Power module and vehicle

Abstract

This application provides a power module and a vehicle, relating to the field of power electronic device technology. The power module includes: a magnetic core; a recess on a signal connector; at least a portion of the magnetic core is embedded within the recess, and the magnetic core and the signal connector form an assembly; a frame enclosing the assembly, the frame, the magnetic core, and the signal connector together forming an integral structure. The power module of this application, by providing a recess on the signal connector, allows at least a portion of the magnetic core to be embedded within the recess during manufacturing, and the magnetic core and the signal connector form an assembly. This enables close integration of the magnetic core and the signal connector, which is beneficial for improving the filtering effect of the magnetic core. Thus, without affecting the electrical transmission performance of the signal connector, the assembly of the magnetic core and the signal connector is more compact, facilitating further integration and miniaturization of the magnetic core and the signal connector, thereby improving space utilization.

Description

Technical Field

[0001] This application relates to the field of power electronic device technology, and more particularly to a power module and a vehicle. Background Technology

[0002] Power modules used in vehicles typically offer advantages such as high power and high efficiency compared to other signal transmission devices, making them highly sought after and favored by the industry. In the packaging of power modules, electrical signals are generally transmitted through conductive busbars such as copper busbars, aluminum busbars, and copper-aluminum composite busbars, while Hall effect magnetic cores monitor the electrical signals.

[0003] However, in existing technologies, the space utilization rate of vehicle power modules is low. Utility Model Content

[0004] In view of the above problems, this application provides a power module and a vehicle to solve the problem of low space utilization of power modules in existing vehicles.

[0005] To achieve the above objectives, the embodiments of this application provide the following technical solutions:

[0006] A first aspect of this application provides a power module, including:

[0007] magnetic core;

[0008] A signal connector has a recess; at least a portion of a magnetic core is embedded in the recess, and the magnetic core and the signal connector form a combination.

[0009] The frame, which encloses the assembly, together with the magnetic core and signal connectors, forms an integral structure.

[0010] In one possible implementation, the assembly is integrally injection molded within the frame.

[0011] In one possible implementation, the signal connector includes a first connecting portion and a second connecting portion and a third connecting portion located at both ends of the first connecting portion along a second direction; a recess is formed on at least one side of the first connecting portion along the first direction;

[0012] The magnetic core is at least partially located within the recess.

[0013] In one possible implementation, the width dimension of the signal connector along the first direction is β, and the recess dimension of a single recess along the first direction is α, where β and α satisfy:

[0014] 8% ≤ α / β ≤ 43%.

[0015] In one possible implementation, the magnetic core has a first target surface on one side along a third direction; the signal connector has a second target surface;

[0016] The second target surface is set parallel to the first target surface.

[0017] In one possible implementation, the magnetic core has a first target surface on one side along a third direction; the signal connector has a second target surface;

[0018] The second target surface is set perpendicular to the first target surface;

[0019] And / or, the second target surface is set at an angle to the first target surface.

[0020] In one possible implementation, the signal connector includes a first connecting portion and a second connecting portion and a third connecting portion located at both ends of the first connecting portion along a second direction; the first connecting portion is angled to the second connecting portion and the third connecting portion; a recess is formed by twisting between the first connecting portion and the second connecting portion and the third connecting portion.

[0021] In one possible implementation, the magnetic core has a first target surface on one side along a third direction; the second connecting portion and the third connecting portion are arranged parallel to the first target surface;

[0022] The first connecting part is perpendicular to the first target surface;

[0023] And / or, the first connecting part is set at an angle to the first target surface.

[0024] In one possible implementation, the magnetic core and the signal connector are spaced apart;

[0025] At least part of the frame is formed between the magnetic core and the signal connector.

[0026] A second aspect of this application provides a vehicle including the power module described above.

[0027] The power module provided in this application mainly includes a magnetic core, a signal connector, and a frame, which together form an integral structure. By providing a recess on the signal connector, at least a portion of the magnetic core is built into the recess during the manufacturing process, and the magnetic core and the signal connector form a combination, enabling close integration of the magnetic core and the signal connector. This is beneficial for improving the filtering effect of the magnetic core, thereby making the assembly of the magnetic core and the signal connector more compact without affecting the electrical transmission performance of the signal connector. This is conducive to further integration and miniaturization of the magnetic core and the signal connector, thereby improving space utilization.

[0028] In addition to the technical problems solved by the embodiments of this application, the technical features constituting the technical solutions, and the beneficial effects brought about by the technical features of these technical solutions described above, other technical problems that the power module and vehicle provided by the embodiments of this application can solve, other technical features included in the technical solutions, and the beneficial effects brought about by these technical features will be further explained in detail in the specific implementation. Attached Figure Description

[0029] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0030] Figure 1 A perspective view of the power module provided in an embodiment of this application;

[0031] Figure 2 for Figure 1 A magnified view of a portion of point A in the middle;

[0032] Figure 3 A perspective view of the magnetic core of the power module provided in an embodiment of this application;

[0033] Figure 4 A perspective view of a first type of signal connector for a power module provided in an embodiment of this application;

[0034] Figure 5 A perspective view of a first assembly of a power module provided in an embodiment of this application;

[0035] Figure 6 A top view of a first type of signal connector for a power module provided in an embodiment of this application;

[0036] Figure 7 A perspective view of a second assembly of a power module provided in an embodiment of this application;

[0037] Figure 8 A perspective view of a third assembly of the power module provided in the embodiments of this application;

[0038] Figure 9 A perspective view of a second type of signal connector for a power module provided in an embodiment of this application;

[0039] Figure 10 A perspective view of a fourth assembly of a power module provided in an embodiment of this application;

[0040] Figure 11A top view of the power module provided in an embodiment of this application;

[0041] Figure 12 for Figure 11 Sectional view of section BB.

[0042] Explanation of reference numerals in the attached figures:

[0043] 10. Magnetic core; 101. Groove; 102. First target surface; 11. Fourth connecting part; 12. Fifth connecting part;

[0044] 20. Signal connector; 201. Recess; 202. Second target surface; 203. Connecting hole; 21. First connecting part; 22. Second connecting part; 23. Third connecting part;

[0045] 30. Composite;

[0046] 40. Framework;

[0047] X, first direction; Y, second direction; Z, third direction. Detailed Implementation

[0048] First, those skilled in the art should understand that these embodiments are merely for explaining the technical principles of this application and are not intended to limit the scope of protection of this application. Those skilled in the art can make adjustments as needed to adapt to specific application scenarios.

[0049] Secondly, it should be noted that, in the description of the embodiments of this application, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this application according to the specific circumstances.

[0050] As described in the background art, the power module of the vehicle in the related art has the problem of low space utilization. The inventors have found that the reason for this problem is that the design and assembly of multiple independent components leads to low integration, large gaps between components, and large space occupation.

[0051] To address the aforementioned technical problems, embodiments of this application provide a power module and a vehicle. The power module includes: a magnetic core; a signal connector with a recess; at least a portion of the magnetic core is embedded within the recess, and the magnetic core and the signal connector form an assembly; a frame enclosing the assembly, the frame, the magnetic core, and the signal connector together forming an integral structure. The power module provided in this application, with the recess on the signal connector, allows for close integration of the magnetic core and the signal connector during manufacturing. This improves the filtering effect of the magnetic core and, without affecting the electrical transmission performance of the signal connector, makes the assembly of the magnetic core and the signal connector more compact. This facilitates further integration and miniaturization of the magnetic core and the signal connector, thereby improving space utilization.

[0052] To make the above-mentioned objectives, features, and advantages of the embodiments of this application more apparent and understandable, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0053] Please refer to Figures 1-12 The first aspect of this application provides a power module, including:

[0054] Magnetic core 10;

[0055] The signal connector 20 has a recess 201; at least a portion of the magnetic core 10 is built into the recess 201, and the magnetic core 10 and the signal connector 20 form a combination 30.

[0056] The frame 40 encloses the assembly 30, and the frame 40, together with the magnetic core 10 and the signal connector 20, forms an integral structure.

[0057] It should be noted that in the text, the first direction X refers to the width direction of the magnetic core 10; the second direction Y refers to the thickness direction of the magnetic core 10; and the third direction Z refers to the height direction of the magnetic core 10. The first direction X, the second direction Y, and the third direction Z intersect each other.

[0058] In this embodiment of the application, please refer to Figure 1 and Figure 2 As shown, the power module mainly includes a magnetic core 10, a signal connector 20, and a frame 40, which together form an integral structure; please refer to [the diagram]. Figure 4 As shown, the signal connector 20 has a recess 201. Please refer to [link / reference]. Figure 5As shown, in the manufacturing process, at least a portion of the magnetic core 10 is built into the recess 201, and the magnetic core 10 and the signal connector 20 form a combination 30, which enables the magnetic core 10 and the signal connector 20 to be integrated in close proximity, which is beneficial to improving the filtering effect of the magnetic core. Thus, without affecting the electrical transmission performance of the signal connector 20, the assembly of the magnetic core 10 and the signal connector 20 is more compact, which is conducive to the further integration and miniaturization of the magnetic core 10 and the signal connector 20, thereby improving space utilization.

[0059] Furthermore, the signal connector 20 can be a copper busbar, aluminum busbar, copper-aluminum composite busbar, or other related conductive busbars.

[0060] In one possible implementation, the assembly 30 is integrally injection molded within the frame 40.

[0061] In this embodiment of the application, by directly injection molding the assembly 30 into the frame 40 in one piece during the manufacturing process, the volume of the frame 40 can be effectively reduced, thus lowering the cost. On the other hand, the production process can be simplified, and the production efficiency can be improved. Furthermore, the highly integrated design of the power module is achieved, which is conducive to further improving the space utilization of the product.

[0062] Furthermore, during the manufacturing process, a positioning fixture can be set in the injection mold to position the magnetic core 10 and the signal connector 20 in the assembly 30.

[0063] In one possible implementation, the signal connector 20 includes a first connecting portion 21 and a second connecting portion 22 and a third connecting portion 23 located at both ends of the first connecting portion 21 along the second direction Y; a recess 201 is formed on at least one side of the first connecting portion 21 along the first direction X;

[0064] The magnetic core 10 is at least partially disposed within the recess 201.

[0065] It should be noted that the magnetic core 10 can have a "C" shaped structure; please refer to [link / reference]. Figure 3 As shown, the magnetic core 10 includes a fourth connecting portion 11 and fifth connecting portions 12 located at both ends of the fourth connecting portion 11 along a first direction X. The fifth connecting portions 12 extend from the ends of the fourth connecting portion 11 along a third direction Z in a direction away from the fourth connecting portion 11. The two fifth connecting portions 12 and the fourth connecting portion 11 together form a groove 101. The fourth connecting portion 11 has a first target surface 102 on one side along the third direction Z. The fifth connecting portions 12 are at least partially disposed within the groove 201. The first connecting portion 21 is at least partially disposed within the groove 101.

[0066] In this embodiment of the application, please refer to Figure 4 As shown, the recesses 201 of the signal connector 20 are formed on both sides of the first connecting portion 21 along the first direction X. Please refer to [link / reference]. Figure 5As shown, in the manufacturing process, by at least partially placing the fifth connecting portion 12 in the recess 201 and at least partially placing the first connecting portion 21 in the groove 101, the magnetic core 10 and the signal connector 20 form a combination 30, thereby enabling close integration of the magnetic core 10 and the signal connector 20. This improves the filtering effect of the magnetic core and, without affecting the electrical transmission performance of the signal connector 20, makes the assembly of the magnetic core 10 and the signal connector 20 more compact. This facilitates further integration and miniaturization of the magnetic core 10 and the signal connector 20, thereby improving space utilization.

[0067] It should be noted that the magnetic core 10 can also be a ring structure or an irregular structure. The signal connector 20 and its recess 201 can be locally modified so that at least part of the magnetic core 10 is built into the recess 201, which can also achieve the purpose of integration and miniaturization.

[0068] In one possible implementation, please see Figure 6 As shown, the width dimension of the signal connector 20 along the first direction X is β, and the recess dimension of a single recess 201 along the first direction X is α. β and α satisfy:

[0069] 8% ≤ α / β ≤ 43%.

[0070] It should be noted that, in order to ensure that the recess 201 fully accommodates the magnetic core 10 and to make the assembly of the magnetic core 10 and the signal connector 20 more compact without affecting the electrical transmission performance of the signal connector 20, β and α must satisfy α / β≥8%. At the same time, since the recess 201 is formed on the signal connector 20, on the one hand, in order to ensure the mechanical properties and structural stability of the signal connector 20 and avoid breakage of the signal connector 20, and on the other hand, in order to ensure the current-carrying area and current transmission performance of the signal connector 20, β and α must also satisfy α / β≤43%.

[0071] Furthermore, in the design and manufacturing process, in order to ensure that the current-carrying area and current transmission performance of the signal connector 20 do not change, the thickness of the corresponding position can be increased after the recess 201 is partially opened in the signal connector 20. For example, after the recess 201 is opened on at least one side of the first connection part 21 along the first direction X, the thickness of the first connection part 21 can be increased, thereby ensuring that the overall current transmission performance of the signal connector 20 does not change.

[0072] In one possible implementation, please see Figure 3 As shown, the magnetic core 10 has a first target surface 102 on one side along the third direction Z; please refer to... Figure 4 As shown, the signal connector 20 has a second target surface 202;

[0073] Please see Figure 5As shown, the second target surface 202 is set parallel to the first target surface 102.

[0074] In this embodiment of the application, during the manufacturing process, by at least partially placing the fifth connecting portion 12 of the magnetic core 10 in the recess 201 and at least partially placing the first connecting portion 21 in the groove 101, and simultaneously making the second target surface 202 parallel to the first target surface 102, not only can the integration and miniaturization of the magnetic core 10 and the signal connector 20 be realized, improving space utilization, but it is also beneficial to ensure the positioning accuracy of the assembly 30 and improve product consistency.

[0075] In one possible implementation, please see Figure 3 As shown, the magnetic core 10 has a first target surface 102 on one side along the third direction Z; please refer to... Figure 4 As shown, the signal connector 20 has a second target surface 202;

[0076] Please see Figure 7 As shown, the second target surface 202 is set perpendicular to the first target surface 102.

[0077] In this embodiment, by setting the second target surface 202 perpendicular to the first target surface 102, the distance between the two fifth connecting portions 12 of the magnetic core 10 along the first direction X is further reduced without affecting the electrical transmission performance of the signal connector 20. This makes the assembly of the magnetic core 10 and the signal connector 20 more compact, which is conducive to the further integration and miniaturization of the magnetic core 10 and the signal connector 20, and further improves the space utilization rate.

[0078] In one possible implementation, please see Figure 8 As shown, the second target surface 202 is set at an angle to the first target surface 102.

[0079] In this embodiment of the application, without affecting the electrical transmission performance of the signal connector 20, in order to improve assembly tolerance, increase production efficiency, or optimize the spatial structure of the power module, the second target surface 202 and the first target surface 102 can be set at an angle, that is, the second target surface 202 can have a certain tilt angle relative to the first target surface 102. By directly injection molding the assembly 30 into the frame 40, the production process can be simplified and the production efficiency and assembly tolerance can be improved.

[0080] In one possible implementation, please see Figure 9As shown, the signal connector 20 includes a first connecting portion 21 and a second connecting portion 22 and a third connecting portion 23 located at both ends of the first connecting portion 21 along the second direction Y; the first connecting portion 21 is angled to the second connecting portion 22 and the third connecting portion 23; the first connecting portion 21 is twisted at a certain angle to form a recess 201.

[0081] In this embodiment, the first connecting part 21 is twisted with the second connecting part 22 and the third connecting part 23 to form a recess 201, which avoids punching the signal connector 20, thereby ensuring the integrity of the signal connector 20. On the one hand, it can ensure the mechanical properties and structural stability of the signal connector 20 and prevent the signal connector 20 from breaking. On the other hand, it can ensure the current-carrying area and current transmission performance of the signal connector 20.

[0082] In one possible implementation, please see Figure 10 As shown, the magnetic core 10 has a first target surface 102 on one side along the third direction Z; the second connecting portion 22 and the third connecting portion 23 are arranged parallel to the first target surface 102;

[0083] The first connecting part 21 is perpendicular to the first target surface 102;

[0084] And / or, the first connecting part 21 is set at an angle to the first target surface 102.

[0085] It should be noted that the torsion angle between the first connecting part 21, the second connecting part 22, and the third connecting part 23 can be adjusted according to the actual needs of the product. For example, the second connecting part 22 and the third connecting part 23 can be arranged parallel to the first target surface 102, the first connecting part 21 can be arranged perpendicular to the first target surface 102, or the first connecting part 21 can be arranged at other angles to the first target surface 102.

[0086] In this embodiment, a recess 201 is formed by twisting the first connecting portion 21, the second connecting portion 22, and the third connecting portion 23 at a certain angle during the manufacturing process. The fifth connecting portion 12 is at least partially disposed in the recess 201, and the first connecting portion 21 is at least partially disposed in the groove 101. This makes the second connecting portion 22 and the third connecting portion 23 parallel to the first target surface 102, and the first connecting portion 21 perpendicular to and / or at an angle to the first target surface 102. On the one hand, this avoids punching the signal connector 20, thereby ensuring the integrity of the signal connector 20. This not only ensures the mechanical properties and structural stability of the signal connector 20 and prevents breakage, but also ensures the current-carrying area and current transmission performance of the signal connector 20. On the other hand, it can further reduce the distance between the two fifth connecting portions 12 of the magnetic core 10 along the first direction X, making the assembly of the magnetic core 10 and the signal connector 20 more compact. This is beneficial for the further integration and miniaturization of the magnetic core 10 and the signal connector 20, and further improves space utilization.

[0087] Further, please see Figure 4 As shown, the second connecting part 22 is provided with a connecting hole 203, which not only facilitates the assembly of the second connecting part 22 with other components to achieve electrical connection, but also facilitates the positioning of the assembly 30 during injection molding.

[0088] In one possible implementation, the magnetic core 10 and the signal connector 20 are spaced apart;

[0089] At least a portion of the frame 40 is formed between the magnetic core 10 and the signal connector 20.

[0090] In this embodiment of the application, please refer to Figure 5 As shown, the magnetic core 10 and the signal connector 20 are spaced apart; please combine them together. Figure 11 and Figure 12 As shown, at least a portion of the frame 40 is formed between the magnetic core 10 and the signal connector 20, thereby isolating the magnetic core 10 and the signal connector 20, reducing direct electromagnetic coupling of the magnetic core 10 to the signal connector 20 to reduce interference and noise, and improving the accuracy and stability of signal measurement.

[0091] This application also provides a vehicle including the power module described above.

[0092] Given that the vehicle in this embodiment includes the power module described in any of the above embodiments, the structure and beneficial effects of the vehicle including the power module will not be described in detail here.

[0093] The various embodiments or implementation methods described in this specification are presented in a progressive manner. Each embodiment focuses on the differences from other embodiments, and the same or similar parts between the embodiments can be referred to each other.

[0094] It should be noted that the terms "one embodiment," "embodiment," "exemplary embodiment," "some embodiments," etc., mentioned in the specification indicate that the described embodiment may include a specific feature, structure, or characteristic, but not every embodiment necessarily includes that specific feature, structure, or characteristic. Furthermore, such phrases do not necessarily refer to the same embodiment. Moreover, when a specific feature, structure, or characteristic is described in connection with an embodiment, implementing such a feature, structure, or characteristic in conjunction with other embodiments, whether explicitly described or not, is within the knowledge scope of those skilled in the art.

[0095] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A power module, characterized in that, include: Magnetic core (10); A signal connector (20) is provided with a recess (201); at least a portion of the magnetic core (10) is built into the recess (201), and the magnetic core (10) and the signal connector (20) form a combination (30); A frame (40) encloses the assembly (30), and the frame (40), together with the magnetic core (10) and the signal connector (20), form an integral structure.

2. The power module according to claim 1, characterized in that, The assembly (30) is integrally injection molded within the frame (40).

3. The power module according to claim 2, characterized in that, The signal connector (20) includes a first connecting portion (21) and a second connecting portion (22) and a third connecting portion (23) located at both ends of the first connecting portion (21) along the second direction (Y); the recess (201) is formed on at least one side of the first connecting portion (21) along the first direction (X); The magnetic core (10) is at least partially disposed within the recess (201).

4. The power module according to claim 3, characterized in that, The width dimension of the signal connector (20) along the first direction (X) is β, and the recess dimension of a single recess (201) along the first direction (X) is α, where β and α satisfy: 8％≤α / β≤43％。 5. The power module according to claim 3, characterized in that, The magnetic core (10) has a first target surface (102) on one side along the third direction (Z); the signal connector (20) has a second target surface (202); The second target surface (202) is set parallel to the first target surface (102).

6. The power module according to claim 3, characterized in that, The magnetic core (10) has a first target surface (102) on one side along the third direction (Z); the signal connector (20) has a second target surface (202); The second target surface (202) is perpendicular to the first target surface (102); And / or, the second target surface (202) is set at an angle to the first target surface (102).

7. The power module according to claim 2, characterized in that, The signal connector (20) includes a first connecting portion (21) and a second connecting portion (22) and a third connecting portion (23) located at both ends of the first connecting portion (21) along a second direction (Y); the first connecting portion (21) is angled to the second connecting portion (22) and the third connecting portion (23); the first connecting portion (21) is twisted with the second connecting portion (22) and the third connecting portion (23) to form the recess (201).

8. The power module according to claim 7, characterized in that, The magnetic core (10) has a first target surface (102) on one side along the third direction (Z); the second connecting part (22) and the third connecting part (23) are arranged parallel to the first target surface (102); The first connecting part (21) is perpendicular to the first target surface (102); And / or, the first connecting portion (21) is set at an angle to the first target surface (102).

9. The power module according to any one of claims 1-7, characterized in that, The magnetic core (10) and the signal connector (20) are spaced apart; At least a portion of the frame (40) is formed between the magnetic core (10) and the signal connector (20).

10. A vehicle, characterized in that, Includes the power module as described in any one of claims 1 to 9 above.

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