An integrated laminated core assembly

Abstract

The integrated laminated core assembly (200) described herein is designed for placement on a printed circuit board (PCB) (202) It incorporates an integrated bracket encapsulation (201) which encloses any two-phase terminals U, V, W (206, 208, 210) and a battery terminal (212,214). The integrated bracket encapsulation, comprises an upper (216) and lower bracket (218) which are locked securely to positions the laminated cores (220) centrally within the unified structure. The lower bracket (218) of the said encapsulation further comprises provisions (228) for accommodating the current sensors (222) of the enclosed phase terminals. Thus, the three current sensor monitors the current supplied to the motor as well as current drawn from the battery. This configuration simplifies the manufacturing and assembly, eliminating the need for multiple components. Additionally, a detailed method for assembling this integrated system is disclosed, enhancing practical implementation on PCB.

Description

AN INTEGRATED LAMINATED CORE ASSEMBLYFIELD OF THE INVENTION

[0001] The present invention generally relates to the field of electronics. More specifically, it relates to the field of an assembly for an integrated bracket encapsulation for laminated cores and current sensors used in a motor controller of an electric vehicle.BACKGROUND

[0002] In an electric vehicle (EV) motor controller, the arrangement of current sensors and laminated cores is crucial for ensuring accurate current measurement and protection from electromagnetic interference (EMI).

[0003] The laminated core acts as a shield against external electromagnetic fields. Current sensors in motor controllers can be sensitive to external EMF, which can interfere with their accuracy. Hence, the laminated cores help to reduce electromagnetic interference (EMI) or act as electromagnetic field (EMF) shields when employed in current sensors, ensuring reliable current detection and contributing to the overall efficiency and performance of the motor controller.

[0004] The laminated core is strategically placed around current sensors in an EV motor controller to protect them from external EMF. The sensors and their laminated cores are integrated into the motor controller’s circuitry, ensuring that all current paths are properly monitored and shielded.

[0005] The current sensor and laminated core assembly is usually encapsulated in a protective housing. This housing can be made of plastic, epoxy, or other insulating materials to protect the components from physical damage and environmental factors such as moisture and dust. In some cases, the assembly might be potted with an insulating compound (such as epoxy or silicone) to further protect the sensor and core from vibrations and mechanical stresses.

[0006] The present invention intends to propose an effective protective mechanism for a current sensor, wherein a bracket encapsulation is used for the protection of the current sensor from external EMF via the laminated core.OBJECTIVES OF THE INVENTION

[0007] The primary objective of the present invention is to provide an encapsulation for a laminated core and current sensor utilized in the motor controller of electric vehicles, wherein the encapsulation comprises of a single two- piece plastic bracket.

[0008] Another objective of the present invention is to provide a two-piece plastic bracket that is also an integrated encapsulation capable of holding more than one laminated core and current sensor within the single two-piece plastic bracket.SUMMARY OF THE INVENTION

[0009] The following summary is provided to facilitate a clear understanding of the new features in the disclosed embodiment, and it is not intended to be a full, detailed description. A detailed description of all the aspects of the disclosed invention can be understood by reviewing the full specification, the drawing, and the claims and the abstract, as a whole.

[0010] An aspect of the present invention relates to an integrated laminated core assembly designed to be positioned on a printed circuit board (PCB). This assembly features a bracket encapsulation that encloses at least three laminated cores, each mounted on at least any of two phases (may be U and V phase, V and W phase, or U and W phase) terminals and at least one battery (positive or negative) terminal. The encapsulation consists of an upper bracket and a lower bracket, which are sealed together to form a unified structure with the laminated cores centrally located.

[0011] Another aspect of this assembly comprises that the lower bracket is designed to accommodate current sensors between the ends of each laminated core. Both the upper and lower brackets are made from plastic materials. This encapsulation system simplifies the design by requiring only a single locking process by means of a snap-fit or any other means and eliminates the need for stacking of multiple components. A further aspect discloses a method of assembling the integrated laminated core assembly featuring the integrated bracket encapsulation, thereof.BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The present invention will be better understood fully from the detailed description that is given herein below with reference to the accompanying drawings of the preferred embodiments of the present invention, which, however, should not be deemed to be a limitation to the invention to the specific embodiments, but, are for the purpose of explanation and understanding only.Fig. 1 illustrates a laminated core assembly according to prior art.Fig.2 illustrates an integrated bracket encapsulation utilized for a laminated core according to the preferred embodiment of the present invention.Fig.3 illustrates an exploded view of the integrated bracket encapsulation utilized for a laminated core according to the preferred embodiment of the present invention.Fig.4 illustrates an integrated laminated core assembly featuring the integrated bracket encapsulation according to the preferred embodiment of the present invention.Fig.5 illustrates an exploded view of the integrated laminated core assembly featuring the integrated bracket encapsulation according to the preferred embodiment of the present invention.Fig.6 illustrates the integrated bracket encapsulation according to a preferred embodiment of the present invention.REFERENCE NUMERALS:102 - Laminated metal Core104 - Hall effect Current Sensor106 - Core Holder108 - Metallic cap shield110 - Insulation Sheet112 - Rubber washer200 - Integrated laminated core assembly201 - integrated bracket encapsulation202 - Printed circuit Board (PCB)204 - Heat sink Plate206 - U phase terminal208 -V Phase terminal210 - W Phase terminal212 - Battery Positive Terminal214 -Battery negative Terminal216 - upper bracket218 - lower bracket220 - laminated core222 - current sensor224 - U terminal current sensor226 - V terminal current sensor228 - provision for current sensorDETAILED DESCRIPTION OF THE INVENTION

[0013] The following is a detailed description of the present disclosure depicted in the accompanying drawings. However, it may be understood by a person having ordinary skill in the art that the present subject matter may be practiced without these specific details. In other instances, well known methods, procedures, and / or components regarding the said method have not been described in detail so as not to obscure the subject matter of the disclosure. The subject matter of the disclosure will be more clearly understood from the following description of the embodimentsthereof, given by way of example only with reference to the accompanying drawings, which are not drawn to scale.

[0014] If the specification states that a component or a feature “may” or “can” be included, that particular component or feature is not required to be included or have the characteristic. The use of open-ended terms like “comprising” and variations herein is meant to encompass the steps listed thereafter and equivalents thereof as well as additional items. As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0015] UVW terminals refer to the three-phase connections of an electric motor or other three-phase devices. The U Terminal represents one phase of the three- phase power supply, the V Terminal representing the second phase, and the W Terminal representing the third phase. A PCB (Printed Circuit Board) is a board used in electronics to physically support and electrically connect electronic components using conductive pathways, traces, or tracks etched from copper sheets. In electric vehicles (EVs), a "lam core" denotes the laminated core constructed from stacked, insulated thin sheets of electrical steel, known as laminations. The term “lam core” and “laminated core” has been used interchangeably. The term “current sensor” and “hall current sensor” has been used interchangeably here.

[0016] Hall current sensors are commonly used in the terminals of a motor controller in electric vehicle (EV). Hall current sensors are placed on the terminals corresponding to different phases of the motor (e.g., U, V, W) to monitor the current flowing to the motor windings. Additionally, a sensor at the battery's positive or negative terminal is employed for charge integration and battery condition monitoring. These sensors send signals to a controller, which optimizes the power supply. Placing the current sensors on two of the three-phase terminals (e.g., U and V, V and W, U and W) and at least one battery terminal (positive or negative) provides comprehensive monitoring of the current flow in an electricvehicle ensuring efficient and safe operation of the motor and battery system. This hall current sensor monitors the current supplied to the motor (power monitoring, power control diagnosis, Power Supply management and motor power load control, etc.,) as well as current drawn from the battery such as charge integration, monitoring battery condition, etc.

[0017] Fig. l shows a laminated metal core (102) positioned over a phase terminal on a PCB, alongside a Hall effect current sensor (104). The sensor detects the magnetic field generated by current flow, providing a Hall voltage corresponding to the current. A core holder (106) secures the laminated core (102) in alignment with the Hall sensor (104). A metallic cap shield (108) with an electrodeposit (ED) coating protects the assembly. An insulation sheet (110) is placed between the phase terminal and the metallic cap shield (108), and a rubber washer (112) atop the shield acts as a damping material to mitigate vibrations.

[0018] Referring to Fig. 1, it is therefore observed that the assembly comprises several components that require precise manufacturing and stacking, which took time and resources. Hall current sensors are essential for current rating measurement, but these sensors are susceptible to electromagnetic interference from other devices. Therefore, they require enclosed protection by lam cores to maintain accuracy and reliability. To address this, an innovative solution is needed to ensure effective shielding and structural integrity.

[0019] Fig.2 illustrates a preferred embodiment of the present invention comprising an integrated laminated core assembly (200) comprising an integrated bracket encapsulation (201) utilized on an electronic device such as a PCB (202) arranged on a heat sink plate (204) in an electric vehicle. Referring to Figs. 2 and 3, the present invention further describes that the integrated bracket encapsulation (201) comprises a two-piece plastic bracket. Fig.3 illustrates an exploded view of the integrated bracket encapsulation (201) utilized for a laminated core (220) in an electronic device such as a motor controller of an electric vehicle according to thepreferred embodiment of the present invention. Referring to Figs. 2 and 3, it is noted that the integrated bracket encapsulation (201) comprises of two pieces, namely, an upper bracket (216) and a lower bracket (218).

[0020] Fig.3 further depicts that the integrated bracket encapsulation (201) comprises multiple integrated upper brackets, and multiple lower brackets that are similarly integrated, to create a unified encapsulation system. This integrated bracket encapsulation (201) system is designed to hold at last three laminated cores (220) within a single encapsulation, as illustrated in Fig. 3. Furthermore, provisions (228) are provided for the current sensors in the integrated bracket encapsulation. This integrated design simplifies the manufacturing and assembly process as well as improves the structural integrity of the encapsulated lam cores. Referring back to Figs. 2 and 3, the two-piece plastic bracket acts as an encapsulation for the laminated core (220), providing protection against electromagnetic interference (EMI). This is crucial in maintaining the performance and reliability of the hall current sensor (222) by minimizing unwanted interference from external electromagnetic sources.

[0021] The hall current sensor (222) is placed on any two of the three-phase terminals (206, 208, 210) of the PCB (202). The current sensor (222) is also placed on at least one of the battery terminals (212,214), either the positive or negative terminal, to monitor the current flow to and from the battery. According to a preferred embodiment of the present invention, the integrated bracket encapsulation (201) comprises a minimum of three similarly integrated upper and lower brackets. The integrated bracket encapsulation (201) encloses at least two of the three phase terminals (206, 208, 210) and one of the battery terminals (positive or negative) (212, 214). In other words, the encapsulation that encloses at least three laminated cores, each mounted on at least any of two phases (may be U and V phase, V and W phase, or U and W phase) terminals and at least one battery (positive or negative) phase terminal.

[0022] Fig.4 depicts an integrated laminated core assembly (200) according to the preferred embodiment of the present invention. According to Fig.4, the lam cores (220) along with current sensors (220) are encapsulated in the two-piece integrated bracket encapsulation (201) and arranged on the PCB (202). Fig.5 illustrates an exploded view of the integrated laminated core assembly (200) featuring the integrated bracket encapsulation (201). The bracket encapsulation comprises a single integrated upper bracket part (216) and lower bracket part (218) and accommodates at least a minimum of three laminated cores within the unified encapsulation. Furthermore, the lower bracket (218) comprises provisions (228) for accommodating the current sensors (222) between the two ends of the toroidal (ring shaped) laminated cores (220) as depicted in Fig.5.

[0023] As seen in Figs.4 and 5, there is no requirement for stacking of multiple components for the assembly of the lam core and current sensors on the PCB as observed in the Fig. l. Similarly, stacking is also not required due to the lack of multiple components. Instead, the assembly of the Lam core and current sensors on the any two terminals and one battery terminal have been simplified by means of the integrated bracket encapsulation disclosed herein. A minimum of three laminated cores (220) are held incorporated within a single upper bracket (216) and lower bracket (218) encapsulation to a form a single enclosed piece, along with provisions for hall current sensors (222).

[0024] The integrated bracket encapsulation of LAM Core and current sensors eliminates the need for stacking and attaching multiple components.. Instead, this approach thus enables to form a unified enclosed unit with at least three laminated cores (220) within the single upper and lower bracket piece encapsulation. The top and bottom pieces are made of plastic, while the mid-section comprises the laminated core themselves. Additionally, the upper and lower pieces of the bracket encapsulation can be locked by means of any locking mechanism, such a snap-fit, groove and protrusion or any other mean thereof, creating an integrated bracket encapsulation. Therefore, it is notable that only a simple locking mechanism between the brackets is required, thereby simplifying the assembly process significantly.

[0025] Fig.6 illustrates the integrated bracket encapsulation arrangement enclosing a specific connection in the motor controller of an electric vehicle (EV). Referring to the Fig.6, the U, V phase terminals (206, 208), and a battery positive terminal (212) are arranged on the PCB according to a preferred embodiment of the present invention. The integrated bracket encapsulation (201) of the present invention includes the laminated cores (220) of the U, V and the battery positive phase terminals. Provisions for accommodating the respective current sensors (224, 226) of these phases are further provided in the bracket encapsulation as depicted in Fig. 6.

[0026] A method of assembling the integrated laminated core assembly featuring the bracket encapsulation, involves several steps. First, the laminated cores are sandwiched between the upper bracket (216) and lower bracket (218) of the bracket encapsulation (201). The upper and lower brackets are locked together, forming an integrated encapsulated bracket (201) with the laminated cores (220) positioned centrally. The laminated cores (220) are then positioned to encircle any of two phase terminals (U,V,W) of motor and one phase terminal of battery (positive or negative). The hall current sensors (222) are then placed in between the ends of ring shaped laminated cores (220) and placed in the provision provided in the integrated bracket encapsulation. Thus, hall current sensor is protected from external EMF

[0027] The use of a plastic bracket encapsulation provides significant advantages in terms of enhanced protection and simplified assembly for laminated cores. By shielding the cores from external electromagnetic disturbances, the encapsulation improves device performance. Additionally, the two-piece design streamlines the assembly process, making it easier to handle multiple laminated cores and thereby increasing manufacturing efficiency.

[0028] Furthermore, encapsulating multiple laminated cores within a single bracket enhances their structural integrity and alignment. This improved stability is beneficial for the overall functionality of the electronic device, ensuring better performance and durability. Together, these benefits underscore the value of plastic bracket encapsulation in the production and operation of electronic devices.

Claims

WE CLAIM:

1. An integrated laminated core assembly (200) positioned on a printed circuit board (PCB), comprising: an upper bracket (216) and a lower bracket (218), to enclose laminated cores (220) of at least two motor phase terminals (206, 208, 210) and at least one battery phase terminal (positive or negative) (212, 214); and provisions (228) provided to accommodate current sensors (222) to monitor current factors of the said motor phase terminals and the battery phase terminal; wherein the upper bracket (216) and lower bracket (218) are locked together to enclose the said laminated cores (220) and current sensors (222), to form an integrated bracket encapsulation (201), for shielding said current sensors (222) from external electromagnetic fields (EMF) interferences.

2. The assembly as claimed in claim 1, wherein the provisions (228) are provided on the lower bracket (218) to accommodate the current sensors (222) provided between the two ends of each of the enclosed laminated cores (220).

3. The assembly as claimed in claim 1, wherein the upper bracket (216) and lower brackets (218) are made of plastic.

4. The assembly as claimed in claim 1 wherein the upper (216) and lower brackets (218) of the integrated bracket encapsulation (201) is locked by means of a single locking mechanism.

5. The assembly as claimed in claim 4 wherein the single locking mechanism may be a snap fit, groove and protrusion or any other similar means.

6. The assembly as claimed in claim 1 wherein the said current sensor (222) is a Hall current sensor.

7. The assembly as claimed in claim 1 wherein the integrated bracket encapsulation (201) eliminates the requirement for stacking of multiple components.

8. A method for assembling an integrated laminated core assembly (200) featuring an integrated bracket encapsulation (201) on a printed circuit board (PCB) (202), comprising the steps of: a) sandwiching laminated cores (220) between an upper bracket (216) and a lower bracket (218) of the said bracket encapsulation (201); b) locking the upper (216) and lower brackets (218) by means of a single locking mechanism, forming the integrated bracket encapsulation (201) with the laminated cores (220) positioned centrally; c) positioning the laminated cores (220) to encircle any two-phase terminals (206, 208, 210) of the motor and one terminal of the battery (positive or negative) (212, 214); and d) placing current sensors (222) between the ends of the ring-shaped laminated cores (220) and in the provisions (228) provided in the integrated bracket encapsulation (201); whereby the current sensors (222) are protected from external electromagnetic fields (EMF).

9. The method as claimed in claim 8 wherein a single locking mechanism unifies the upper bracket (216) and the lower bracket (218) together, to form the integrated bracket encapsulation.

10. The method as claimed in claim 6 wherein less time is required in the assembling process of the integrated laminated core assembly featuring the integrated bracket encapsulation (201).

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