surface and a contact surface that contacts the sub-power module; The non-contact surface is a non-metallic surface.

2. The power module according to claim 1, characterized in that, The non-metallic surface is an engineering plastic surface.

3. The power module according to claim 1, characterized in that, The heat sink has multiple non-contact surfaces with the sub-power module.

4. The power module according to claim 1, characterized in that, The contact surface and non-contact surface between the heat sink and the sub-power module are both sealed surfaces.

5. The power module according to claim 1, characterized in that, The contact surface between the heat sink and the sub-power module is a metal surface.

6. The power module according to claim 5, characterized in that, The material of the metal surface includes copper.

7. The power module according to claim 1, characterized in that, The number of contact surfaces between the heat sink and the sub-power module is 1.

8. The power module according to claim 1, characterized in that, The material of the non-metallic surface includes at least one of polyetheretherketone, polytetrafluoroethylene, polyethersulfone, polycarbonate, polyoxymethylene, polyolamine, polyethylene terephthalate, and acrylonitrile styrene.

9. The power module according to any one of claims 1-8, characterized in that, The capacitance to ground of the sub-power module is less than 40pF.

10. A motor controller, characterized in that, Includes the power module as described in any one of claims 1-9.

11. An electric drive assembly, characterized in that, Including the motor controller as described in claim 10.

12. A vehicle, characterized in that, Includes the electric drive assembly as described in claim 11.

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