A resilient member installed inside an electric vehicle controller

Abstract

The application relates to a flexible piece installed in the interior of an electric vehicle controller and belongs to the technical field of the electric vehicle controller. The flexible piece comprises a horizontal piece and a vertical piece, a first exhaust hole is formed in the horizontal piece, and a second exhaust hole is formed in the vertical piece. The flexible piece is fixed through the clamping of a clamping column at the end of a connecting piece and a clamping groove on an aluminum alloy shell. The end of the horizontal piece abuts against a MOS tube and presses the MOS tube against the aluminum alloy shell. The end of the horizontal piece is provided with a pressing enhancement part and a separation groove, and a plurality of pressing teeth are formed. A reinforcing rib structure is arranged between the horizontal piece and the vertical piece. The application effectively discharges glue pouring gas while ensuring the pressing and heat dissipation of the MOS tube through the porous structure and the reinforcing design, reduces the generation of air bubbles, and improves the appearance quality and reliability of the product.

Description

Technical Field

[0001] This application relates to the technical field of electric vehicle controllers, and more particularly to an elastic element installed inside an electric vehicle controller. Background Technology

[0002] The electric vehicle controller is the core control component of an electric vehicle. Its function is to receive user commands and adjust the output current to precisely drive the motor and control the vehicle's starting, acceleration, cruising, and braking states.

[0003] The MOSFETs, the power devices inside this controller, generate a significant amount of heat during operation, making their heat dissipation performance crucial. Controllers typically incorporate a clamping spring mechanism to press the MOSFETs firmly against the aluminum alloy housing, ensuring tight contact and reducing thermal resistance. This allows the heat generated by the MOSFETs to be efficiently conducted to the housing for dissipation. With market development, to meet higher demands for heat dissipation and protection, the industry has begun using potting compounding for controller encapsulation. However, during potting, air can easily be trapped as the adhesive flows past the clamping spring mechanism, causing air bubbles to form at that location. These bubbles solidify and remain within the adhesive, severely impacting the aesthetic appearance of the finished product. Utility Model Content

[0004] To address the problem of air bubbles being trapped at the compression elastic element during the glue-filling process of electric vehicle controllers, this application provides an elastic element installed inside the electric vehicle controller.

[0005] The elastic element installed inside the electric vehicle controller provided in this application adopts the following technical solution: An elastic element installed inside an electric vehicle controller includes a horizontal plate and a vertical plate, the horizontal plate being connected to the vertical plate; a first vent hole is formed on the horizontal plate, and a second vent hole is formed on the vertical plate; the elastic element is snapped onto an aluminum alloy housing, and the elastic element is used to press a MOSFET into the aluminum alloy housing; a mounting groove is formed on the aluminum alloy housing, and a snap-fit ​​groove is formed on the side wall of the mounting groove; a connecting piece is connected to the side wall of the vertical plate, the connecting piece is inclined, and a snap-fit ​​post is connected to the end of the connecting piece; the snap-fit ​​post engages with the snap-fit ​​groove; the end of the horizontal plate away from the vertical plate abuts against the MOSFET.

[0006] By adopting the above technical solution, this solution forms an exhaust channel during the potting process through the first and second exhaust holes on the horizontal and vertical plates, promoting air discharge and reducing air bubble residue. The elastic element is securely installed on the aluminum alloy housing through the cooperation of the snap-fit ​​post and snap-fit ​​groove, and the end of the horizontal plate continuously presses the MOSFET against the housing to ensure heat conduction efficiency.

[0007] Preferably, the end of the transverse piece away from the vertical piece is connected to a compression reinforcement.

[0008] By adopting the above technical solution, this solution increases the contact stress with the MOSFET through the clamping reinforcement section, thereby improving the clamping reliability.

[0009] Preferably, a row of dividing grooves is provided at the end of the horizontal piece away from the vertical piece, dividing the end of the horizontal piece away from the vertical piece into a row of pressing teeth.

[0010] By adopting the above technical solution, this solution divides the end of the transverse plate into multiple pressing teeth through the dividing groove, so as to achieve adaptive pressing, ensure uniform pressure distribution, and at the same time, the gap between the teeth assists in air exhaust.

[0011] Preferably, the compression reinforcement is a downwardly convex arc portion, and the bottom of the downwardly convex arc portion abuts against the MOS transistor.

[0012] By adopting the above technical solution, the compression reinforcement part adopts a downward convex arc structure, with the arc bottom contacting the MOSFET, increasing the contact area and improving the heat dissipation effect.

[0013] Preferably, the angle between the horizontal piece and the vertical piece is an acute angle.

[0014] By adopting the above technical solution, the horizontal and vertical pieces are connected at an acute angle, giving the elastic element spring characteristics and providing a continuous and stable clamping force.

[0015] Preferably, the transverse plate has a row of first exhaust holes along its length, and the vertical plate has a row of second exhaust holes along its length.

[0016] By adopting the above technical solution, a row of first exhaust holes and a row of second exhaust holes are respectively provided on the horizontal plate and the vertical plate to form a continuous exhaust path and improve exhaust efficiency.

[0017] Preferably, a reinforcing rib connects the vertical sheet and the horizontal sheet.

[0018] By adopting the above technical solution, this solution connects the horizontal and vertical plates with reinforcing ribs to compensate for the stiffness loss caused by opening vent holes, thus ensuring the overall structural strength of the elastic component.

[0019] Preferably, the reinforcing ribs include transverse reinforcing ribs and vertical reinforcing ribs, the transverse reinforcing ribs being connected to the sidewalls of the transverse pieces, the vertical reinforcing ribs being connected to the sidewalls of the vertical pieces, and the transverse reinforcing ribs being connected to the vertical reinforcing ribs.

[0020] By adopting the above technical solution, the reinforcing ribs include transverse reinforcing ribs and vertical reinforcing ribs, which respectively enhance the rigidity of the transverse and vertical plates, so that the elastic element can maintain sufficient clamping force while maintaining the venting function.

[0021] In summary, this application includes at least one of the following beneficial technical effects: 1. By opening the first vent hole and the second vent hole on the horizontal sheet and the vertical sheet respectively, a through venting channel is formed, which allows the gas to be effectively discharged during the flow of the adhesive, reduces the residual air bubbles, and improves the appearance quality of the glue.

[0022] 2. The reinforcing rib structure compensates for the stiffness loss caused by the opening, ensuring that the clamping force of the elastic element on the MOSFET is not affected and maintaining heat dissipation performance.

[0023] 3. The partition groove design at the end of the transverse plate forms multiple pressing teeth, which realizes uniform pressing and auxiliary exhaust, further improving heat dissipation reliability and appearance quality. Attached Figure Description

[0024] Figure 1 This is a schematic diagram illustrating the overall structure in the embodiments of this application.

[0025] Figure 2 This is a cross-sectional schematic diagram used to illustrate the overall structure in the embodiments of this application.

[0026] Figure 3 This is a front structural diagram illustrating the elastic element in the embodiments of this application.

[0027] Figure 4 This is a schematic diagram of the back structure of the elastic element in the embodiments of this application.

[0028] Explanation of reference numerals in the attached drawings: 1. Aluminum alloy housing; 11. Contact block; 12. Mounting groove; 121. Snap-fit ​​groove; 13. Mounting platform; 2. MOSFET; 3. Circuit board; 4. Horizontal plate; 41. First vent hole; 42. Separator groove; 43. Pressing reinforcement part; 5. Vertical plate; 51. Second vent hole; 52. Connecting plate; 53. Snap-fit ​​post; 6. Reinforcing rib; 61. Horizontal reinforcing rib; 62. Vertical reinforcing rib. Detailed Implementation

[0029] The following is in conjunction with the appendix Figure 1-4 This application will be described in further detail.

[0030] This application discloses an elastic element installed inside an electric vehicle controller. (Refer to...) Figure 1 ~3. The elastic element includes a horizontal piece 4 and a vertical piece 5, which are used to press the MOSFET 2 into the aluminum alloy housing 1. The horizontal piece 4 is fixedly connected to the upper end of the vertical piece 5, and the included angle between the horizontal piece 4 and the vertical piece 5 is an acute angle. The horizontal piece 4 has a row of first exhaust holes 41 along its length, and the vertical piece 5 has a row of second exhaust holes 51 along its length. The aluminum alloy housing 1 has a mounting groove 12, and an abutment block 11 is also fixedly connected to the aluminum alloy housing 1, located above the mounting groove 12. The lower end of the vertical piece 5 is installed in the mounting groove 12, and the abutment block 11 is used to abut the upper end of the vertical piece 5, thereby pressing the vertical piece 5 into the mounting groove 12. The end of the horizontal piece 4 away from the vertical piece 5 abuts against the top wall of the MOSFET 2.

[0031] Reference Figure 2 A mounting platform 13 is fixedly connected to the aluminum alloy housing 1. The mounting platform 13 is located on one side of the snap-fit ​​groove 121 and is used to position the MOSFET 2. An elastic element is used to press the MOSFET 2 onto the mounting platform 13. A circuit board 3 is fixedly connected inside the aluminum alloy housing 1 and is located on one side of the mounting groove 12. The output pins of the MOSFET 2 are fixedly connected to the circuit board 3.

[0032] Reference Figures 2-3 A pressing reinforcement part 43 is fixedly connected to the end of the horizontal plate 4 away from the vertical plate 5. In this embodiment, the pressing reinforcement part 43 is a downwardly protruding arc part, and the bottom of the downwardly protruding arc part abuts against the top wall of the MOS transistor 2.

[0033] Reference Figures 2-3 A connecting piece 52 is fixedly connected to each of the two side walls of the vertical piece 5, and the connecting pieces 52 are inclined from top to bottom. The two connecting pieces 52 are symmetrically fixedly connected to the vertical piece 5, and a snap-fit ​​post 53 is fixedly connected to the lower end of each connecting piece 52. A snap-fit ​​groove 121 is opened on each of the two side walls of the mounting groove 12, and the snap-fit ​​post 53 snaps into the snap-fit ​​groove 121. In the installed state, the initial distance between the two snap-fit ​​posts 53 is greater than the distance between the two snap-fit ​​grooves 121, so that when the snap-fit ​​post 53 snaps into the snap-fit ​​groove 121, it will undergo elastic deformation, forming an interference fit to ensure a secure fixation.

[0034] Reference Figures 2-4A reinforcing rib 6 is installed between the vertical plate 5 and the horizontal plate 4. The reinforcing rib 6 includes a horizontal reinforcing rib 61 and a vertical reinforcing rib 62. The horizontal reinforcing rib 61 is fixedly connected to the horizontal plate 4, and the vertical reinforcing rib 62 is fixedly connected to the vertical plate 5. The vertical plate 5 and the horizontal plate 4 are also fixedly connected. The vertical plate 5 and the horizontal plate 4 avoid the first vent hole 41 and the second vent hole 51. Since the vertical plate 5 and the horizontal plate 4 have vent holes, this will weaken the overall stiffness of the elastic element. In order to prevent the elastic element with weakened stiffness from failing to hold the MOS transistor 2, a reinforcing rib 6 is added to the elastic element to compensate for a certain stiffness.

[0035] Reference Figure 3 A row of dividing grooves 42 is formed along the length of the end of the transverse piece 4 away from the vertical piece 5, thereby dividing the end of the transverse piece 4 away from the vertical piece 5 into a row of pressing teeth. The purpose of this design is to achieve adaptive pressing through multiple independent pressing teeth, ensuring uniform and reliable heat dissipation. The gaps between the teeth provide an efficient venting channel for the potting process.

[0036] This patent embodiment discloses an elastic element installed inside an electric vehicle controller to press a MOSFET 2 against an aluminum alloy housing 1 for efficient heat dissipation. The elastic element consists of a horizontal piece 4 and a vertical piece 5, with an acute angle between them. This acute angle allows the elastic element to act like a spring, always firmly pressing the MOSFET 2. The horizontal piece 4 has a row of first vent holes 41 along its length, and the vertical piece 5 has a row of second vent holes 51 along its length. The aluminum alloy housing 1 is provided with a mounting groove 12 and a contact block 11. The lower end of the vertical piece 5 is installed in the mounting groove 12, and the contact block 11 abuts against the upper end of the vertical piece 5 to position the elastic element. The end of the horizontal piece 4 away from the vertical piece 5 abuts against the top wall of the MOSFET 2 through a pressing reinforcement part 43.

[0037] During the potting process, as the adhesive flows through the elastic element, the first vent 41 and the second vent 51 form a continuous venting channel, allowing air to escape smoothly from the holes and preventing air from being trapped by the adhesive and generating bubbles. The dividing groove 42 at the end of the transverse plate 4 divides the end into a row of pressing teeth. These pressing teeth can achieve uniform pressing, thereby ensuring consistent heat conduction. The reinforcing rib 6 includes transverse reinforcing rib 61 and vertical reinforcing rib 62, providing additional stiffness compensation for the elastic element and ensuring that the elastic element can still maintain sufficient clamping force after the vent holes are opened, preventing the MOS transistor 2 from loosening.

[0038] This application effectively solves the problem of residual air bubbles during the potting process through a porous structure and adaptive compression design, improving the appearance quality of the product while maintaining reliable heat dissipation performance, ensuring that the heat of the controller can be efficiently conducted to the housing for dissipation during operation.

[0039] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. An elastic element installed inside an electric vehicle controller, characterized in that: The elastic element includes a transverse piece (4) and a vertical piece (5), wherein the transverse piece (4) is connected to the vertical piece (5); The horizontal plate (4) is provided with a first exhaust hole (41), and the vertical plate (5) is provided with a second exhaust hole (51); The elastic element is snapped onto the aluminum alloy housing (1), and the elastic element is used to press the MOS tube (2) into the aluminum alloy housing (1); The aluminum alloy housing (1) is provided with a mounting groove (12), and a snap-fit ​​groove (121) is provided on the side wall of the mounting groove (12); a connecting piece (52) is connected to the side wall of the vertical piece (5), the connecting piece (52) is inclined, and a snap-fit ​​post (53) is connected to the end of the connecting piece (52); the snap-fit ​​post (53) is engaged with the snap-fit ​​groove (121); The end of the horizontal plate (4) away from the vertical plate (5) abuts against the MOS transistor (2).

2. The elastic element installed inside the electric vehicle controller according to claim 1, characterized in that: The end of the transverse piece (4) away from the vertical piece (5) is connected to a clamping reinforcement part (43).

3. The elastic element installed inside the electric vehicle controller according to claim 2, characterized in that: A row of dividing grooves (42) is provided at the end of the transverse piece (4) away from the vertical piece (5), dividing the end of the transverse piece (4) away from the vertical piece (5) into a row of pressing teeth.

4. The elastic element installed inside the electric vehicle controller according to claim 2, characterized in that: The compression reinforcement part (43) is a downwardly protruding arc part, and the bottom of the downwardly protruding arc part abuts against the MOS transistor (2).

5. The elastic element installed inside an electric vehicle controller according to claim 1, characterized in that: The angle between the horizontal piece (4) and the vertical piece (5) is an acute angle.

6. The elastic element installed inside an electric vehicle controller according to claim 1, characterized in that: The transverse piece (4) has a row of first exhaust holes (41) along its length, and the vertical piece (5) has a row of second exhaust holes (51) along its length.

7. The elastic element installed inside an electric vehicle controller according to claim 1, characterized in that: A reinforcing rib (6) connects the vertical piece (5) and the horizontal piece (4).

8. The elastic element installed inside an electric vehicle controller according to claim 7, characterized in that: The reinforcing rib (6) includes a transverse reinforcing rib (61) and a vertical reinforcing rib (62). The transverse reinforcing rib (61) is connected to the side wall of the transverse piece (4), and the vertical reinforcing rib (62) is connected to the side wall of the vertical piece (5). The transverse reinforcing rib (61) and the vertical reinforcing rib (62) are connected.

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