Electrical device comprising insulating film

Abstract

To provide a method for allowing a durable electrical insulation for electrical devices for electric or hybrid vehicles.SOLUTION: An electrical device comprises: a casing (10) comprising a cavity (11) receiving an electronic component; and at least one electrical conductor connected to the electronic component so as to supply electric power to the electronic component. The electrical device comprises a first insulating film (F1) disposed against and electrically insulating a surface of the first conductor. The first insulating film (F1) has at least one holding member (F1-1). The at least one holding member (F1-1) enables the first insulating film (F1) to be attached to a mechanical element, in particular a mechanical element of the electrical device.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to an electrical device having an improved electrical insulation system and an electrical appliance (in particular, a voltage converter, a charger or a power inverter) comprising such an electrical device.

[0002] The electrical appliance is in particular for an electric vehicle or a hybrid vehicle.

[0003] In particular, the object of the present invention is to enable durable electrical insulation for such an electrical device.

Background Art

[0004] [Prior Art] As is known, in an electric vehicle or a hybrid vehicle, the power supply function of the electric motor system enabling vehicle travel is provided by a high-voltage power battery. More precisely, it is known that the direct current provided by the high-voltage power battery can be converted into one or more alternating current (for example, sine wave) control currents using a power inverter in order to control the electric machine driving the vehicle wheels.

[0005] In addition, for charging, the high-voltage power battery is connected to, for example, an external power grid (in particular, via an on-board charger, in particular one comprising at least one DC-DC voltage converter).

[0006] The power inverter is provided with a housing dedicated to this device. Further, the power inverter is provided with a capacitive block including a casing configured to be inserted into the housing of the power inverter. The capacitive block includes a cavity disposed within the casing and a smoothing capacitor configured to be inserted into the cavity of the casing. The direct current provided by the power battery can be smoothed by the capacitive block and then converted into an alternating control current. In this way, this capacitor can remove residual disturbances in the direct current and filter and convert it into an alternating control current.

[0007] Also, the capacitive block includes at least two conductors (in particular, a conductor connected to the negative terminal of the capacitor and a conductor connected to the positive terminal of the capacitor). Each conductor is, for example, in the form of a bent copper foil. These conductors enable easy access to the negative and positive terminals of the capacitor in order to easily connect the capacitor to other parts of the system.

[0008] However, each conductor is arranged in proximity to each other along separate parallel planes. Therefore, in order to avoid the risk of short circuit that may inhibit the optimal operation of the power inverter, insulation should be provided between each conductor and between each conductor and the housing to insulate these elements from each other.

[0009] According to the prior art, the first solution involves using a first insulating film disposed between each conductor and the housing and a second insulating film disposed between each conductor. According to this solution, the first and second insulating films are fixed, in particular, by being attached using an adhesive (such as glue).

[0010] However, the lifespan of the adhesive material may be limited or much shorter than the lifespan of the vehicle. Therefore, the adhesive material may deteriorate over time, and there is a possibility of a short circuit problem occurring.

[0011] Therefore, there is a need for an efficient and durable solution for a system for attaching insulating elements to various elements of an electrical device, particularly capacitive blocks.

[0012] [Disclosure of the Invention] More precisely, the subject of the present invention is a casing having a cavity for housing electronic components, at least one first conductor connected to the electronic components for supplying power to the electronic components, an electrical device comprising wherein the electrical device comprises a first electrical insulating film that electrically insulates the first conductor with respect to its surface, the first insulating film has at least one holding member, the at least one holding member enables the first insulating film to be attached to mechanical elements (particularly of the electrical device), which is worthy of note.

[0013] Advantageously, the electrical device comprises a second conductor connected to the electronic components for supplying power to the electronic components, the first and second conductors are overlapped with each other and extend along two separate parallel planes, the mechanical element is a second insulating film, the second insulating film is disposed between each of the conductors, thereby insulating the first and second conductors from each other.

[0014] Preferably, the second insulating film of the electrical device comprises at least one holding member, the at least one holding member is configured to be attached to the holding member of the first insulating film.

[0015] Preferably, the second insulating film of the electrical device has at least one protrusion, The at least one protrusion is inserted into the cavity of the casing for embedding in the filling material of the cavity of the casing, The protrusion is disposed at an edge on the opposite side of the second insulating film with respect to the holding member.

[0016] Preferably, the first insulating film of the electrical device has at least one protrusion, The at least one protrusion is inserted into the cavity of the casing for embedding in the filling material of the cavity of the casing, The protrusion is disposed at an edge on the opposite side of the first insulating film with respect to the holding member.

[0017] Advantageously, the first insulating film of the electrical device is made of plastic.

[0018] According to one embodiment, the first insulating film of the electrical device is held against the surface of the first conductor by a first mechanical means (e.g., an adhesive material), and held against the mechanical element by a second mechanical means of another nature (e.g., welding).

[0019] According to another embodiment, the first insulating film of the electrical device has at least one bent portion, thereby conforming to the surface of the first conductor and being held against the surface of the first conductor only by the first holding member and the protrusion of the first insulating film.

[0020] Furthermore, the present invention relates to a housing, an electrical device housed in the housing, and relates to an electrical apparatus comprising the same, wherein, in the electrical apparatus, the first insulating film is - from the wall of the housing of the electrical apparatus, or - from other components of the electrical apparatus disposed in the housing of the electrical apparatus, configured to electrically insulate the first conductor, the second electrical insulating film is configured to insulate the conductors from each other.

[0021] Advantageously, the electrical device is configured to be mounted on a vehicle, the electrical device, - forms a power inverter configured to supply power from a battery to an electric motor that drives the vehicle, or - forms a DC-DC converter configured to convert voltage between a high-voltage power battery and a low-voltage power battery, or - forms a charger configured to convert voltage between an external power grid of the vehicle and the vehicle's battery.

[0022] The present invention will be better understood by reading the following description, given by way of example only, with reference to the accompanying drawings which are given by way of non-limiting example. In the accompanying drawings, the same reference signs are given to similar objects.

[0023] Each figure illustrating the present invention shows the present invention in more detail for purposes of carrying out the present invention, but it should be noted that, of course, each figure can be used to better define the present invention if necessary.

Brief Description of the Drawings

[0024]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Embodiments for Carrying Out the Invention

[0025] In the following description, the present invention will be described particularly in the context of electrical devices (such as power inverters) for electric vehicles or hybrid vehicles, but this does not limit the scope of the present invention.

[0026] Actually, in an electric vehicle or a hybrid vehicle, a high-voltage power battery provides a power supply function for an electric motor system through a power inverter (which can convert the direct current provided by the high-voltage power battery into one or more alternating current (e.g., sine wave) control currents), enabling vehicle travel.

[0027] Referring to FIG. 1, the electrical device includes a dedicated housing. In this example, the electrical device is a power inverter. The power inverter includes a capacitive block 12 having a casing 10 configured to be inserted into the housing. The capacitive block 12 also includes a cavity 11 (disposed within the casing 10 and particularly defined by the housing 10). Further, the capacitive block 12 includes capacitive elements 121, 122 configured to be inserted into the cavity 11 of the casing 10. The capacitive block 12 enables the direct current provided by the power battery to be smoothed and then converted into an alternating current control current. The capacitive block 12 has a positive terminal and a negative terminal, thereby enabling the removal of residual external disturbances of the direct current, filtering it, and converting it into an alternating current control current (by electronic switches not particularly shown here). The capacitive elements 121, 122 are, for example, chemical capacitors or film capacitors or any other type of capacitive element.

[0028] Referring to FIGS. 1 and 2, the capacitive block 12 also includes at least two conductors C1, C2 that are arranged in parallel and adjacent to each other along separate planes. In particular, the conductors C1, C2 are superimposed on each other. The first conductor C1 is connected to the negative terminals of the capacitive elements 121, 122 of the capacitive block 12, respectively. The second conductor C2 is connected to the positive terminals of the capacitive elements 121, 122 of the capacitive block 12, respectively. To achieve this, the capacitive block 12 may include a first welding portion S1, which enables the first conductor C1 to be connected to the negative terminals of the capacitive elements 121, 122, respectively. In FIG. 1, the first conductor C1 is welded to the surface of the first capacitive element 121, for example. A part of the first conductor C1 passes between the capacitive elements 121, 122 and connects to the surface on the opposite side of the second capacitive element 122. Similarly, the capacitive block 12 may include a second welding portion S2, which enables the second conductor C2 to be connected to the positive terminals of the capacitive elements 121, 122, respectively. In FIG. 1, the second conductor C2 is welded to the surface of the second capacitive element 122, for example. A part of the second conductor C2 passes between the capacitive elements 121, 122 and connects to the surface on the opposite side of the first capacitive element 121.

[0029] In addition, the conductors C1, C2 may be arranged in the vicinity of the wall P1 of the housing of the electrical device or in the vicinity of other components that may be arranged within the housing of the electrical device. For example, as shown in FIG. 6, the electrical device 1 (here a power inverter) includes, in particular, a capacitive block 12 and a power electronics module 13 separated by a cooling circuit 14. Further, the first conductor C1 is in the vicinity of the wall P1 of the housing 100. This wall P1 is included in the surface of the cooling circuit 14 for cooling the components of the electrical device 1 (in particular the capacitive block 12).

[0030] Referring to FIG. 2, the conductors C1 and C2 each include at least one connection terminal C10 and C20, whereby the negative and positive terminals of the capacitive block 12 can be connected to other parts of the system (especially for supplying power to the motor system). For example, the connection terminals C10 and C20 of the conductors C1 and C2 are connected to the respective terminals of the power electronics module 13.

[0031] The connection terminals C10 and C20 may represent, for example, a part of the conductors C1 and C2. In order to supply power to other components, these parts are penetrated, for example, by one or more ports, and a connector is screwed into this port. These parts may be connected to the connector by other means (for example, by welding).

[0032] Referring to FIGS. 3 and 4, in order to electrically insulate the conductors C1 and C2 of the housing 100 and thus avoid short circuits, the capacitive block 12 includes a first insulating film F1. The first insulating film F1 is arranged with respect to the conductor closest to the housing 100 among at least two conductors C1 and C2, thereby electrically insulating the conductor from other parts of the housing 100. In the embodiment shown with reference to FIGS. 3 and 4, the first insulating film F1 is arranged with respect to the wall of the first conductor C1. The first insulating film F1 includes at least one protrusion F 10 and at least one holding member F1-1, whereby the first insulating film F1 can be held against the surface of the first conductor C1.

[0033] This protrusion F 10 represents a part protruding from the first insulating film F1. This protrusion F 10 is configured to extend into the cavity 11 of the casing 10 for embedding and mounting in the filling material of the cavity 11 of the casing 10. In addition, at least one holding member F1-1 is another part protruding from the first insulating film F1 (for example, at least one protrusion F 10(which is arranged on the edge opposite to the first insulating film F1). The holding member F1-1 is attached to the mechanical element of the capacitive block 12. Thus, the first insulating film F1 is held at the first edge by the holding member F1-1 and by the protrusion F 10 at the opposite edge thereof, thereby improving the mechanical holding. In particular, the adhesive material for holding the first insulating film F1 against the surface of the first conductor C1 can be omitted. This omission is made especially when the first insulating film F1 is sufficiently rigid and can be bent before being mounted on the first conductor C1 and maintain its shape after being mounted on the first conductor C1. Therefore, the useful time of the adhesive material does not affect the service life of the capacitive block 12.

[0034] In particular, referring to FIGS. 3 and 4, the mechanical element is a second insulating film F2 that is inserted between the conductors C1, C2 and extends into the cavity 11 of the casing 10. In other words, the second insulating film F2 is held by being sandwiched between both of the conductors C1, C2 of the capacitive block 12. The second insulating film F2 is configured to insulate the conductors C1, C2 from each other and avoid a short circuit therebetween. Further, this second insulating film F2 forms a mechanical element to which the first insulating film F1 is attached. Also, the second insulating film F2 includes at least one protrusion F 20 and at least one holding member F2-1.

[0035] The protrusion F 20 represents a portion protruding from the second insulating film F2. This protrusion F 20 is configured to extend into the cavity 11 of the casing 10 for embedding and attaching into the filling material of the cavity 11 of the casing 10. In addition, at least one holding member F2-1 represents another portion protruding from the second insulating film F2 (configured to face the holding member F1-1 of the first insulating film F1).

[0036] The first insulating film F1 and the second insulating film F2 are particularly composed of a plastic material.

[0037] In particular, the filling material is fluid when filling the cavity 11 of the casing 10 and becomes solid after the polymerization process. In particular, the filling material is a polymerizable substance (such as a polymerizable resin, etc., in particular an epoxy resin).

[0038] At least one holding member F1-1 of the first insulating film F1 and at least one holding member F2-1 of the second insulating film F2 are configured to be attached to each other by any suitable plastic welding means, and in particular, by using ultrasonic welding treatment.

[0039] Thus, the attachment and holding of the first insulating film F1 and the second insulating film F2 are ensured, on the one hand, by the protrusions F 10 ,F 20 extending into the filling material and, on the other hand, by the welded portions formed between the holding members F1-1, F1-2.

[0040] Referring to FIG. 5, only the first insulating film F1 and the second insulating film F2 are shown together with their respective protrusions F 10 ,F 20 and their respective holding members F1-1, F2-1.

[0041] Instead of attaching to the second insulating film F2, the first insulating film F1 may be attached to other mechanical elements (in particular of the electrical device 1). Thus, the mechanical element may be, for example, the wall P2 of the housing illustrated in FIG. 7. This wall P2 may alternatively be the surface of another electronic component of the electrical device 1.

Claims

1. a casing (10) with a cavity (11) for housing electronic components; at least one first conductor (C1) connected to said electronic component for supplying power thereto; An electrical device comprising: The electrical device comprises: a first electrically insulating film (F1) for electrically insulating a surface of the first conductor (C1); The first insulating film (F1) has at least one holding member (F1-1), the at least one holding member (F1-1) allowing the first insulating film (F1) to be attached to a mechanical element (in particular of the electrical device).

1. An electrical device comprising:

2. a second conductor (C2) connected to the electronic component for supplying power to the electronic component; the first and second conductors (C1, C2) are stacked on top of each other and extend along two separate parallel planes; the mechanical element being a second insulating film (F2), the second insulating film (F2) is disposed between each of the conductors (C1, C2), thereby insulating the first and second conductors (C1, C2) from each other; 10. The electrical device of claim 1.

3. The second insulating film (F2) comprises at least one holding member (F2-1), and the at least one holding member (F2-1) is configured to be attached to the holding member (F1-1) of the first insulating film (F1).

3. An electrical device according to claim 1 or 2.

4. The second insulating film (F2) has at least one protrusion (F ２０ ) The at least one protrusion (F ２０ ) is inserted into the cavity (11) of the casing (10) for embedding in the filling material of said cavity (11) of the casing (10). Inserted into the cavity (11), The protrusion (F ２０ ) is disposed on the edge of the second insulating film (F2) opposite to the holding member (F2-1); 4. An electrical device according to claim 2 or 3.

5. The first insulating film (F1) has at least one protrusion (F １０ ) The at least one protrusion (F １０ ) is inserted into the cavity (11) of the casing (10) for embedding in the filling material of said cavity (11) of the casing (10). Inserted into the cavity (11), The protrusion (F １０ ) is disposed on an opposite edge of the first insulating film (F1) with respect to the holding member (F1-1); An electrical device according to any one of claims 1 to 4.

6. An electrical device according to any one of the preceding claims, wherein the first insulating film (F1) is made of plastic.

7. The first insulating film (F1) is held by a first mechanical means (e.g., an adhesive material) against a surface of the first conductor (C1); held to said mechanical element by a second mechanical means of a different nature (e.g. welding); An electrical device according to any one of the preceding claims.

8. The first insulating film (F1) has at least one bent portion, which fits the surface of the first conductor (C1) and allows the first holding member (F1-1) and the protrusion (F1-2) to be held against the surface of the first conductor (C1). １０ 8. The electrical device of claim 5, wherein the electrical device is held only by a tension member.

9. A housing (100); An electric device according to any one of claims 3 to 8 housed in the housing (100); An electrical device (1) comprising: In the electrical device (1), the first insulating film (F1) is from a wall (P1) of the housing (100) of the electrical device (1), or from other components of the electrical equipment (1) arranged in the housing (100) of the electrical equipment (1), configured to electrically insulate the first conductor (C1); the second electrically insulating film (F2) is configured to insulate the conductors (C1, C2) from each other; Electrical equipment (1).

10. The electrical device (1) is configured to be mounted on a vehicle, The electrical device (1) comprises: forming a power inverter adapted to supply from a battery to an electric motor driving said vehicle, or forming a DC-DC converter adapted to convert voltage between a high-voltage power battery and a low-voltage power battery, or forming a charger configured to convert voltage between a power grid external to the vehicle and a battery of the vehicle, An electrical appliance (1) according to claim 9.

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