A plastic laminated power brick structure
By stacking capacitor modules and power modules vertically and incorporating internal cooling channels, and using stacked copper busbars and an integrated injection-molded housing, the problems of large area occupation and low heat dissipation efficiency of horizontally arranged capacitor modules and power modules are solved, achieving efficient heat dissipation and improved power density with low resistance.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- JIANG SU JIN MAI DIAN KONG KE JI YOU XIAN GONG SI
- Filing Date
- 2025-08-04
- Publication Date
- 2026-07-31
AI Technical Summary
The horizontal arrangement of capacitor modules and power modules occupies a large area, the independent arrangement of the heat dissipation system results in a long heat transfer path and low heat dissipation efficiency, the lengthy copper busbar connection path leads to increased parasitic inductance and resistance, and the use of metal material for the casing increases weight and complicates the manufacturing process.
The device adopts a plastic stacked power brick structure, with capacitor modules and power modules stacked on top of each other. The capacitor modules have built-in heat dissipation channels, the copper busbars adopt a stacked design, and the shell is a one-piece injection molded plastic shell with water channels.
It improves heat dissipation efficiency, reduces parasitic inductance and resistance, reduces the number and weight of parts, simplifies the manufacturing process, and increases power density and vehicle layout convenience.
Smart Images
Figure CN224583064U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of power module technology, specifically to a plastic laminated power brick structure. Background Technology
[0002] With the development of electric vehicle functions integration, the powertrain unit integrates motors, reducers and electronic controls into one unit, reducing the size of the core powertrain unit, improving power density and drive efficiency, and reducing costs for OEMs and suppliers, thereby enhancing the market competitiveness of the whole vehicle. As electric vehicle powertrains develop towards multi-integration (motor, reducer and electronic control integration), the layout space of motor controllers is severely compressed.
[0003] Especially in all-in-one systems, the bottom of the motor controller is often constrained by the V-shaped deep groove structure of the motor and reducer, making it difficult to make efficient use of space for the traditional planar layout of power modules, capacitors and heat dissipation systems.
[0004] However, existing technologies have the following problems:
[0005] The capacitor module and power module are arranged horizontally, which takes up a large area and cannot be adapted to the space of the V-groove.
[0006] The heat dissipation system is arranged independently, the water channels are separated from the power components, the heat transfer path is long, and the heat dissipation efficiency is low.
[0007] The long copper busbar connection path leads to increased parasitic inductance (ESL) and resistance (ESR), which affects power density and conversion efficiency.
[0008] The casing is mostly made of metal, which increases the weight and makes the manufacturing process more complicated.
[0009] In view of this, we propose a plastic laminated power brick structure. Utility Model Content
[0010] The purpose of this invention is to provide a plastic laminated power brick structure to solve the problems mentioned in the background art.
[0011] To achieve the above objectives, this utility model provides the following technical solution:
[0012] A plastic laminated power brick structure includes a capacitor module, on the upper end of which a power module is stacked, and negative connection copper busbars are provided on the sides of the capacitor module and the power module.
[0013] The capacitor module includes a plastic housing with water channels. The plastic housing with water channels is provided with an embedded nut and a pressure limiting sleeve. A capacitor module output negative copper busbar and a capacitor module output positive copper busbar are provided on one side of the plastic housing with water channels. A capacitor module input positive copper busbar and a capacitor module input negative copper busbar are provided on the other side of the plastic housing located at the front end of the capacitor module output negative copper busbar and the capacitor module output positive copper busbar.
[0014] Preferably, one side of the power module is provided with a positive power module input copper busbar and a negative power module input copper busbar, and the other side of the power module is provided with a U-phase copper busbar, a V-phase copper busbar and a W-phase copper busbar.
[0015] Preferably, the positive copper busbar of the capacitor module output is laser-welded to the positive copper busbar of the power module input, and the negative connection copper busbar is laser-welded to both the negative copper busbar of the capacitor module output and the negative copper busbar of the power module input.
[0016] Preferably, the remaining space of the plastic housing with water channels is filled with potting epoxy resin.
[0017] Preferably, a sealing ring is placed inside the plastic housing with water channels of the capacitor module, the power module is installed onto the capacitor module by positioning, and the power module and the capacitor module are fastened with screws.
[0018] By employing the above technical solution, this utility model provides a plastic laminated power brick structure. It possesses at least the following beneficial effects:
[0019] (1) This utility model combines the power module, the heat dissipation channel and the capacitor module in an up-and-down stacking manner to form a power brick. The heat dissipation channel dissipates heat for both the power module and the capacitor module. The structure is compact, the heat dissipation is good, the power density is high, and it is easy to arrange in the whole vehicle.
[0020] (2) By using a stacked arrangement of the positive and negative copper busbars of the capacitor module, this utility model effectively reduces the parasitic inductance ESL of the inverter system, fully utilizes the performance advantages of the power module, and the capacitor module transmits power to the power module through the side stacked copper busbar, reducing the electrical transmission path, thereby reducing the parasitic resistance ESR and reducing power loss.
[0021] (3) This utility model reduces the number of parts, lowers costs, and reduces product weight by integrally injection molding the heat dissipation channel and capacitor shell into one part. The heat dissipation channel also dissipates heat for the thin film capacitor core, improving the lifespan and efficiency of the thin film capacitor core, thus improving performance while reducing costs. Attached Figure Description
[0022] The accompanying drawings, which are included to provide a further understanding of the present invention, form part of this application:
[0023] Figure 1 This is an exploded view of the overall structure of this utility model;
[0024] Figure 2 This is a schematic diagram of the capacitor module in this utility model;
[0025] Figure 3 This is a schematic diagram of the power module in this utility model;
[0026] Figure 4 This is a schematic diagram of the assembly of the power module and capacitor module in this utility model;
[0027] Figure 5 This is a schematic diagram of the welding of the electrical connection copper busbar in this utility model;
[0028] Figure 6 This is a schematic diagram of the input and output terminals of the inverter brick in this utility model;
[0029] Figure 7 This is a schematic diagram of the plastic waterway in this utility model.
[0030] In the diagram: 1. Capacitor module; 11. Plastic housing with water channel; 12. Encapsulated epoxy resin; 13. Capacitor module output negative copper busbar; 14. Capacitor module output positive copper busbar; 15. Insert nut; 16. Capacitor module input positive copper busbar; 17. Capacitor module input negative copper busbar; 18. Voltage limiting bushing; 2. Sealing ring; 3. Power module; 31. Power module input positive copper busbar; 32. Power module input negative copper busbar; 33. U-phase copper busbar; 34. V-phase copper busbar; 35. W-phase copper busbar; 4. Screw; 5. Negative connection copper busbar. Detailed Implementation
[0031] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.
[0032] Please see Figures 1-7 As shown, this utility model proposes a plastic stacked power brick structure, including a capacitor module 1, a power module 3 stacked on the upper end of the capacitor module 1, and a negative connection copper busbar 5 provided on the side of the capacitor module 1 and the power module 3.
[0033] The capacitor module 1 and the power module 3 are stacked vertically instead of the traditional horizontal arrangement. The capacitor module 1 is placed at the bottom and the power module is stacked on top of it. They are fastened and sealed by screws 4 and sealing rings 2. This design is compatible with the V-shaped deep groove space at the bottom of the motor controller, reducing the volume by more than 40%.
[0034] The capacitor module 1 includes a plastic housing 11 with water channels. The plastic housing 11 with water channels is provided with an embedded nut 15 and a pressure limiting sleeve 18. On one side of the plastic housing 11 with water channels, there are capacitor module output negative copper busbar 13 and capacitor module output positive copper busbar 14. On one side of the plastic housing 11 with water channels, extending outward from the front end of the capacitor module output negative copper busbar 13 and capacitor module output positive copper busbar 14, there are capacitor module input positive copper busbar 16 and capacitor module input negative copper busbar 17.
[0035] The plastic housing 11 with water channels of capacitor module 1 is integrally injection molded and has built-in cooling water channels. The water channels on the left and right sides are either end-face sealed or radially sealed, and both sides can serve as inlets and outlets to meet the requirements of various structural designs. The coolant flows into the plastic water channel from the left inlet, flows through the bottom of the capacitor core and the heat dissipation substrate of the power module, and flows out from the right outlet. The water channel adopts a serpentine flow channel design. When the flow rate is 1.5-2L / min, the heat dissipation power reaches more than 5kW. When the coolant flows through the water channel, it dissipates heat for both the IGBT of the power module and the capacitor core, shortens the heat transfer path, and improves the heat dissipation efficiency by 30%. The plastic housing 11 with water channels is made of engineering plastic (such as PPS) and integrates embedded nuts 15 and pressure limiting sleeves 18, which reduces the weight by 30% and simplifies assembly.
[0036] The power module 3 has a positive input copper busbar 31 and a negative input copper busbar 32 on one side, and a U-phase copper busbar 33, a V-phase copper busbar 34 and a W-phase copper busbar 35 on the other side.
[0037] The positive output copper busbar 14 of the capacitor module is laser-welded to the positive input copper busbar 31 of the power module. The negative connection copper busbar 5 is laser-welded to the negative output copper busbar 13 of the capacitor module and the negative input copper busbar 32 of the power module, respectively. The copper busbar stack design shortens the current path by 60%, significantly reduces parasitic inductance (ESL) and resistance (ESR), and improves power density.
[0038] The remaining space of the plastic shell 11 with water channels is filled with potting epoxy resin 12;
[0039] The remaining space of the housing is filled with potting epoxy resin 12 to enhance insulation and assist in heat dissipation. At the same time, DC input terminals (capacitor module input positive copper busbar 16 and capacitor module input negative copper busbar 17) and output welding terminals (capacitor module output negative copper busbar 13 and capacitor module output positive copper busbar 14) are reserved for external power supply connection and laser welding.
[0040] A sealing ring 2 is placed inside the plastic housing 11 with water channels of the capacitor module 1. The power module 3 is installed on the capacitor module 1 by positioning, and the power module 3 and the capacitor module 1 are fastened with screws 4.
[0041] In use, the plastic laminated power brick structure of this utility model allows external DC power to enter the capacitor module 1 through the positive input copper busbar 16 and the negative input copper busbar 17 of the capacitor module. The electrical energy is stored in the capacitor core encapsulated in epoxy resin 12. The positive output copper busbar 14 of the capacitor module is directly connected to the positive input copper busbar 31 of the power module through laser welding. The negative connection copper busbar 5 is simultaneously laser welded to the negative output copper busbar 13 of the capacitor module and the negative input copper busbar 32 of the power module, forming a "three-point welding" low-impedance path. The power module 3 converts the DC power stored in the capacitor module 1 into three-phase AC power, which is output through the U-phase copper busbar 33, the V-phase copper busbar 34 and the W-phase copper busbar 35 to drive the motor.
[0042] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.
[0043] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.
Claims
1. A plastic laminated power brick structure comprising a capacitor module (1), characterized in that: A power module (3) is stacked on the upper end of the capacitor module (1), and a negative connection copper busbar (5) is provided on the side of the capacitor module (1) and the power module (3); The capacitor module (1) includes a plastic housing (11) with water channels. The plastic housing (11) with water channels is provided with an inlaid nut (15) and a pressure limiting sleeve (18). On one side of the plastic housing (11) with water channels, there are capacitor module output negative copper busbar (13) and capacitor module output positive copper busbar (14). On one side of the plastic housing (11) with water channels, there are capacitor module input positive copper busbar (16) and capacitor module input negative copper busbar (17) extending outward from the front end of the capacitor module output negative copper busbar (13) and capacitor module output positive copper busbar (14).
2. A plastic laminate power brick structure according to claim 1, wherein: The power module (3) has a positive input copper busbar (31) and a negative input copper busbar (32) on one side, and a U-phase copper busbar (33), a V-phase copper busbar (34), and a W-phase copper busbar (35) on the other side.
3. A plastic laminate power brick structure according to claim 1, wherein: The positive output copper busbar (14) of the capacitor module is laser welded to the positive input copper busbar (31) of the power module, and the negative connection copper busbar (5) is laser welded to the negative output copper busbar (13) of the capacitor module and the negative input copper busbar (32) of the power module respectively.
4. The plastic laminate power brick structure of claim 1, wherein: The remaining space of the plastic housing (11) with water channels is filled with potting epoxy resin (12).
5. The plastic laminate power brick structure of claim 1, wherein: A sealing ring (2) is placed inside the plastic housing (11) with water channels of the capacitor module (1). The power module (3) is installed on the capacitor module (1) by positioning. The power module (3) and the capacitor module (1) are fastened with screws (4).