Motor controller module, motor controller, powertrain, and electric vehicle

Abstract

The present application provides a motor controller module, a motor controller, a powertrain, and an electric vehicle. The motor controller module comprises a bus capacitor and a heat dissipation plate, the heat dissipation plate is stacked on the outer side of a housing, and one side surface of the heat dissipation plate is used for fixing a three-phase bridge arm. The housing comprises a recess, and the recess is used for accommodating a partition plate. One surface of the partition plate is used for forming a liquid cooling cavity together with the recess bottom of the recess and part of the peripheral wall of the recess, and the other surface of the partition plate is used for forming another liquid cooling cavity together with the other side surface of the heat dissipation plate and the other part of the peripheral wall of the recess. The maximum distance between the other surface and the recess bottom of one recess is less than the depth of the recess. The heat dissipation plate, the partition plate, and the recess of the housing are used to form a double-layer flow channel, to cool the bus capacitor and the three-phase bridge arm, thereby improving the cooling efficiency and integration level of the motor controller, and facilitating the miniaturization of the motor controller.

Description

Motor controller module, motor controller, powertrain and electric vehicle

[0001] This application claims priority to Chinese Patent Application No. 202421703635.3, filed on July 17, 2024, entitled "Motor Controller Module, Motor Controller, Powertrain and Electric Vehicle", the entire contents of which are incorporated herein by reference. Technical Field

[0002] This application relates to the field of electric vehicle technology, and in particular to a motor controller module, a motor controller, a powertrain, and an electric vehicle. Background Technology

[0003] Currently in the field of electric vehicles, the powertrain includes a motor controller and a motor. The motor controller supplies power to the motor and drives the wheels. The motor controller contains many electronic and electrical components such as bus capacitors, three-phase bridge arms, radiators, and circuit boards. The large number of parts and the complex assembly result in a low level of integration of the motor controller, which makes the motor controller relatively large in size. Summary of the Invention

[0004] This application provides a motor controller module, a motor controller, a powertrain, and an electric vehicle.

[0005] In a first aspect, this application provides a motor controller module, which includes a bus capacitor and a heat sink. The inner cavity of a housing of the bus capacitor accommodates a capacitor core. A heat sink is stacked on the outer side of the housing. Along the stacking direction of the heat sink and the housing, the heat sink includes two sides. One side is used to fix a three-phase bridge arm, which receives power from the electric vehicle's power battery through the capacitor core and outputs three-phase current to drive the electric vehicle's motor. The housing includes a recess. Along the stacking direction of the heat sink and the housing, the opening of the recess faces the heat sink. The recess accommodates a partition. The partition includes two surfaces. One surface forms a liquid-cooling cavity with the bottom of the recess and a portion of the recess's peripheral wall. The other surface forms another liquid-cooling cavity with another side of the heat sink and another portion of the recess's peripheral wall. The maximum distance between the other surface and the bottom of the recess is less than the depth of the recess.

[0006] In this embodiment, the housing includes a groove, with the groove opening facing the heat sink along the stacking direction of the heat sink and the housing. The groove is used to accommodate a partition, so that the groove, the heat sink, and the partition can enclose two liquid cooling cavities. One liquid cooling cavity and the other liquid cooling cavity are used for the flow of coolant. The two liquid cooling cavities are stacked. The coolant in one liquid cooling cavity is used to cool the bus capacitor, and the coolant in the other liquid cooling cavity is used to cool the three-phase bridge arm. This forms a double-layer flow channel to cool the three-phase bridge arm and the bus capacitor, which can improve the heat dissipation efficiency of the motor controller module and enable the motor controller module to operate smoothly.

[0007] In this embodiment, one surface forms a liquid cooling cavity with the bottom of a groove and a portion of the groove's peripheral wall, while the other surface forms another liquid cooling cavity with the other side of the heat sink and another portion of the groove's peripheral wall. By directly utilizing the bottom and a portion of the groove formed by the housing to form one liquid cooling cavity with a surface of the partition, and then utilizing the other surface of the partition to form another liquid cooling cavity with the other side of the heat sink and another portion of the groove's peripheral wall, the bus capacitor and heat sink in the motor controller module achieve higher integration. Directly using a groove in the housing to form two liquid cooling cavities not only improves the integration of the motor controller module but also allows for a smaller volume along the stacking direction of the heat sink and housing, facilitating miniaturization of the motor controller module and the overall miniaturization of the motor controller.

[0008] In this embodiment, the maximum distance between the other surface and the bottom of a groove is less than the depth of the groove, so that a portion of the groove wall can participate in forming a liquid cooling cavity, and another portion of the groove wall can participate in forming another liquid cooling cavity. When forming a double-layer flow channel, it will not occupy too much space of the motor controller module along the stacking direction of the heat sink and the housing, which is beneficial to improve the heat dissipation efficiency of the motor controller module while having a smaller volume.

[0009] In one embodiment, along the stacking direction of a heat sink and a housing, the distance between one surface and the bottom of a groove is greater than or equal to the distance between another surface and the opening of a groove.

[0010] In this embodiment, the distance between one surface and the bottom of a groove along the stacking direction of the heat sink and the housing is greater than the distance between the other surface and the opening of a groove. This allows for a larger space in the liquid cooling cavity formed by the surface and the bottom of the groove, facilitating the flow of more coolant within the cavity and improving the heat dissipation effect of the liquid cooling cavity on the bus capacitor, thereby enhancing the cooling efficiency of the motor controller module. The smaller distance between the other surface and the opening of the groove ensures that the partition and the groove do not excessively occupy the space of the motor controller module along the stacking direction of the heat sink and the housing, thus promoting the miniaturization of the motor controller module.

[0011] In this embodiment, the distance between the bottom of one surface and the groove of one groove along the stacking direction of the heat sink and the housing is equal to the distance between the opening of another surface and the groove of one groove. This allows the other liquid cooling cavity formed by the other surface and the other part of the groove wall and the other side of the heat sink to have a larger volume, thereby improving the heat dissipation and cooling effect of the three-phase bridge arm.

[0012] In one embodiment, a housing further includes a plurality of baffles, each baffle extending from the bottom of a groove toward the opening of a groove along the stacking direction of a heat sink and a housing, and the height of each baffle is less than the depth of a groove.

[0013] In this embodiment, each turbulence tooth extends from the bottom of a groove toward the opening of a groove along the stacking direction of the heat sink and the housing, thereby enabling the turbulence tooth to agitate the coolant in a liquid cooling cavity formed at the bottom of a groove, increasing the heat dissipation area between the coolant and the housing, and extending the flow path of the coolant in a liquid cooling cavity. This is beneficial to improving the heat dissipation effect of a liquid cooling cavity on the bus capacitor and improving the cooling efficiency of the motor controller module.

[0014] In this embodiment of the application, the height of each turbulence tooth is less than the depth of a groove, so that there is space above the turbulence tooth for accommodating a partition and for forming another liquid cooling cavity.

[0015] In one embodiment, the three-phase bridge arm includes multiple power modules spaced apart along the length of the three-phase bridge arm. Each power module includes two sets of copper busbars facing each other along the width of the three-phase bridge arm. The length of the three-phase bridge arm is greater than its width. A partition includes multiple pairs of through holes for connecting one liquid cooling cavity to another. These through holes penetrate the partition along the stacking direction of a heat sink and a housing. Each pair of through holes includes two through holes. The multiple pairs of through holes are spaced apart along the length of the three-phase bridge arm, and the two through holes in each pair are spaced apart along the width of the three-phase bridge arm. Each power module is aligned with a pair of through holes along the stacking direction of the heat sink and the housing.

[0016] In this embodiment, multiple power modules are arranged at intervals along the length of the three-phase bridge arm, allowing them to operate relatively independently without interference. Each power module includes two sets of copper busbars, which face each other along the width of the three-phase bridge arm. One set of copper busbars receives DC power from the power battery, converts it into AC power, and outputs it to the motor via the other set of copper busbars. The facing arrangement of the two sets of copper busbars along the width of the three-phase bridge arm facilitates the layout of the circuitry within the motor controller and also allows the power battery current to drive the motor more smoothly.

[0017] In this embodiment, the length of the three-phase bridge arm along its length direction is greater than its length along its width direction, so that the three-phase bridge arm will not occupy too much space of the motor controller module along the width direction of the three-phase bridge arm.

[0018] In this embodiment, multiple pairs of through holes are used to connect one liquid cooling cavity and another liquid cooling cavity. The multiple pairs of through holes penetrate the partition along the stacking direction of the heat sink and the housing, so that the two liquid cooling cavities in the motor controller module have a higher degree of integration. The multiple pairs of through holes connecting one liquid cooling cavity and another liquid cooling cavity allow the coolant flowing into the motor controller module to flow in parallel in one liquid cooling cavity and another liquid cooling cavity, thereby cooling the three-phase bridge arm and bus capacitor, which is beneficial to improving the cooling efficiency of the motor controller module.

[0019] In this embodiment, each pair of through holes includes two through holes, and multiple pairs of through holes are arranged at intervals along the length of the three-phase bridge arm. This allows more coolant in one liquid cooling cavity and another liquid cooling cavity to flow through the multiple pairs of through holes, which helps to accelerate the exchange rate of coolant between the two liquid cooling cavities and improve heat dissipation efficiency. The multiple pairs of through holes are arranged at intervals along the length of the three-phase bridge arm, and the two through holes in each pair are arranged at intervals along the width of the three-phase bridge arm. This allows coolant in another liquid cooling cavity to flow through each pair of through holes in parallel, which helps the coolant flow through the other liquid cooling cavity more quickly, rapidly removing heat from the three-phase bridge arm and improving the heat dissipation efficiency of the motor controller module.

[0020] In this embodiment, each power module is aligned with a pair of through holes along the stacking direction of the heat sink and the housing. The two through holes in each pair are spaced apart along the width direction of the three-phase bridge arm, so that the arrangement direction of each pair of through holes is the same as that of the two sets of copper busbars in each power module. This ensures that the direction of coolant flow from the two through holes in each pair is the same as the direction of current flow in each power module, which is beneficial for improving heat dissipation efficiency. Aligning each power module with a pair of through holes along the stacking direction of the heat sink and the housing also allows each power module to have a larger heat dissipation area with the coolant in the other liquid cooling cavity, further improving heat dissipation efficiency.

[0021] In one embodiment, the length of each through-hole along the length direction of the three-phase bridge arm is greater than its width along the width direction of the three-phase bridge arm. The spacing between the two through-holes in each pair along the width direction of the three-phase bridge arm is greater than half the width of a groove along the width direction of the three-phase bridge arm.

[0022] In this embodiment, the length of each through-hole along the length of the three-phase bridge arm is greater than its width along the width of the three-phase bridge arm, while the width of each through-hole along the width of the three-phase bridge arm is smaller. This allows the coolant to flow along a longer path along the width of the three-phase bridge arm, thereby increasing the contact between the coolant and more turbulence teeth within a groove, thus improving the heat dissipation effect on the bus capacitor. The larger length of each through-hole along the length of the three-phase bridge arm facilitates wider parallel flow of each pair of through-holes in another liquid cooling cavity along the length of the three-phase bridge arm. This allows more coolant to flow from the through-holes to the upper liquid cooling cavity. The fact that the length of the through-holes is the same as the length of the three-phase bridge arm results in more uniform cooling efficiency for the three-phase bridge arm. Therefore, the greater length of each through-hole along the length of the three-phase bridge arm than its width along the width of the three-phase bridge arm allows the coolant to remove more heat from the capacitor module without affecting the flow efficiency of the through-holes. This facilitates faster heat removal from the three-phase bridge arm and improves the heat dissipation efficiency of the motor controller module.

[0023] In the embodiments of this application, the spacing between the two through holes of each pair of through holes along the width direction of the three-phase bridge arm is greater than half the width of a groove along the width direction of the three-phase bridge arm. This is beneficial to increase the flow distance of the coolant between the two through holes of each pair of through holes, thereby effectively removing the heat of the turbulence teeth and making the coolant flow of one liquid cooling cavity and the other liquid cooling cavity uniform.

[0024] In one embodiment, the housing further includes a plurality of reinforcing ribs, each rib protruding from the bottom of a groove toward a partition along the stacking direction of a heat sink and a housing. The height of each reinforcing rib is less than the depth of a groove along the stacking direction of the heat sink and the housing. Partial through holes and partial reinforcing ribs are arranged alternately along the length of the three-phase bridge arm.

[0025] In this embodiment, the housing also includes multiple reinforcing ribs. Each reinforcing rib protrudes from the bottom of a groove toward the partition along the stacking direction of the heat sink and the housing. The reinforcing rib protruding from the bottom of a groove toward the partition can reinforce the partition, thereby compensating for the reduced structural strength caused by the formation of through holes in the partition, and thus helping to improve the overall structural strength of the motor controller module.

[0026] In this embodiment, along the stacking direction of the heat sink and the housing, the height of each reinforcing rib is less than the depth of a groove, so as to avoid the reinforcing rib being too high and thus making the position of the partition too high, so that there is space above the partition to form another liquid cooling cavity.

[0027] In this embodiment, some through holes and some reinforcing ribs are arranged alternately along the length of the three-phase bridge arm, so that the reinforcing ribs can strengthen the partition whose structural strength is weakened due to the opening of through holes, which is beneficial to improving the structural strength of the motor controller module. Furthermore, the alternating arrangement of some through holes and some reinforcing ribs avoids the reinforcing ribs blocking the through holes and affecting the flow of coolant.

[0028] In one embodiment, a housing further includes a protrusion and two inlets / outlets. Along the stacking direction of a heat sink and a housing, the protrusion extends from the bottom of a groove towards the opening of another groove. A partition is stacked on the protrusion. The protrusion divides a liquid-cooled cavity into two liquid-cooled sub-cavities and separates the two inlets / outlets. Each liquid-cooled sub-cavity connects to the other liquid-cooled cavity and one inlet / outlet. The two inlets / outlets connect to an external flow channel. Along the stacking direction of the heat sink and the housing, the height of the protrusion is less than the depth of the groove. The length of the protrusion is greater than or equal to the length of the groove along the length of the three-phase bridge arm.

[0029] In this embodiment, a protrusion extends from the bottom of a groove toward the opening of another groove along the stacking direction of the heat sink and the housing. A partition is stacked on the protrusion, allowing it to divide a liquid cooling cavity into two liquid cooling sub-cavities. The protrusion separates two inlets and outlets. Each liquid cooling sub-cavity connects to another liquid cooling cavity and one inlet / outlet, or connects to another liquid cooling cavity and another inlet / outlet. The two inlets / outlets connect to external flow channels. The protrusion prevents the coolant in one liquid cooling cavity from flowing directly through only the two inlets / outlets. It also allows the coolant in one liquid cooling cavity to communicate with the coolant in the other liquid cooling cavity through through-holes.

[0030] In this embodiment, along the stacking direction of the heat sink and the housing, the height of the protrusion is less than the depth of a groove, so that the partition is stacked on the protrusion, and there is space in the groove above the partition to form another liquid cooling cavity.

[0031] In the embodiments of this application, the length of the protrusion is greater than or equal to the length of a groove along the length direction of the three-phase bridge arm, so that the protrusion can enhance the structural strength of a groove and effectively separate the two inlets and outlets.

[0032] In one embodiment, a protrusion includes a sealing groove recessed away from a partition along the stacking direction of a heat sink and a housing. The sealing groove is used to accommodate a seal. Another side of the heat sink includes a plurality of heat dissipation teeth protruding towards the partition along the stacking direction of the heat sink and the housing. A seal is used to seal the gap between the partition and the protrusion and to abut against the plurality of heat dissipation teeth on the other surface of the partition. Wherein, along the stacking direction of the heat sink and the housing, the distance between the plurality of heat dissipation teeth and the bottom of the sealing groove is less than the sum of the free length of the seal and the length of the portion of the partition that contacts the seal.

[0033] In this embodiment, the sealing groove is recessed away from the partition along the stacking direction of the heat sink and the housing. The sealing groove is used to accommodate a sealing element, so that the sealing element can seal the gap between the partition and the protrusion, so that the coolant in the two liquid-cooled sub-cavities can be effectively isolated, so that the coolant in one liquid-cooled sub-cavity needs to flow through the other liquid-cooled sub-cavity and then flow back to the other liquid-cooled sub-cavity.

[0034] In this embodiment, the other side of the heat sink includes multiple heat dissipation teeth. The multiple heat dissipation teeth protrude toward the partition along the stacking direction of the heat sink and the housing. The multiple heat dissipation teeth are located in another liquid cooling cavity, which is used to increase the heat dissipation area in the other liquid cooling cavity, improve the heat dissipation effect of the coolant in the other liquid cooling cavity, improve the cooling efficiency of the coolant on the three-phase bridge arm, and thus improve the cooling efficiency of the motor controller module.

[0035] In this embodiment, the seal is used to seal the gap between the partition and the protrusion and to abut the other surface of the partition against the multiple heat dissipation teeth. This allows the seal to not only seal the two liquid-cooled sub-cavities relatively independently, but also to prevent the coolant flowing into the other liquid-cooled cavity from laminar flow due to the gap between the tooth surface of the heat dissipation teeth and the other surface of the partition. Laminar flow of coolant has less resistance than coolant flowing between the heat dissipation teeth. If laminar flow occurs, more coolant will flow over the tooth surface of the heat dissipation teeth and will not have more contact with the heat dissipation teeth, thus reducing the cooling effect of the coolant in the other liquid-cooled cavity on the three-phase bridge arm and hindering the improvement of the cooling efficiency of the motor controller module.

[0036] In this embodiment, along the stacking direction of the heat sink and the housing, the distance between the multiple heat dissipation teeth and the bottom of the sealing groove is less than the sum of the free length of the seal and the length of the partition plate in contact with the seal. This allows the seal in the sealing groove to apply an upward elastic force to the partition plate along the stacking direction of the heat sink and the housing, so that the other surface of the partition plate can abut against the multiple heat dissipation teeth. This prevents the coolant flowing from the liquid cooling cavity into another liquid cooling cavity through the through hole from the liquid cooling cavity from laminar flow on the tooth surface of the heat dissipation teeth, which helps to increase the contact area between the coolant and the heat dissipation teeth, thereby improving the cooling effect of the other liquid cooling cavity on the three-phase bridge arm, and thus improving the cooling efficiency of the motor controller module.

[0037] In one embodiment, a surface of a partition includes a sealing protrusion that protrudes toward a sealing groove along the stacking direction of a heat sink and a housing. The sealing groove is used to receive the sealing protrusion, and the sealing protrusion is used to compress a seal. Wherein, along the stacking direction of the heat sink and the housing, the sum of the length of the sealing protrusion and the free length of the seal is greater than the depth of the sealing groove.

[0038] In this embodiment, the sealing protrusion protrudes towards the sealing groove along the stacking direction of the heat sink and the housing. The sealing groove is used to accommodate the sealing protrusion, and the sealing protrusion is used to compress the sealing element. The sealing protrusion, the sealing groove, and the sealing element cooperate with each other, making the sealing connection between the partition and the protrusion more stable. This not only allows one liquid cooling chamber to be divided into two liquid cooling sub-chambers, but also allows the sealing element to better apply force to the partition, so that the other surface of the partition abuts against multiple heat dissipation teeth. This prevents the coolant in the other liquid cooling chamber from flowing between the heat dissipation teeth and the partition, allowing more coolant to flow between the heat dissipation teeth, thereby improving the cooling effect of the other liquid cooling chamber on the three-phase bridge arm.

[0039] In this embodiment, along the stacking direction of the heat sink and the housing, the sum of the length of the sealing protrusion and the free length of the sealing element is greater than the depth of the sealing groove, so that the sealing element can have an upward elastic force on the partition, so that the other surface of the partition abuts against multiple heat dissipation teeth, preventing the coolant in the other liquid cooling cavity from flowing between the heat dissipation teeth and the partition, so that more coolant flows between the heat dissipation teeth, thereby improving the cooling effect of the other liquid cooling cavity on the three-phase bridge arm.

[0040] In one embodiment, a protrusion includes a first segment, a second segment, and a third segment connected in sequence. The first and second segments are arranged on opposite sides of the two inlets / outlets along the length of the three-phase bridge arm. The two ends of the second segment are arranged on different sides of the two inlets / outlets along the width of the three-phase bridge arm.

[0041] In this embodiment, the first and second segments are arranged on both sides of the two inlets and outlets along the length of the three-phase bridge arm, so that the protrusions can better isolate the two inlets and outlets, and can also improve the problem that the strength of the housing is reduced due to the opening of two inlets and outlets.

[0042] In this embodiment, the two ends of the second segment along its length are arranged on different sides of the two inlets and outlets along the width of the three-phase bridge arm, so that the two inlets and outlets can be isolated in two liquid-cooled sub-cavities respectively. This ensures that the coolant flowing into one liquid-cooled cavity will not flow only between the two inlets and outlets without flowing through the other liquid-cooled cavity. The double-layer flow channel allows the three-phase bridge arm and bus capacitor of the motor controller module to be cooled down simultaneously, thereby improving the cooling efficiency of the motor controller module.

[0043] In one embodiment, the peripheral wall of a groove includes a plurality of locking protrusions for limiting the position of a partition. Specifically, along the stacking direction of a heat sink and a housing, the distance between each locking protrusion and the bottom of a groove is greater than the distance between the other surface of a partition and the bottom of a groove.

[0044] In this embodiment, the peripheral wall of a groove includes multiple locking protrusions. These protrusions limit the positioning of the partition, allowing the partition to be fixedly placed above the housing. This facilitates the formation of two relatively stable liquid cooling cavities, improving the structural reliability of the motor controller module and consequently the motor controller itself. The locking protrusions are located on the peripheral wall of one groove and are used to secure the side plate below them. This allows the other portion of the peripheral wall where the locking protrusion is located, the other surface of the partition, and the heat sink to enclose and form another liquid cooling cavity, enhancing the integration and cohesion of the motor controller module's structure.

[0045] In this embodiment, along the stacking direction of the heat sink and the housing, the distance between each locking protrusion and the bottom of a groove is greater than the distance between the other surface of the partition and the bottom of a groove. This allows the locking protrusion to be stacked on the partition along the stacking direction of the heat sink and the housing. Along the stacking direction of the heat sink and the housing, the locking protrusion, the partition, and the groove opening are arranged in sequence, so that the locking protrusion can limit the partition and fix the partition on a groove, making the structure of the motor controller module more stable.

[0046] In one embodiment, another side of a heat sink further includes another groove and a plurality of heat dissipation teeth. Along the stacking direction of the heat sink and the housing, the other groove is recessed away from a partition, and the plurality of heat dissipation teeth protrude from the bottom of the other groove toward the partition. Another surface is used to form another liquid cooling cavity with the other groove on the other side of the heat sink and another portion of the peripheral wall of the first groove. Wherein, along the stacking direction of the heat sink and the housing, the depth of the other groove is less than the length of at least a portion of the heat dissipation teeth, the depth of the other groove is less than the maximum distance between the bottom of the first groove and the partition, and the length of the plurality of heat dissipation teeth is less than the depth of the first groove.

[0047] In this embodiment, another groove is recessed away from the partition along the stacking direction of the heat sink and the housing. This allows the other groove of the heat sink to form a larger liquid cooling cavity with the partition, providing sufficient space for the arrangement of multiple heat dissipation fins. It also allows more coolant to flow in the other liquid cooling cavity, improving the cooling effect of the coolant on the three-phase bridge arm. Multiple heat dissipation fins protrude from the bottom of the other groove towards the partition, allowing them to be arranged in the other liquid cooling cavity to turbulently flow the coolant, thereby improving the cooling efficiency of the motor controller module.

[0048] In this embodiment, another surface is used to form another liquid cooling cavity with another groove on the other side of the heat sink and another part of the groove peripheral wall. The groove peripheral wall is used not only to form one liquid cooling cavity but also to form another liquid cooling cavity. This ensures that the formation of the two liquid cooling cavities does not occupy too much space of the motor controller module along the stacking direction of the heat sink and the housing. This is beneficial for the miniaturization of the motor controller module and can also improve the integration of the motor controller module.

[0049] In this embodiment, along the stacking direction of the heat sink and the housing, the depth of the other groove is less than the length of at least a portion of the heat dissipation teeth. This allows at least a portion of the heat dissipation teeth to abut against the other surface of the partition, preventing laminar flow of the coolant in another liquid-cooled cavity due to gaps between the tooth surfaces of the heat dissipation teeth and the other surface of the partition, thereby improving heat dissipation efficiency. The longer length of the heat dissipation teeth also increases the contact area between the coolant and the heat dissipation teeth, thus improving the cooling effect of the coolant and the cooling efficiency of the motor controller module.

[0050] In this embodiment, the depth of the other groove is less than the maximum distance between the bottom of the first groove and the partition, so that the formation of one liquid cooling cavity and the other liquid cooling cavity will not occupy too much space of the motor controller module along the stacking direction of the heat sink and the housing, which is beneficial to the miniaturization of the motor controller module.

[0051] In this embodiment, the length of multiple heat dissipation teeth is less than the depth of a groove, so that when the heat dissipation plate uses a groove to form another liquid cooling cavity, the other liquid cooling cavity will not occupy too much space of the motor controller module along the stacking direction of the heat dissipation plate and the housing, which is beneficial to the miniaturization of the motor controller module.

[0052] In a second aspect, this application provides a motor controller, which includes a housing and a motor controller module as described in the first aspect. The housing is used to house the motor controller module, and the internal flow channel of the housing is used to connect two inlets and outlets of a housing of a bus capacitor in the motor controller module.

[0053] In the motor controller module of this application embodiment, two liquid-cooled chambers are formed by utilizing a heat sink, a partition, and a groove in the casing of the bus capacitor. These two liquid-cooled chambers form a double-layer flow channel for coolant circulation, cooling the bus capacitor and the three-phase bridge arm, thereby improving the cooling efficiency of the motor controller module. Utilizing the groove formed by the bus capacitor casing to create the liquid-cooled chambers also increases the integration of the motor controller module, facilitating its miniaturization, and consequently, the miniaturization of the motor controller itself.

[0054] Thirdly, this application provides a powertrain including a motor and a motor controller as described in the second aspect, wherein the motor is used to receive power from a motor controller module of the motor controller.

[0055] The motor controller in this embodiment includes a motor controller module. The motor controller module forms two liquid-cooled chambers by utilizing a heat sink, a partition, and a recess in the bus capacitor housing. These two liquid-cooled chambers form a double-layer flow channel for coolant circulation, cooling the bus capacitor and the three-phase bridge arm, thereby improving the cooling efficiency of the motor controller module. Utilizing the recess formed by the bus capacitor housing to create the liquid-cooled chambers also increases the integration of the motor controller module, facilitating its miniaturization, which in turn contributes to the miniaturization of the motor controller and the powertrain.

[0056] Fourthly, this application provides an electric vehicle, which includes a frame, a power battery, and a powertrain as described in the third aspect. The frame is used to fix the power battery and the powertrain, and the motor of the powertrain is used to receive power from the power battery through a motor controller to drive the wheels.

[0057] The powertrain in this embodiment includes a motor controller module. The motor controller module forms two liquid-cooled chambers using a heat sink, a partition, and a recess in the bus capacitor housing. These two chambers form a double-layer flow channel for coolant circulation, cooling the bus capacitor and three-phase bridge arms and improving the cooling efficiency of the motor controller module. Utilizing the recess formed by the bus capacitor housing to create the liquid-cooled chambers also increases the integration of the motor controller module, facilitating its miniaturization. This, in turn, contributes to the miniaturization of the motor controller and the powertrain, thereby optimizing the overall vehicle layout. Attached Figure Description

[0058] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the embodiments of this application will be described below.

[0059] Figure 1 is a structural schematic diagram of the electric vehicle provided in an embodiment of this application;

[0060] Figure 2 is a schematic diagram of the powertrain provided in an embodiment of this application;

[0061] Figure 3 is a structural schematic diagram of the motor controller module provided in an embodiment of this application;

[0062] Figure 4 is an exploded view of the motor controller module provided in an embodiment of this application;

[0063] Figure 5 is a cross-sectional view of the motor controller module provided in an embodiment of this application;

[0064] Figure 6 is a partial enlarged view of the M1 part of the motor controller module in Figure 5;

[0065] Figure 7 is a schematic diagram of the structure of the shell provided in an embodiment of this application;

[0066] Figure 8 is a cross-sectional view of the housing provided in an embodiment of this application;

[0067] Figure 9 is a schematic diagram of the structure of the partition provided in an embodiment of this application;

[0068] Figure 10 is a structural schematic diagram of a partition provided in another embodiment of this application;

[0069] Figure 11 is a partial enlarged view of the M2 part of the motor controller module in Figure 5;

[0070] Figure 12 is another structural schematic diagram of the partition provided in an embodiment of this application;

[0071] Figure 13 is a partial enlarged view of the M1 part of the motor controller module in Figure 5;

[0072] Figure 14 is another exploded view of the motor controller module provided in the embodiment of this application;

[0073] Figure 15 is another structural schematic diagram of the motor controller module provided in the embodiment of this application. Detailed Implementation

[0074] The technical solutions of the embodiments of this application will be described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments.

[0075] To improve the heat dissipation efficiency of the motor controller and to miniaturize the layout of the motor controller module, this application provides a motor controller module. The motor controller module includes a bus capacitor and a heat sink. The inner cavity of a housing of the bus capacitor is used to accommodate a capacitor core. The heat sink is stacked on the outer side of the housing. Along the stacking direction of the heat sink and the housing, the heat sink includes two sides. One side is used to fix a three-phase bridge arm. The three-phase bridge arm is used to receive power from the electric vehicle's power battery through the capacitor core and output three-phase current to drive the electric vehicle's motor. The housing includes a groove. Along the stacking direction of the heat sink and the housing, the groove opening faces the heat sink. The groove is used to accommodate a partition. The partition includes two surfaces. One surface is used to form a liquid cooling cavity with the bottom of the groove and a portion of the groove's peripheral wall. The other surface is used to form another liquid cooling cavity with another side of the heat sink and another portion of the groove's peripheral wall. The maximum distance between the other surface and the bottom of the groove is less than the depth of the groove. Two liquid-cooling chambers are formed by utilizing the heat sink, partition, and grooves in the bus capacitor housing. These two chambers create a double-layer flow channel for coolant circulation, cooling the bus capacitor and three-phase bridge arms and improving the cooling efficiency of the motor controller module. Using the grooves in the bus capacitor housing to form the liquid-cooling chambers also increases the integration of the motor controller module, facilitating its miniaturization and ultimately contributing to the miniaturization of the motor controller itself.

[0076] The motor controller module provided in this application embodiment is used for a motor controller, which is applied to a powertrain, and the powertrain is applied to an electric vehicle to improve the overall performance of the electric vehicle.

[0077] Figure 1 is a structural schematic diagram of the electric vehicle 1 provided in an embodiment of this application, Figure 2 is a structural schematic diagram of the powertrain 10 provided in an embodiment of this application, and Figure 3 is a structural schematic diagram of the motor controller module 100 provided in an embodiment of this application.

[0078] In one embodiment, the electric vehicle 1 includes a powertrain 10, a frame 20, and a power battery 30, as shown in FIG1. ​​The frame 20 is used to fix the power battery 30 and the powertrain 10. In this embodiment, the powertrain 10 is used to receive power from the power battery 30 and to drive the wheels 40.

[0079] In this embodiment, the power battery 30 may also be referred to as a battery pack. In this embodiment, the electric vehicle 1 refers to a wheeled device driven or towed by a power unit.

[0080] In one embodiment, the powertrain 10 includes a motor 11, a reducer 12, and a motor controller 13. As shown in FIG2, in this embodiment, the motor 11 includes a motor shaft (not shown), a motor stator (not shown), and a motor rotor (not shown). The motor rotor is fixedly sleeved on the motor shaft. After receiving AC power, the motor stator drives the motor rotor to rotate, thereby driving the motor shaft to rotate. The reducer 12 includes a gear assembly (not shown), an input shaft (not shown), and an output shaft (not shown). The motor shaft of the motor 11 is used for transmission connection with the input shaft of the reducer 12. The input shaft receives the power transmitted from the motor shaft of the motor 11 and transmits the power to the output shaft through the gear assembly. The gear assembly can be configured as needed and can be a single-speed reduction gear assembly, a two-speed or multi-speed reduction gear assembly.

[0081] In this embodiment, the motor controller 13 is used to control the motor 11 of the electric vehicle 1 to drive the wheels 40 of the electric vehicle 1. The motor controller 13 is used to receive the DC power supplied by the power battery 30 and convert the DC power into AC power to be supplied to the motor 11. The power battery 30 is connected to the windings of the motor 11 through the motor controller 13 to drive the motor 11.

[0082] In one embodiment, the motor controller 13 is also used to charge and discharge the power battery 30. The motor controller 13 is also used to integrate at least one of an on-board charger, a vehicle controller, and a power distribution device.

[0083] In one embodiment, as shown in Figures 2 and 3, the motor controller 13 includes a housing (not shown) and a motor controller module 100. The housing houses the motor controller module 100, and the motor 11 receives power from the motor controller module 100 of the motor controller 13. The motor controller module 100 includes a heat sink, a bus capacitor 101, and a three-phase bridge arm 103. The heat sink cools the bus capacitor 101 and the three-phase bridge arm 103.

[0084] In one embodiment, the motor controller 13 further includes components such as a DC filter, a Hall busbar assembly, and a circuit board.

[0085] The motor controller of an electric vehicle requires a large number of electronic and electrical components, such as DC filters, bus capacitors, power modules, and heat sinks. The large number of components makes the motor controller bulky and results in low integration. The bus capacitors and power modules generate heat during operation, so it is necessary to improve the cooling effect of the heat sink on the bus capacitors and power modules.

[0086] In this embodiment, two liquid cooling chambers are formed by utilizing a heat sink, a partition, and a groove in the bus capacitor housing. These two chambers form a double-layer flow channel for coolant circulation, cooling the bus capacitor and the three-phase bridge arm, thereby improving the cooling efficiency of the motor controller module. Using the groove formed by the bus capacitor housing to create a liquid cooling chamber also increases the integration of the motor controller module, facilitating its miniaturization and ultimately contributing to the miniaturization of the motor controller itself.

[0087] The motor controller module 100 with a capacitor housing forming a dual liquid cooling cavity, provided in the embodiments of this application, will be described in detail below.

[0088] Figure 4 is an exploded view of the motor controller module 100 provided in the embodiment of this application, Figure 5 is a cross-sectional view of the motor controller module 100 provided in the embodiment of this application, and Figure 6 is a partial enlarged view of the M1 part of the motor controller module 100 in Figure 5.

[0089] In one embodiment, the motor controller module 100 includes a bus capacitor 101 and a heat sink 102, as shown in Figures 1 to 4. The inner cavity of a housing 110 of the bus capacitor 101 is used to accommodate a capacitor core 111. The heat sink 102 is stacked on the outer side of the housing 110. Along the stacking direction Z of the heat sink 102 and the housing 110, the heat sink 102 includes two sides 121 and 122. One side 121 is used to fix a three-phase bridge arm 103. The three-phase bridge arm 103 is used to receive power from the power battery 30 of the electric vehicle 1 through the capacitor core 111 and output three-phase current to drive the motor 11 of the electric vehicle 1.

[0090] In this embodiment, the bus capacitor 101 is used to smooth the bus voltage, reduce inductance parameters, absorb high pulse current, or prevent overcharging and transient voltage effects, so as to ensure the safe operation of the motor controller 13. The three-phase bridge arm 103 is used to realize the mutual conversion between three-phase AC and DC power.

[0091] In one embodiment, the housing 110 includes a groove 113, as shown in Figures 5 and 6. Along the stacking direction of the heat sink 102 and the housing 110, the groove opening 113a of the groove 113 faces the heat sink 102. The groove 113 is used to accommodate a partition 104. The partition 104 includes two surfaces 141 and 142. One surface 141 is used to form a liquid cooling cavity 105a with the bottom 113b of the groove 113 and a portion of the peripheral wall 113c of the groove 113. The other surface 142 is used to form another liquid cooling cavity 105b with another side 122 of the heat sink 102 and another portion of the peripheral wall 113d of the groove 113. The maximum distance between the other surface 142 and the bottom 113b of the groove 113 is less than the depth of the groove 113.

[0092] In this embodiment, the housing 110 includes a groove 113. Along the stacking direction of the heat sink 102 and the housing 110, the groove 113a faces the heat sink 102. The groove 113 is used to accommodate a partition 104, so that the groove 113, the heat sink 102, and the partition 104 can enclose and form two liquid cooling cavities 105a and 105b. The liquid cooling cavities 105a and 105b are used for the flow of coolant. The liquid cooling cavities 105a and 105b are stacked. The coolant in the liquid cooling cavity 105a is used to cool the bus capacitor 101, and the coolant in the liquid cooling cavity 105b is used to cool the three-phase bridge arm 103. The double-layer flow channel cools the three-phase bridge arm 103 and the bus capacitor 101, which can improve the heat dissipation efficiency of the motor controller module 100 and enable the motor controller module 100 to operate smoothly.

[0093] In this embodiment, one surface 141 is used to form a liquid cooling cavity 105a with the bottom 113b of the groove 113 and a portion of the groove peripheral wall 113c of the groove 113, and another surface 142 is used to form another liquid cooling cavity 105b with the other side 122 of the heat sink 102 and another portion of the groove peripheral wall 113d of the groove 113. The bottom 113b and a portion of the groove peripheral wall 113c of the groove 113 formed by the housing 110 are directly used to form the liquid cooling cavity 105a with the surface 141 of the partition 104, and the surface 142 of the partition 104 is used to form the liquid cooling cavity 105b with the side 122 of the heat sink 102 and another portion of the groove peripheral wall 113d of the groove 113, so that the bus capacitor 101 and the heat sink 102 in the motor controller module 100 have a higher degree of integration. By directly using the groove 113 of the housing 110 to form two liquid cooling cavities 105a and 105b, not only can the integration of the motor controller module 100 be improved, but the motor controller module 100 can also have a smaller volume along the stacking direction Z of the heat sink 102 and the housing 110, which is beneficial to the miniaturization of the motor controller module 100 and the motor controller 13.

[0094] In this embodiment of the application, as shown in FIG6, the maximum distance between the surface 142 and the bottom 113b of the groove 113 is denoted as L1, and the depth of the groove 113 is denoted as L2, where L1 < L2. This allows a portion of the groove peripheral wall 113c of the groove 113 to participate in forming the liquid cooling cavity 105a, and another portion of the groove peripheral wall 113d of the groove 113 to participate in forming the liquid cooling cavity 105b. When forming a double-layer flow channel, it will not occupy too much space of the motor controller module 100 along the stacking direction Z of the heat sink 102 and the housing 110, which is beneficial for the motor controller module 100 to improve heat dissipation efficiency while having a smaller volume.

[0095] In one embodiment, as shown in FIG6, the distance between the surface 141 and the bottom 113b of the groove 113 along the stacking direction Z of the heat sink 102 and the housing 110 is greater than the distance between the surface 142 and the opening 113a of the groove 113.

[0096] In this embodiment, the distance between the surface 141 and the bottom 113b of the groove 113 along the Z-direction of the stacking of the heat sink 102 and the housing 110 is denoted as L3, and the distance between the surface 142 and the opening 113a of the groove 113 is denoted as L4. L3 > L4, which allows the liquid cooling cavity 105a formed by the surface 141 and the bottom 113b of the groove 113 to have a larger space. This facilitates the flow of more coolant within the liquid cooling cavity 105a, which improves the heat dissipation effect of the liquid cooling cavity 105a on the bus capacitor 101, thereby improving the cooling efficiency of the motor controller module 100. A smaller L4 ensures that the partition 104 and the groove 113 do not occupy too much space of the motor controller module 100 along the Z-direction of the stacking of the heat sink 102 and the housing 110, which is beneficial for the miniaturization of the motor controller module 100.

[0097] In one embodiment, the distance between surface 141 and the bottom 113b of groove 113 along the stacking direction Z of heat sink 102 and housing 110 is equal to the distance between surface 142 and the opening 113a of groove 113. This allows the liquid cooling cavity 105b formed by surface 142 and another part of the groove peripheral wall 113d of groove 113 and the side surface 122 of heat sink 102 to have a larger volume, thereby improving the heat dissipation and cooling effect of three-phase bridge arm 103.

[0098] In one embodiment, when the side 122 of the heat sink 102 is a plane, setting L3 = L4 can make the liquid cooling cavity 105b and the liquid cooling cavity 105a have the same height, thereby improving the overall heat dissipation effect on the bus capacitor 101 and the three-phase bridge arm 103.

[0099] In one embodiment, when L3 > L4, the side surface 122 of the heat sink 102 can be formed into a groove (not shown) facing away from the partition. The groove on the side surface 122 of the heat sink 102, together with the surface 142 and another part of the groove peripheral wall 113d of the groove 113, forms a liquid cooling cavity 105b, thereby increasing the height of the liquid cooling cavity 105b and thus improving the heat dissipation and cooling effect on the three-phase bridge arm 103.

[0100] Figure 7 is a structural schematic diagram of the housing 110 provided in the embodiment of this application, and Figure 8 is a cross-sectional view of the housing 110 provided in the embodiment of this application.

[0101] In one embodiment, the housing 110 further includes a plurality of baffle teeth 115, as shown in Figures 7 and 8. Each baffle tooth 115 extends from the bottom 113b of the groove 113 toward the opening 113a of the groove 113 along the stacking direction Z of the heat sink 102 and the housing 110. As shown in Figures 6 and 8, the height of each baffle tooth 115 is less than the depth of the groove 113.

[0102] In this embodiment, along the stacking direction Z of the heat sink 102 and the housing 110, each turbulence tooth 115 extends from the bottom 113b of the groove 113 toward the opening 113a of the groove 113, thereby enabling the turbulence tooth 115 to agitate the coolant in the liquid cooling cavity 105a formed in the bottom 113b of the groove 113, increasing the heat dissipation area between the coolant and the housing 110, and extending the flow path of the coolant in the liquid cooling cavity 105a. This is beneficial to improving the heat dissipation effect of the liquid cooling cavity 105a on the bus capacitor 101 and improving the cooling efficiency of the motor controller module 100.

[0103] In this embodiment of the application, as shown in Figures 6 and 8, the height of each turbulence tooth 115 is denoted as L5, and the depth of the groove 113 is L2, where L5 < L2, so that there is space above the turbulence tooth 115 for accommodating the partition 104 and for forming the liquid cooling cavity 105b.

[0104] In one embodiment, the height of each baffle tooth 115 is greater than the distance between the surface 142 and the groove 113a of the recess 113. In this embodiment, as shown in Figures 6 and 8, the height of each baffle tooth 115 is L5, and the distance between the surface 142 and the groove 113a of the recess 113 is L4, where L5 > L4. This allows each baffle tooth 115 to have a higher height within the recess 113, making fuller use of the space in the liquid cooling cavity 105a. This facilitates a larger contact area between each baffle tooth 115 and the coolant in the liquid cooling cavity 105a, thereby improving the heat dissipation effect of the liquid cooling cavity 105a on the bus capacitor 101 and ultimately enhancing the heat dissipation efficiency of the motor controller module 100.

[0105] In one embodiment, the height of each baffle tooth 115 is equal to the maximum distance between the partition 104 and the bottom 113b of the groove 113. The maximum distance between the partition 104 and the bottom 113b of the groove 113 is denoted as L6, and L5 is equal to L6. This allows the partition 104 to fit against each baffle tooth 115, so that the coolant flows through the gap between each baffle tooth 115, improving the heat dissipation effect and preventing the baffle tooth 115 from having a gap with the partition 104, which would cause laminar flow and reduce the cooling effect.

[0106] Figure 9 is a schematic diagram of the structure of the partition 104 provided in the embodiment of this application.

[0107] In one embodiment, the three-phase bridge arm 103 includes a plurality of power modules 131, as shown in FIG4. The plurality of power modules 131 are arranged at intervals along the length direction X of the three-phase bridge arm 103. Each power module 131 includes two sets of copper busbars 131a and 131b. The two sets of copper busbars 131a and 131b are opposite each other along the width direction Y of the three-phase bridge arm 103. The length of the three-phase bridge arm 103 along its length direction X is greater than the length along its width direction Y. As shown in Figures 4 and 9, the partition 104 includes multiple pairs of through holes 143a, which are used to connect the liquid cooling cavity 105a and the liquid cooling cavity 105b. The multiple pairs of through holes 143a penetrate the partition 104 along the stacking direction Z of the heat sink 102 and the housing 110. Each pair of through holes 143a includes two through holes 143. The multiple pairs of through holes 143a are arranged at intervals along the length direction X of the three-phase bridge arm 103. The two through holes 143 of each pair of through holes 143a are arranged at intervals along the width direction Y of the three-phase bridge arm 103. Each power module 131 is aligned with a pair of through holes 143a along the stacking direction Z of the heat sink 102 and the housing 110.

[0108] In this embodiment, multiple power modules 131 are arranged at intervals along the length direction X of the three-phase bridge arm 103, allowing the multiple power modules 131 to operate relatively independently without interfering with each other. Each power module 131 includes two sets of copper busbars 131a and 131b, which are opposite each other along the width direction Y of the three-phase bridge arm 103. One set of copper busbars 131a of the power module 131 receives DC power supplied from the power battery 30, converts the DC power into AC power, and outputs it to the motor 11 through the other set of copper busbars 131b. The opposite arrangement of the two sets of copper busbars 131a and 131b along the width direction Y of the three-phase bridge arm 103 facilitates the layout of the circuit within the motor controller 13 and also helps the current from the power battery 30 to drive the motor 11 more smoothly.

[0109] In this embodiment, the length of the three-phase bridge arm 103 along its length direction X is greater than its length along its width direction Y, so that the three-phase bridge arm 103 will not occupy too much space of the motor controller module 100 along the width direction Y of the three-phase bridge arm 103.

[0110] In this embodiment, multiple pairs of through holes 143a are used to connect the liquid cooling cavity 105a and the liquid cooling cavity 105b. The multiple pairs of through holes 143a penetrate the partition 104 along the stacking direction Z of the heat sink 102 and the housing 110, so that the two liquid cooling cavities 105a and 105b in the motor controller module 100 have a higher degree of integration. The multiple pairs of through holes 143a connecting the liquid cooling cavity 105a and the liquid cooling cavity 105b allows the coolant flowing into the motor controller module 100 to flow in parallel in the liquid cooling cavity 105a and the liquid cooling cavity 105b, thereby cooling the three-phase bridge arm 103 and the bus capacitor 101 and improving the cooling efficiency of the motor controller module 100.

[0111] In this embodiment, each pair of through holes 143a includes two through holes 143. Multiple pairs of through holes 143a are arranged at intervals along the length X direction of the three-phase bridge arm 103, allowing more coolant in the liquid cooling chambers 105a and 105b to flow through the through holes 143a. This facilitates faster coolant exchange within the liquid cooling chambers 105a and 105b, improving heat dissipation efficiency. The multiple pairs of through holes 143a are arranged at intervals along the length X direction of the three-phase bridge arm 103, and the two through holes 143 in each pair are arranged at intervals along the width Y direction of the three-phase bridge arm 103. This allows the coolant in the liquid cooling chamber 105b to flow through each pair of through holes 143a in parallel, facilitating faster coolant flow through the liquid cooling chamber 105b and quickly removing heat from the three-phase bridge arm 103, thus improving the heat dissipation efficiency of the motor controller module 100.

[0112] In this embodiment, the alignment of each power module 131 with a pair of through holes 143a along the stacking direction Z of the heat sink 102 and the housing 110 means that the projections of each power module 131 and the pair of through holes 143a in the stacking direction Z of the heat sink 102 and the housing 110 at least partially overlap. In this embodiment, the alignment of each power module 131 with a pair of through holes 143a along the stacking direction Z of the heat sink 102 and the housing 110, with the two through holes 143 of each pair of through holes 143a arranged at intervals along the width direction Y of the three-phase bridge arm 103, ensures that the arrangement direction of each pair of through holes 143a is the same as that of the two sets of copper busbars 131a and 131b of each power module 131. This ensures that the direction of coolant flow from the two through holes 143 of each pair of through holes 143a is the same as the current flow direction of each power module 131, which is beneficial for improving heat dissipation efficiency. Aligning each power module 131 with a pair of through holes 143a along the stacking direction Z of the heat sink 102 and the housing 110 also helps each power module 131 to have a larger heat dissipation area with the coolant in the liquid cooling cavity 105b, which is beneficial to improving heat dissipation efficiency.

[0113] Figure 10 is a structural schematic diagram of the partition 104 provided in another embodiment of this application.

[0114] In one embodiment, as shown in FIG10, each of the multiple pairs of through holes 143a on the partition 104 can be a slot that opens along the width direction Y of the three-phase bridge arm 103, and the processing technology is simple.

[0115] In one embodiment, as shown in FIG9, the length of each through hole 143 along the length direction X of the three-phase bridge arm 103 is greater than its width along the width direction Y of the three-phase bridge arm 103. As shown in FIG5 and FIG9, the spacing between the two through holes 143 of each pair of through holes 143a along the width direction Y of the three-phase bridge arm 103 is greater than half the width of the groove 113 along the width direction Y of the three-phase bridge arm 103.

[0116] In this embodiment of the application, as shown in FIG9, the length of each through hole 143 along the length direction X of the three-phase bridge arm 103 is denoted as L7, and the width of each through hole 143 along the width direction Y of the three-phase bridge arm 103 is denoted as L8. L7 > L8, and L8 is smaller, so that the coolant flows through a longer path along the width direction Y of the three-phase bridge arm 103, thereby allowing the coolant to contact more turbulence teeth 115 in the groove 113 to improve the heat dissipation effect on the bus capacitor. A larger L7 facilitates wider parallel flow of each pair of through holes 143a along the length X of the three-phase bridge arm 103 in the liquid cooling cavity 105b. This allows more coolant to flow from the through holes 143a to the upper liquid cooling cavity 105b. The length direction of the through holes 143a is the same as the length direction X of the three-phase bridge arm 103, resulting in a more uniform cooling efficiency for the three-phase bridge arm 103. Therefore, setting L7 > L8 allows the coolant to remove more heat from the capacitor module without affecting the flow efficiency of the through holes 143a. This helps the coolant remove heat from the three-phase bridge arm 103 more quickly, thus improving the heat dissipation efficiency of the motor controller module 100.

[0117] In this embodiment of the application, as shown in Figures 5 and 9, the distance between the two through holes 143 of each pair of through holes 143a along the width direction Y of the three-phase bridge arm 103 is denoted as L9, and the width of the groove 113 along the width direction Y of the three-phase bridge arm 103 is denoted as L10. L9 > 0.5L10, which is beneficial to increase the flow distance of the coolant between the two through holes 143 of each pair of through holes 143a, thereby effectively carrying away the flow of the turbulence tooth 115, so that the coolant flow in the liquid cooling cavity 105a and the liquid cooling cavity 105b is uniform.

[0118] In one embodiment, the housing 110 further includes a plurality of reinforcing ribs 116, as shown in Figures 4 and 7. Each reinforcing rib 116 protrudes from the bottom 113b of the groove 113 toward the partition 104 along the stacking direction Z of the heat sink 102 and the housing 110. The height of each reinforcing rib 116 is less than the depth of the groove 113 along the stacking direction Z of the heat sink 102 and the housing 110. As shown in Figures 7 and 9, some through holes 143 and some reinforcing ribs 116 are arranged alternately along the length direction X of the three-phase bridge arm 103.

[0119] In this embodiment, the housing 110 further includes a plurality of reinforcing ribs 116. Each reinforcing rib 116 protrudes from the bottom 113b of the groove 113 toward the partition 104 along the stacking direction Z of the heat sink 102 and the housing 110. The protrusion of the reinforcing ribs 116 from the bottom 113b of the groove 113 toward the partition 104 can reinforce the partition 104 to compensate for the reduced structural strength caused by the formation of the through hole 143a in the partition 104, thereby improving the overall structural strength of the motor controller module 100.

[0120] In this embodiment, along the stacking direction Z of the heat sink 102 and the housing 110, the height of each reinforcing rib 116 is less than the depth of the groove 113, so as to avoid the reinforcing rib 116 being too high and thus supporting the partition 104 at a high position, so that there is space above the partition 104 to form a liquid cooling cavity 105b.

[0121] In this embodiment, some through holes 143 and some reinforcing ribs 116 are arranged alternately along the length direction X of the three-phase bridge arm 103, so that the reinforcing ribs 116 can reinforce the partition 104 whose structural strength is weakened due to the opening of through holes 143, which is beneficial to improve the structural strength of the motor controller module 100. Furthermore, the alternating arrangement of some through holes 143 and some reinforcing ribs 116 avoids the reinforcing ribs 116 from blocking the through holes 143 and affecting the flow of coolant.

[0122] Figure 11 is a partial enlarged view of the M2 part of the motor controller module 100 in Figure 5.

[0123] In one embodiment, the housing 110 further includes a protrusion 117 and two inlets / outlets 114a, 114b, as shown in Figures 7 and 8. Along the stacking direction of the heat sink 102 and the housing 110, the protrusion 117 protrudes from the bottom 113b of the groove 113 toward the opening 113a of the groove 113, as shown in Figures 5 and 11. The partition 104 is stacked on the protrusion 117, as shown in Figure 7. The protrusion 117 is used to divide the liquid cooling cavity 105a into two liquid cooling sub-cavities 151, 152 and to separate the two inlets / outlets 114a, 114b. Each liquid cooling sub-cavity 150 is used to connect the liquid cooling cavity 105b and one inlet / outlet 114a or to connect the liquid cooling cavity 105b and another inlet / outlet 114b. The two inlets / outlets 114a, 114b are used to connect to an external flow channel. As shown in Figure 11, along the stacking direction Z of the heat sink 102 and the housing 110, the height of the protrusion 117 is less than the depth of the groove 113. As shown in Figure 7, the length of the protrusion 117 is greater than or equal to the length of the groove 113 along the length direction X of the three-phase bridge arm 103.

[0124] In this embodiment, a Z-shaped protrusion 117 protrudes from the bottom 113b of the groove 113 toward the opening 113a of the groove 113 along the stacking direction of the heat sink 102 and the housing 110. A partition 104 is stacked on the protrusion 117, such that the protrusion 117 can divide the liquid cooling cavity 105a into two liquid cooling sub-cavities 151 and 152. The protrusion 117 is used to separate two inlets and outlets 114a and 114b. Each liquid cooling sub-cavity 150 is used to connect the liquid cooling cavity 105b and one inlet and outlet 114a or to connect the liquid cooling cavity 105b and another inlet and outlet 114b. The two inlets and outlets 114a and 114b are used to connect to an external flow channel. The protrusion 117 ensures that the coolant in the liquid cooling cavity 105a does not flow directly only through the two inlets and outlets 114a and 114b. The protrusion 117 allows the coolant in the liquid cooling cavity 105a and the liquid cooling cavity 105b to be connected through the through hole 143. For example, coolant flows into liquid-cooled sub-cavity 151 from inlet / outlet 114a, flows into liquid-cooled cavity 105b through part of through hole 143, flows into liquid-cooled sub-cavity 152 through another part of through hole 143 in liquid-cooled cavity 105b, and then flows out of housing 110 from inlet / outlet 114b and into the vehicle's cooling system.

[0125] In this embodiment, as shown in Figures 6 and 11, along the stacking direction Z of the heat sink 102 and the housing 110, the height of the protrusion 117 is denoted as L11, and the depth of the groove 113 is L2, where L11 < L2. This allows the partition 104 to be stacked on top of the protrusion 117, and the groove 113 above the partition 104 still has space to form a liquid cooling cavity 105b. In one embodiment, the sum of the height of the protrusion 117 and the thickness of the portion of the partition 104 in contact with the protrusion 117 is less than the depth of the groove 113, so that the groove 113 above the partition 104 still has space to form a liquid cooling cavity 105b.

[0126] In this embodiment of the application, as shown in FIG7, along the length direction X of the three-phase bridge arm 103, the length of the protrusion 117 is denoted as L12, and the length of the groove 113 is denoted as L13, L12≥L13, so that the protrusion 117 can enhance the structural strength of the groove 113, and also enable the protrusion 117 to effectively separate the two inlets and outlets 114a and 114b.

[0127] In one embodiment, two inlets 114a and 114b are formed on the heat sink 102. In another embodiment, one inlet 114a is formed on the housing 110 of the bus capacitor 101, and one inlet 114b is formed on the heat sink 102. The two liquid cooling cavities 105a and 105b form two-layer flow channels that are connected in series.

[0128] In one embodiment, the protrusion 117 includes a sealing groove 117a, as shown in Figures 8 and 11. The sealing groove 117a is recessed away from the partition 104 along the stacking direction Z of the heat sink 102 and the housing 110. The sealing groove 117a is used to accommodate a seal 1171. The side surface 122 of the heat sink 102 includes multiple heat dissipation teeth 123. Along the stacking direction Z of the heat sink 102 and the housing 110, the multiple heat dissipation teeth 123 protrude towards the partition 104. The seal 1171 is used to seal the gap between the partition 104 and the protrusion 117a and to abut against the multiple heat dissipation teeth 123. Specifically, along the stacking direction Z of the heat sink 102 and the housing 110, the distance between the multiple heat dissipation teeth 123 and the bottom of the sealing groove 117a is less than the sum of the free length of the seal 1171 and the length of the portion of the partition 104 in contact with the seal 1171.

[0129] In this embodiment, the sealing groove 117a is recessed away from the partition 104 along the stacking direction of the heat sink 102 and the housing 110. The sealing groove 117a is used to accommodate a sealing element 1171, so that the sealing element 1171 can seal the gap between the partition 104 and the protrusion 117, so that the coolant in the two liquid cooling sub-cavities 151 and 152 can be effectively isolated, and the coolant in the liquid cooling sub-cavity 151 needs to flow through the liquid cooling cavity 105b and then flow back into the liquid cooling sub-cavity 152. In one embodiment, the sealing element 1171 is a sealing ring or adhesive.

[0130] In this embodiment, the side 122 of the heat sink 102 includes a plurality of heat dissipation teeth 123. The plurality of heat dissipation teeth 123 protrude toward the partition 104 along the stacking direction Z of the heat sink 102 and the housing 110. The plurality of heat dissipation teeth 123 are located in the liquid cooling cavity 105b, which is used to increase the heat dissipation area in the liquid cooling cavity 105b, improve the heat dissipation effect of the coolant in the liquid cooling cavity 105b, improve the cooling efficiency of the coolant on the three-phase bridge arm 103, and thus improve the cooling efficiency of the motor controller module 100.

[0131] In this embodiment, the seal 1171 is used to seal the gap between the partition 104 and the protrusion 117 and to abut the surface 142 of the partition 104 against the multiple heat dissipation teeth 123. This allows the seal 1171 to not only seal the two liquid-cooled sub-cavities 151 and 152 relatively independently, but also to prevent the coolant flowing into the liquid-cooled cavity 105b from laminar flow due to the gap between the tooth surface of the heat dissipation teeth 123 and the surface 142 of the partition 104. Laminar flow of coolant has less resistance than flow between the heat dissipation teeth 123. If laminar flow occurs, more coolant will flow over the tooth surface of the heat dissipation teeth 123 and will not have more contact with the heat dissipation teeth 123, thus reducing the cooling effect of the coolant in the liquid-cooled cavity 105b on the three-phase bridge arm 103 and hindering the improvement of the cooling efficiency of the motor controller module 100.

[0132] In this embodiment of the application, as shown in FIG11, along the stacking direction Z of the heat sink 102 and the housing 110, the distance between the multiple heat dissipation teeth 123 and the bottom of the sealing groove 117a is denoted as L14, and the sum of the free length of the sealing member 1171 and the length of the partition plate 104 in contact with the sealing member 1171 is denoted as L15, where L14 < L15. This allows the sealing member 1171 in the sealing groove 117a to apply an upward elastic force along the stacking direction Z of the heat sink 102 and the housing 110 to the partition plate 104, so that the surface 142 of the partition plate 104 can abut against the multiple heat dissipation teeth 123. This prevents the coolant flowing from the liquid cooling cavity 105 into the liquid cooling cavity 105b through the through hole 143 from the liquid cooling cavity 105 from laminar flow on the tooth surface of the heat dissipation teeth 123, which is beneficial to increase the contact area between the coolant and the heat dissipation teeth 123, thereby improving the cooling effect of the liquid cooling cavity 105b on the three-phase bridge arm 103, and thus improving the cooling efficiency of the motor controller module 100.

[0133] In one embodiment, the surface 142 of the partition 104 has a vulcanized rubber or other buffer layer for contacting the tooth surfaces of the plurality of heat dissipation teeth 123, preventing laminar flow caused by gaps between the surface 142 and the heat dissipation teeth 123, which would affect the heat dissipation effect.

[0134] Figure 12 is another structural schematic diagram of the partition 104 provided in the embodiment of this application.

[0135] In one embodiment, the surface 141 of the partition 104 includes a sealing protrusion 144, as shown in Figures 11 and 12. The sealing protrusion 144 protrudes towards a sealing groove 117a along the stacking direction Z of the heat sink 102 and the housing 110. The sealing groove 117a accommodates the sealing protrusion 144, and the sealing protrusion 144 compresses the seal 1171. The sum of the length of the sealing protrusion 144 and the free length of the seal 1171 along the stacking direction Z of the heat sink 102 and the housing 110 is greater than the depth of the sealing groove 117a.

[0136] In this embodiment, the sealing protrusion 144 protrudes towards the sealing groove 117a along the stacking direction of the heat sink 102 and the housing 110. The sealing groove 117a is used to accommodate the sealing protrusion 144, and the sealing protrusion 144 is used to compress the sealing member 1171. The sealing protrusion 144 cooperates with the sealing groove 117a and the sealing member 1171, making the sealing connection between the partition 104 and the protrusion 117 more stable. This not only allows the liquid cooling cavity 105a to be divided into two liquid cooling sub-cavities 151 and 152, but also allows the sealing member 1171 to better apply force to the partition 104, so that the surface 142 of the partition 104 abuts against the multiple heat dissipation teeth 123, preventing the coolant in the liquid cooling cavity 105b from flowing between the heat dissipation teeth 123 and the partition 104, so that more coolant flows between the heat dissipation teeth 123, thereby improving the cooling effect of the liquid cooling cavity 105b on the three-phase bridge arm 103.

[0137] In this embodiment of the application, as shown in FIG11, along the stacking direction Z of the heat sink 102 and the housing 110, the sum of the length of the sealing protrusion 144 and the free length of the sealing member 1171 is denoted as L16, and the depth of the sealing groove 117a is denoted as L17. L16 > L17, so that the sealing member 1171 can have an upward elastic force on the partition 104, so that the surface 142 of the partition 104 abuts against the multiple heat dissipation teeth 123, preventing the coolant in the liquid cooling cavity 105b from flowing between the heat dissipation teeth 123 and the partition 104, so that more coolant flows between the heat dissipation teeth 123, thereby improving the cooling effect of the liquid cooling cavity 105b on the three-phase bridge arm 103.

[0138] In one embodiment, the sealing protrusion 144 and the partition 104 are independent components. The sealing protrusion 144 is a separate component, which is accommodated in the sealing groove 117a to separate the two liquid-cooled sub-cavities 151 and 152.

[0139] In one embodiment, the surface 141 of the partition 104 has no sealing protrusion 144, and the surface 141 is a plane. Along the stacking direction Z of the heat sink 102 and the housing 110, the thickness of the seal 1171 is greater than the distance between the bottom of the sealing groove 117a and the partition 104, or the thickness of the seal 1171 is greater than the depth of the sealing groove 117a. The seal 1171 can abut and seal the partition 104, and the seal 1171 can also apply force to the partition 104 so that the surface 142 of the partition 104 abuts against the multiple heat dissipation teeth 123, avoiding laminar flow of coolant in the liquid cooling cavity 105b due to gaps between the tooth surface of the heat dissipation teeth 123 and the surface 142 of the partition 104.

[0140] In one embodiment, the sealing protrusion 144 of the partition 104 includes a sealing groove for accommodating a seal and a protrusion 117. The seal has an elastic force on the protrusion 117 in the Z-direction of the stacking direction of the heat sink 102 and the housing 110, thereby causing the sealing protrusion 144 to separate the two liquid-cooled sub-cavities 151, 152 and causing the surface 142 of the partition 104 to abut against the heat dissipation teeth 123 to eliminate the gap between the tooth surface of the heat dissipation teeth 123 and the surface 142 of the partition 104.

[0141] In one embodiment, as shown in FIG7, the protrusion 117 includes a first segment 117b, a second segment 117c, and a third segment 117d connected in sequence. The first segment 117b and the second segment 117c are arranged on both sides of the two inlets / outlets 114a and 114b along the length direction X of the three-phase bridge arm 103. The two ends of the second segment 117c are arranged on different sides of the two inlets / outlets 114a and 114b along the width direction Y of the three-phase bridge arm 103.

[0142] In this embodiment of the application, the first segment 117b and the second segment 117c are arranged on both sides of the two inlets and outlets 114a and 114b along the length direction X of the three-phase bridge arm 103, so that the protrusion 117 can better isolate the two inlets and outlets 114a and 114b, and can also improve the problem that the strength of the housing 110 is reduced due to the opening of two inlets and outlets 114a and 114b.

[0143] In this embodiment, the two ends of the second segment 117c along its length direction are arranged on different sides of the two inlets 114a and 114b along the width direction Y of the three-phase bridge arm 103, so that the two inlets 114a and 114b can be isolated in the two liquid-cooled sub-cavities 151 and 152 respectively. This ensures that the coolant flowing into the liquid-cooled cavity 105a will not flow only between the two inlets 114a and 114b without flowing through the liquid-cooled cavity 105b. This is beneficial for constructing a double-layer flow channel of the motor controller module 100, so that the three-phase bridge arm 103 and the bus capacitor 101 of the motor controller module 100 can be cooled down at the same time, thereby improving the cooling efficiency of the motor controller module 100.

[0144] In one embodiment, the two ends of the protrusion 117 are respectively connected to the two groove sidewalls of the groove 113 along the length direction X of the three-phase bridge arm 103. The protrusion 117 and a part of the groove peripheral wall 113c of the groove 113 enclose a liquid-cooled sub-cavity 151, and the protrusion 117 and another part of the groove peripheral wall 113d of the groove 113 enclose another liquid-cooled sub-cavity 152.

[0145] In one embodiment, as shown in Figures 6 and 7, the peripheral wall of the groove 113 includes a plurality of locking protrusions 113e, which are used to limit the positioning of the partition 104. Specifically, along the stacking direction Z of the heat sink 102 and the housing 110, the distance between each locking protrusion 113e and the bottom 113b of the groove 113 is greater than the distance between the surface 142 of the partition 104 and the bottom 113b of the groove 113.

[0146] In this embodiment, the groove 113 has a plurality of locking protrusions 113e on its peripheral wall. The locking protrusions 113e are used to limit the partition 104. The plurality of locking protrusions 113e allow the partition 104 to be fixedly placed above the housing 110, which is beneficial to forming two more stable liquid cooling cavities 105a and 105b, improving the structural reliability of the motor controller module 100, and thus improving the structural reliability of the motor controller 13. The locking protrusions 113e are located on the peripheral wall of the groove 113 and are used to lock the partition 104 below the locking protrusions 113, so that the other part of the peripheral wall 113d where the locking protrusions 113 are located, the surface 142 of the partition 104 and the heat sink 102 surround to form the liquid cooling cavity 105b, improving the integration and fusion between the structures of the motor controller module 100.

[0147] In this embodiment of the application, as shown in FIG6, along the stacking direction Z of the heat sink 102 and the housing 110, the distance between each locking protrusion 113e and the bottom 113b of the groove 113 is denoted as L18, and the distance between the surface 142 of the partition 104 and the bottom 113b of the groove 113 is L1, where L18 > L1, so that the locking protrusion 113e can be stacked on the partition 104 along the stacking direction Z of the heat sink 102 and the housing 110. Along the stacking direction Z of the heat sink 102 and the housing 110, the locking protrusion 113e, the partition 104, and the groove opening 113a of the groove 113 are arranged in sequence, so that the locking protrusion 113e can play a limiting role on the partition 104, fixing the partition 104 on the groove 113, making the structure of the motor controller module 100 more stable.

[0148] Figure 13 is a partial enlarged view of the M1 part of the motor controller module 100 in Figure 5.

[0149] In one embodiment, the side surface 122 of the heat sink 102 further includes another groove 124 and a plurality of heat dissipation teeth 123, as shown in Figures 5 and 13. Along the stacking direction Z of the heat sink 102 and the housing 110, the groove 124 is recessed away from the partition 104, and the plurality of heat dissipation teeth 123 protrude from the bottom of the groove 124 toward the partition 104. The surface 142 is used to form a liquid cooling cavity 105b with the groove 124 of the side surface 122 of the heat sink 102 and another part of the groove peripheral wall 113d of the groove 113. Wherein, along the stacking direction Z of the heat sink 102 and the housing 110, the depth of the groove 124 is less than the length of at least a portion of the heat dissipation teeth 123, the depth of the groove 124 is less than the maximum distance between the bottom 113b of the groove 113 and the partition 104, and the length of the plurality of heat dissipation teeth 123 is less than the depth of the groove 113.

[0150] In this embodiment, as shown in Figures 3, 5, and 13, the Z-groove 124 is recessed away from the partition plate 104 along the stacking direction of the heat sink 102 and the housing 110. This allows the groove 124 of the heat sink 102 to form a larger liquid cooling cavity 105b with the partition plate 104, providing sufficient space for the arrangement of multiple heat dissipation teeth 123. It also allows more coolant to flow in the liquid cooling cavity 105b, improving the cooling effect of the coolant on the three-phase bridge arm 103. Multiple heat dissipation teeth 123 protrude from the bottom of the groove 124 towards the partition plate 104, allowing the heat dissipation teeth 123 to be arranged in the liquid cooling cavity 105b to turbulently flow the coolant within, thereby improving the cooling efficiency of the motor controller module 100.

[0151] In this embodiment, surface 142 is used to form a liquid cooling cavity 105b with the groove 124 of the side 122 of the heat sink 102 and another part of the groove peripheral wall 113d of the groove 113. The groove peripheral wall of the groove 113 is used not only to form the liquid cooling cavity 105a but also to form the liquid cooling cavity 105b. This ensures that the formation of the two liquid cooling cavities 105a and 105b will not occupy too much space of the motor controller module 100 along the stacking direction Z of the heat sink 102 and the housing 110. This is beneficial for the miniaturization of the motor controller module 100 and can also improve the integration of the motor controller module 100.

[0152] In this embodiment, as shown in FIG13, along the stacking direction Z of the heat sink 102 and the housing 110, the depth of the groove 124 is denoted as L19, and the length of at least a portion of the heat dissipation teeth 123 is denoted as L20, where L19 < L20. This allows at least a portion of the heat dissipation teeth 123 to abut against the surface 142 of the partition 104, preventing laminar flow of the coolant in the liquid cooling cavity 105b due to gaps between the tooth surfaces of the heat dissipation teeth 123 and the surface 142 of the partition 104, thereby improving heat dissipation efficiency. The longer length of the heat dissipation teeth 123 also helps to increase the contact area between the coolant and the heat dissipation teeth 123, thereby improving the cooling effect of the coolant and the cooling efficiency of the motor controller module 100.

[0153] In this embodiment of the application, as shown in FIG13, the depth of the groove 124 is L19, and the maximum distance between the bottom 113b of the groove 113 and the partition 104 is L6, L19 < L6, so that the liquid cooling cavity 105a and liquid cooling cavity 105b will not occupy too much space of the motor controller module 100 along the stacking direction Z of the heat sink 102 and the housing 110, which is beneficial to the miniaturization of the motor controller module 100.

[0154] In this embodiment of the application, as shown in FIG13, the length of the plurality of heat dissipation teeth 123 is L20, the depth of the groove 113 is L2, and L20 < L2, so that when the heat dissipation plate 102 uses the groove 113 to form a liquid cooling cavity 105b, the liquid cooling cavity 105b will not occupy too much space of the motor controller module 100 along the stacking direction Z of the heat dissipation plate 102 and the housing 110, which is beneficial to the miniaturization of the motor controller module 100.

[0155] Figure 14 is another exploded view of the motor controller module 100 provided in the embodiment of this application.

[0156] In one embodiment, the capacitor core package 111 includes two sets of capacitor cores 111a and 111b, as shown in Figures 4 and 14. One set of capacitor cores 111a and the other set of capacitor cores 111b are arranged adjacent to each other at intervals along the width direction Y of the three-phase bridge arm 103. Along the length direction X of the three-phase bridge arm 103, the length of one set of capacitor cores 111a is less than the length of the other set of capacitor cores 111b. The other set of capacitor cores 111b and the groove 113 are stacked together along the stacking direction Z of the heat sink 102 and the housing 110.

[0157] In this embodiment, along the length direction X of the three-phase bridge arm 103, the length of one set of capacitor cores 111a is less than the length of another set of capacitor cores 111b. This provides space for the arrangement of other components of the motor controller module 100, which is beneficial to improving the integration of the motor controller module 100.

[0158] In this embodiment, another set of capacitor cores 111b and grooves 113 are stacked along the stacking direction Z of heat sink 102 and housing 110, so that the coolant flowing in the grooves 113 can more directly carry away the heat of the capacitor core package 111, which is beneficial to cooling down the bus capacitor 101 and improving the heat dissipation efficiency of the motor controller module 100.

[0159] In one embodiment, the housing 110 of the bus capacitor 101 further includes a window 118, as shown in Figures 4 and 14. The window 118 is used to accommodate the bus capacitor 101. The bus capacitor 101 also includes two input copper plates 112. The opening of the window 118 faces the width direction Y along the three-phase bridge arm 103 and the stacking direction Z along the heat sink 102 and the housing 110. The two input copper plates 112 are stacked on the bus capacitor 101. The two input copper plates 112 are bent from the window 118 toward the three-phase bridge arm 103. The two input copper plates 112 are electrically connected to a set of copper busbars 131a of a plurality of power modules 131.

[0160] In this embodiment, the opening of a window 118 along the width direction Y of the three-phase bridge arm 103 is arranged on the same side as a set of copper busbars 131a of the power module 131. This facilitates the two input copper plates 112 to bend from the window 118 toward the three-phase bridge arm 103 via a short path and to be electrically connected to a set of copper busbars 131a of the multiple power modules 131. This allows the DC power from the power battery 30 to be transmitted to the three-phase bridge arm 103 for DC to AC power output. It also improves the integration and fusion of the motor controller module 100.

[0161] Figure 15 is another structural schematic diagram of the motor controller module 100 provided in the embodiment of this application.

[0162] In one embodiment, the motor controller module 100 further includes a filter slot 119, as shown in Figures 4, 14, and 15. Along the stacking direction Z of the heat sink 102 and the housing 110, the opening of the filter slot 119 faces away from the opening 113a of the recess 113. The filter slot 119 is used to accommodate an EMC filter component 106 and two input connection copper busbars 107. The two input connection copper busbars 107 are used to receive DC power from the DC power supply and transmit the DC power to the two input copper plates 112 of the bus capacitor 101 after filtering by the EMC filter component 106. Along the length direction X of the three-phase bridge arm 103, the filter slot 119 is arranged adjacent to and spaced apart from a set of capacitor cores 111a.

[0163] In this embodiment, the filter slot 119 is formed by using the space of a set of capacitor cores 111a that is shorter than the length of another set of capacitor cores 111b along the length direction X of the three-phase bridge arm 103. This does not occupy too much space of the motor controller module 100 along the width direction Y and the length direction X of the three-phase bridge arm 103, which is beneficial to the miniaturization layout of the motor controller module 100 and can also improve the integration of the motor controller module 100.

[0164] In this embodiment, the filter slot 119 is used to accommodate the EMC filter component 106 and two input connection copper busbars 107. The DC power input from the DC power supply is input into the motor controller module 100 through the two input connection copper busbars 107. The EMC filter component 106 filters and regulates the voltage, making the current signal transmitted to the bus capacitor 101 more stable and accurate.

[0165] In one embodiment, the motor controller module 100 further includes an output copper plate 108, as shown in Figures 3, 4, and 14. The output copper plate 108 is used to electrically connect another set of copper busbars 131b of multiple power modules 131. Along the stacking direction Z of the heat sink 102 and the housing 110, the output copper plate 108 is stacked on a set of capacitor cores 111a. Along the width direction Y of the three-phase bridge arm 103, the output copper plate 108 is arranged adjacent to the groove 113.

[0166] In one embodiment, the motor controller module 100 further includes a plurality of reinforcing ribs 109, as shown in Figures 4 and 7. The plurality of reinforcing ribs 109 and the window 118 are stacked along the stacking direction Z of the heat sink 102 and the housing 110. The opening of the window 118 and the groove 113 in the housing 110 will reduce the structural strength of the housing 110. The reinforcement ribs 109 are used to compensate for the structural strength, which is beneficial to the stability of the overall structure of the motor controller module 100.

[0167] In one embodiment, as shown in Figures 5 and 6, the heat sink 102 and the housing 110 are sealed by a sealing ring 102a, so that the coolant in the two liquid cooling chambers 105a and 105b will not leak, thus preventing short circuits in other electrical components in the motor controller module 100 and affecting the normal operation of the motor controller module 100.

[0168] The motor controller module, motor controller, powertrain, and electric vehicle provided in the embodiments of this application have been described in detail above. Specific examples have been used to illustrate the principles and embodiments of this application. The description of the embodiments above is only for the purpose of helping to understand the method and core ideas of this application. At the same time, for those skilled in the art, there will be changes in specific embodiments and application scope based on the ideas of this application. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A motor controller module, characterized in that, The motor controller module includes a bus capacitor and a heat sink. The inner cavity of a housing of the bus capacitor accommodates a capacitor core. The heat sink is stacked on the outer side of the housing. Along the stacking direction of the heat sink and the housing, the heat sink includes two sides. One side is used to fix a three-phase bridge arm. The three-phase bridge arm receives power from the electric vehicle's battery through the capacitor core and outputs three-phase current to drive the electric vehicle's motor. The housing includes a groove, with the groove opening facing the heat sink along the stacking direction of the heat sink and the housing. The groove is used to accommodate a partition, which includes two surfaces. One surface forms a liquid cooling cavity with the bottom of the groove and a portion of the groove's peripheral wall. The other surface forms another liquid cooling cavity with another side of the heat sink and another portion of the groove's peripheral wall. The maximum distance between the other surface and the bottom of the groove is less than the depth of the groove.

2. The motor controller module according to claim 1, characterized in that, Along the stacking direction of the heat sink and the housing, the distance between the bottom of the groove of the one surface and the groove of the one groove is greater than or equal to the distance between the opening of the groove of the other surface and the groove of the one groove.

3. The motor controller module according to claim 1 or 2, characterized in that, The housing also includes a plurality of baffles, each baffle extending from the bottom of the groove toward the opening of the groove along the stacking direction of the heat sink and the housing, and the height of each baffle is less than the depth of the groove.

4. The motor controller module according to any one of claims 1-3, characterized in that, The three-phase bridge arm includes multiple power modules, which are spaced apart along the length of the three-phase bridge arm. Each power module includes two sets of copper busbars, which are opposite each other along the width of the three-phase bridge arm. The length of the three-phase bridge arm is greater than its width. The partition includes multiple pairs of through holes for connecting the liquid cooling cavity and the other liquid cooling cavity. The multiple pairs of through holes penetrate the partition along the stacking direction of the heat sink and the housing. Each pair of through holes includes two through holes. The multiple pairs of through holes are spaced apart along the length direction of the three-phase bridge arm. The two through holes in each pair are spaced apart along the width direction of the three-phase bridge arm. Each power module is aligned with a pair of through holes along the stacking direction of the heat sink and the housing.

5. The motor controller module according to claim 4, characterized in that, The length of each of the through holes along the length direction of the three-phase bridge arm is greater than its width along the width direction of the three-phase bridge arm; The spacing between the two through holes in each pair along the width direction of the three-phase bridge arm is greater than half the width of the groove along the width direction of the three-phase bridge arm.

6. The motor controller module according to claim 4, characterized in that, The housing further includes a plurality of reinforcing ribs, each reinforcing rib protruding from the bottom of the groove toward the partition along the stacking direction of the heat sink and the housing, wherein: Along the stacking direction of the heat sink and the housing, the height of each reinforcing rib is less than the depth of the groove; Some of the through holes and some of the reinforcing ribs are arranged alternately along the length of the three-phase bridge arm.

7. The motor controller module according to any one of claims 1-6, characterized in that, The housing further includes a protrusion and two inlets / outlets. Along the stacking direction of the heat sink and the housing, the protrusion extends from the bottom of the groove toward the opening of the groove. A partition is stacked on the protrusion. The protrusion divides the liquid-cooled cavity into two liquid-cooled sub-cavities and separates the two inlets / outlets. Each liquid-cooled sub-cavity connects to the other liquid-cooled cavity and one of the inlets / outlets. The two inlets / outlets connect to an external flow channel, wherein: Along the stacking direction of the heat sink and the housing, the height of the protrusion is less than the depth of the groove; The length of the protrusion is greater than or equal to the length of the groove along the length direction of the three-phase bridge arm.

8. The motor controller module according to claim 7, characterized in that, The protrusion includes a sealing groove recessed away from the partition along the stacking direction of the heat sink and the housing. The sealing groove is used to accommodate a sealing element. The other side of the heat sink includes a plurality of heat dissipation teeth protruding towards the partition along the stacking direction of the heat sink and the housing. The sealing element is used to seal the gap between the partition and the protrusion and to abut against the plurality of heat dissipation teeth on the other surface of the partition, wherein: Along the stacking direction of the heat sink and the housing, the distance between the plurality of heat dissipation teeth and the bottom of the sealing groove is less than the sum of the free length of the sealing element and the length of the partition plate in contact with the sealing element.

9. The motor controller module according to claim 8, characterized in that, One surface of the partition includes a sealing protrusion that protrudes toward a sealing groove along the stacking direction of the heat sink and the housing. The sealing groove is used to receive the sealing protrusion, and the sealing protrusion is used to compress the seal, wherein: Along the stacking direction of the heat sink and the housing, the sum of the length of the sealing protrusion and the free length of the seal is greater than the depth of the sealing groove.

10. The motor controller module according to claim 7, characterized in that, The protrusion comprises a first segment, a second segment, and a third segment connected in sequence, wherein: The first and second segments are arranged on both sides of the two inlets and outlets along the length of the three-phase bridge arm; The two ends of the second segment are arranged on different sides of the two inlets and outlets along the width direction of the three-phase bridge arm.

11. The motor controller module according to any one of claims 1-10, characterized in that, The groove peripheral wall includes multiple locking protrusions, which are used to limit the position of the partition, wherein: Along the stacking direction of the heat sink and the housing, the distance between each of the locking protrusions and the bottom of the groove is greater than the distance between the other surface of the partition and the bottom of the groove.

12. The motor controller module according to any one of claims 1-11, characterized in that, The other side of the heat sink further includes another groove and a plurality of heat dissipation teeth. Along the stacking direction of the heat sink and the housing, the other groove is recessed away from the partition. The plurality of heat dissipation teeth protrude from the bottom of the other groove toward the partition. The other surface is used to form the other liquid cooling cavity with the other groove on the other side of the heat sink and another portion of the groove's peripheral wall, wherein: Along the stacking direction of the heat sink and the housing, the depth of the other groove is less than at least a portion of the length of the heat dissipation teeth, the depth of the other groove is less than the maximum distance between the bottom of the first groove and the partition, and the length of the plurality of heat dissipation teeth is less than the depth of the first groove.

13. A motor controller, characterized in that, The motor controller includes a housing and a motor controller module as described in any one of claims 1-12, the housing being used to house the motor controller module, and the internal flow channels of the housing being used to connect the two inlets and outlets of the housing of the bus capacitor in the motor controller module.

14. A powertrain, characterized in that, The powertrain includes an electric motor and a motor controller as described in claim 13, wherein the electric motor is configured to receive power from the motor controller module of the motor controller.

15. An electric vehicle, characterized in that, The electric vehicle includes a frame, a power battery, and a powertrain as described in claim 14, wherein the frame is used to fix the power battery and the powertrain, and the motor of the powertrain is used to receive power from the power battery through the motor controller to drive the wheels.

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