CN218958035U - Metal connecting piece for electric vehicle controller, electric vehicle controller and electric vehicle - Google Patents

Abstract

The application is applicable to the technical field of electric vehicle controllers, and provides a metal connecting piece, electric vehicle controller and electric vehicle, and the metal connecting piece is used for connecting the anodal input of power or the motor three-phase output of electric vehicle controller, and the main part of metal connecting piece is used for electrically conductive heat connection with the metal backplate of power tube, and the power tube has a plurality of pins along same direction interval arrangement. The extension portion is connected with the main body, the orthographic projection area of the extension portion and the main body in the arrangement direction of the pins is at least partially misaligned, and the orthographic projection area of the extension portion and the main body in the arrangement direction perpendicular to the pins is at least partially misaligned. Therefore, on one hand, the heat radiating area can be increased, and the heat radiating performance of the power tube can be improved, and on the other hand, the arrangement mode of the extension part can enable the arrangement mode of the wiring terminal of the electric vehicle controller to be more flexible, and the wiring terminal can be arranged at any position only by changing the extension direction and the extension form of the extension part.

Description

Metal connecting piece for electric vehicle controller, electric vehicle controller and electric vehicle

Technical Field

The application relates to the technical field of electric vehicle controllers, in particular to a metal connecting piece for an electric vehicle controller, the electric vehicle controller and an electric vehicle.

Background

Currently, power device technology applied to electric vehicle controllers (three-phase motor controllers) has enabled the die of a single device to withstand relatively large currents, which means that much heat is generated.

In the prior art, on one hand, in order to solve the heat dissipation problem of the power tube, the heat dissipation of the power tube can be performed by arranging a heat dissipation piece, but the heat dissipation capacity of the power tube is weaker;

on the other hand, terminals of the electric vehicle controller for connecting an external power source and the three-phase motor are generally fixed positions where the three-phase motor control is provided, however, in some application scenarios, it is necessary to provide the terminals of the three-phase motor at a relatively remote position from the power tube, or it is necessary to flexibly provide the positions of the terminals of the electric vehicle controller according to the layout of the elements of the electric vehicle controller.

Therefore, how to solve the heat dissipation problem of the power tube and enable the setting position of the terminal of the electric vehicle controller to be more flexible becomes a technical problem to be solved urgently by technicians.

Disclosure of Invention

The application provides a metal connecting piece for electric vehicle controller, electric vehicle controller and electric vehicle, aims at solving the technical problem that the heat dispersion of power tube is weaker and can't set up the position of three-phase motor's terminal in a flexible way among the prior art.

This application is realized like this, and the metal connecting piece in this application embodiment is used for connecting the anodal input of power or the motor three-phase output of electric motor car controller, the metal connecting piece includes:

the main body is used for conducting and electrically connecting with a metal backboard of the power tube, and the power tube is provided with a plurality of pins which are arranged at intervals along the same direction; and

the extension part is connected with the main body, the orthographic projection areas of the extension part and the main body in the arrangement direction of the pins are at least partially misaligned, and the orthographic projection areas of the extension part and the main body in the arrangement direction perpendicular to the pins are at least partially misaligned.

Still further, the body and the extension are integrally formed.

Still further, the extension is configured to connect with a terminal of the electric vehicle controller;

the terminal provides the positive input of the power supply or the three-phase output of the motor.

Further, the terminal is detachably connected to the extension portion or integrally formed therewith.

Further, the main body is provided with a fixing hole for connecting with the metal backboard.

Still further, the extension portion extends in a plane parallel to a circuit board of the electric vehicle controller.

Still further, the extension portion includes a first extension portion and a second extension portion, the first extension portion is connected to the main body and extends along an arrangement direction perpendicular to the leads, and the second extension portion extends along the arrangement direction of the leads.

The application also provides an electric vehicle controller adopting the metal connecting piece, the electric vehicle controller includes:

a housing;

a circuit board mounted within the housing;

at least 6 power tubes welded on the circuit board;

a plurality of thermal relays employing the metal connector of any one of the above;

the heat relay body is connected with the power supply positive electrode input of the electric vehicle controller or the three-phase output of the motor, the main body is electrically and thermally connected with the metal backboard of the power tube, and the heat relay body is in insulating thermal connection with the shell.

Further, at least 6 of the power transistors are configured as A, B, C three-phase upper bridge arm power transistors and A, B, C three-phase lower bridge arm power transistors;

the thermal relay comprises at least one upper bridge arm thermal relay body and at least three lower bridge arm thermal relay bodies;

at least one upper bridge arm thermal relay is jointly and electrically connected with the metal backboard of the upper bridge arm power tube of at least two phases;

The metal backboard of the lower bridge arm power tube of each phase is in conductive thermal connection with at least one lower bridge arm thermal relay;

the upper bridge arm thermal relay is connected with the power supply positive electrode input of the electric vehicle controller, and/or the lower bridge arm thermal relay is connected with the motor three-phase output of the electric vehicle controller.

Further, the thermal relay body comprises a heat transfer surface in insulating thermal connection with the shell, and the surface areas of the heat transfer surfaces of at least three lower bridge arm thermal relay bodies are similar or equal.

Further, the thermal relay comprises a heat transfer surface in insulating thermal connection with the housing, the heat transfer surface comprising a bottom surface of the main body and a bottom surface of the extension;

the bottom surface of the main body and the bottom surface of the extension part are positioned on the same plane; and/or

The heat transfer surface has at least one curved or folded surface thereon.

The application also provides an electric vehicle, the electric vehicle includes the electric vehicle controller of any one of the above-mentioned, the electric vehicle is configured with three-phase motor, three-phase line interface electricity of three-phase motor connects the motor three-phase output of electric vehicle controller.

The beneficial effects that this application reached are: the orthographic projection areas of the extension part and the main body in the two directions are not overlapped, so that on one hand, the heat dissipation area can be increased, and on the other hand, the arrangement mode of the extension part can enable the arrangement mode of the wiring terminal of the electric vehicle controller to be more flexible, and the wiring terminal can be arranged at any position only by changing the extension direction and the extension form of the extension part.

Additional aspects and advantages of the application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the application.

Drawings

Fig. 1 is a schematic block diagram of an electric vehicle according to an embodiment of the present disclosure;

fig. 2 is a schematic structural diagram of an electric vehicle controller according to an embodiment of the present disclosure;

FIG. 3 is an exploded schematic view of an electric vehicle controller provided by an embodiment of the present application;

fig. 4 is a schematic view of a part of the structure of an electric vehicle controller according to an embodiment of the present application;

fig. 5 is a schematic structural diagram of each thermal relay of the electric vehicle controller according to the embodiment of the present application;

FIG. 6 is an exploded schematic view of each of the thermal relays of FIG. 5;

FIG. 7 is a schematic view of the structure of a thermal relay (metal connection) in an embodiment of the present application;

FIG. 8 is a schematic view of the thermal relay of FIG. 7 in projection along the direction A of FIG. 7;

FIG. 9 is a schematic view of the thermal relay of FIG. 7 in projection along the direction B of FIG. 7;

fig. 10 is a schematic plan view of an electric vehicle controller according to an embodiment of the present disclosure;

FIG. 11 is a schematic cross-sectional view of the electric vehicle controller of FIG. 10 taken along line XI-XI;

FIG. 12 is a schematic cross-sectional view of the electric vehicle controller of FIG. 10 taken along line XII-XII;

Fig. 13 is another schematic structural diagram of another portion of the electric vehicle controller according to the embodiment of the present application;

fig. 14 is a schematic structural diagram of still another portion of the electric vehicle controller according to the embodiment of the present application;

fig. 15 is a schematic view of a further part of the structure of the electric vehicle controller provided in the embodiment of the present application;

FIG. 16 is a schematic view of a further portion of the architecture of an electric vehicle controller provided in an embodiment of the present application;

FIG. 17 is a schematic view of a further portion of the structure of an electric vehicle controller provided in an embodiment of the present application;

fig. 18 is a schematic structural view of a lower housing of the electric vehicle controller provided in the embodiment of the present application;

FIG. 19 is a schematic view of a further portion of the architecture of an electric vehicle controller provided in an embodiment of the present application;

FIG. 20 is a schematic structural view of a seal and a buffer for an electric vehicle controller provided by an embodiment of the present application;

fig. 21 is a schematic structural view of an upper housing of an electric vehicle controller according to an embodiment of the present disclosure;

fig. 22 is another schematic structural view of an upper housing of an electric vehicle controller according to an embodiment of the present disclosure.

Detailed Description

In order to make the objects, technical solutions and advantages of the present application more apparent, the present application will be further described in detail with reference to the accompanying drawings and examples. Examples of the embodiments are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to like or similar elements throughout or elements having like or similar functionality. The embodiments described below by referring to the drawings are exemplary only for the purpose of explaining the present application and are not to be construed as limiting the present application. Furthermore, it should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the present application.

In the description of the present application, it should be understood that the orientation or positional relationship indicated in the description of the direction and positional relationship is based on the orientation or positional relationship shown in the drawings, and is merely for convenience of description of the present application and for simplification of the description, and is not indicative or implying that the apparatus or element in question must have a specific orientation, be configured and operated in a specific orientation, and therefore should not be construed as limiting the present application.

Furthermore, the terms "first," "second," and the like, are used for descriptive purposes only and are not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include one or more of the described features. In the description of the present application, the meaning of "a plurality" is two or more, unless explicitly defined otherwise.

The following disclosure provides many different embodiments, or examples, for implementing different structures of the application. In order to simplify the disclosure of the present application, the components and arrangements of specific examples are described below. Of course, they are merely examples and are not intended to limit the present application. Furthermore, the present application may repeat reference numerals and/or letters in the various examples, which are for the purpose of brevity and clarity, and which do not in themselves indicate the relationship between the various embodiments and/or arrangements discussed. In addition, the present application provides examples of various specific processes and materials, but one of ordinary skill in the art may recognize the application of other processes and/or the use of other materials.

In the embodiment of the application, the metal connecting piece (namely, the thermal relay) is used for connecting the power supply positive electrode input of the electric vehicle controller, or the motor three-phase output, and the heat dissipation area and the heat dissipation performance of the metal connecting piece can be improved by not overlapping the extension part setting of the metal connecting piece and the orthographic projection area of the main body 41 in two directions, and meanwhile, the setting mode of the wiring terminal of the electric vehicle controller can be more flexible.

Example 1

Referring to fig. 1, an electric vehicle 1000 in the embodiment of the present application may be a two-wheeled electric vehicle or a three-wheeled electric vehicle. The electric vehicle 1000 may include a three-phase motor 200 and an electric vehicle controller 100 in the embodiment of the present application, the three-phase motor 200 having a three-phase line interface (not shown) that connects motor three-phase outputs of the electric vehicle controller 100. The external power input of the electric vehicle controller 100 is connected with a power supply, and the motor three-phase output of the electric vehicle controller 100 is connected with the three-phase motor 200.

Referring to fig. 2-6, an electric vehicle controller 100 according to an embodiment of the present application may include a housing 10, a circuit board 20, a plurality of power tubes 30, and a plurality of thermal relays 40, wherein the thermal relays 40 employ metal connectors according to an embodiment of the present application.

The housing 10 is a heat dissipation housing, which may be made of metal or other materials. Preferably, the housing 10 may have a metal heat sink or be thermally connected to the housing 10 and the metal heat sink, so that rapid heat dissipation is achieved by the metal heat sink, which is not limited herein.

It will be appreciated that the heat sink may preferably be an integral part of the housing 10, although it will be appreciated that in some embodiments the heat sink may not be an integral part of the housing 10, e.g., the heat sink may be secured to the housing 10 and thermally coupled to the housing 10 by other means.

The circuit board 20 may be mounted in the housing 10, and the circuit board 10 may be provided with signal connection terminals.

The number of the power tubes 30 is at least 6, and the power tubes 30 are welded on the circuit board 20. The power tube 30 may be an in-line visible metal-encapsulated power tube, for example, the power tube 30 may be a metal-encapsulated power tube model TO 220.

The power tube 30 is provided with a metal back plate 31 and a plastic package positioned on the metal back plate 31, a plurality of pins 32 extend out of the plastic package, the number of the pins 32 can be preferably 3, the metal back plate 31 is positioned on the back surface of the power tube 30, the three pins 32 of the power tube 30 are respectively a grid electrode, a drain electrode and a source electrode, the plurality of pins 32 of the power tube 30 are arranged at intervals along the same direction, and the metal back plate 31 is electrically connected with the drain electrode.

The thermal relays 40 are connected to the positive input of the power supply of the electric vehicle controller 100 or the three-phase output of the motor, the thermal relays 40 can be used for radiating heat from the power tube 30, each thermal relay 40 is in insulating thermal connection with the radiator on the housing 10, and each thermal relay 40 can quickly absorb heat generated by the power tube 30 and conduct the heat to the housing 10, so that the heat is radiated to the outside through the housing 10. Wherein each thermal relay 40 in the present application may employ a metal connector in the embodiments of the present application.

Referring to fig. 4 to 6, the metal connector (i.e., the thermal relay 40) in the embodiment of the present application may be used to connect to the positive input of the power source or the three-phase output of the motor of the electric vehicle controller 100.

The metal connection member (i.e., the thermal relay 40) may include a main body 41 for conductive thermal connection with the back surface of the metal back plate 31 of the power tube 30, and an extension 42 connected with the main body 41, each thermal relay 40 being thermally connected with the housing 10 in an insulating manner.

Referring to fig. 7 to 9, the projection area of the extension portion 42 and the main body 41 in the arrangement direction (i.e. the direction a in fig. 7) of the pins 32 of the power tube 30 is at least partially misaligned, that is, as shown in fig. 8, the projection area Y2 formed by the front projection of the main body 41 and the projection area Y1 formed by the front projection of the extension portion 42 are at least partially misaligned in the direction a in fig. 7.

In addition, the orthographic projection areas of the extension portion 42 and the main body 41 in the direction perpendicular to the arrangement direction of the pins 32 of the power tube 30 (i.e., the direction B in fig. 7) are at least partially misaligned, that is, as shown in fig. 9, in the direction a in fig. 7, the orthographic projection area y2+y3 of the main body 41 is at least partially misaligned with the orthographic projection area y1+y3 of the extension portion 42. It will be understood that, in fig. 9, the projection area y2+y3 is a projection area formed by orthographic projection of the main body 41 in the B direction, and y1+y3 is a projection area formed by orthographic projection of the main body 41 in the B direction, and the projection area Y3 is a superposition area of orthographic projections of the extension portion 42 and the main body 41 in the B direction.

In the metal connecting piece, the electric vehicle controller 100 and the electric vehicle 1000 of the embodiment of the present application, the metal connecting piece is used for connecting a power supply positive electrode input or a motor three-phase output of the electric vehicle controller 100, the main body 41 of the metal connecting piece is electrically connected with a back surface of the metal back plate 31, the orthographic projection areas of the extension portion 42 and the main body 41 in the arrangement direction (i.e., the a direction in fig. 7) of the pins 32 of the power tube 30 are at least partially misaligned, and the orthographic projection areas of the extension portion 42 and the main body 41 in the arrangement direction (i.e., the B direction in fig. 7) perpendicular to the pins 32 of the power tube 30 are also at least partially misaligned. In this way, the orthographic projection areas of the extension portion 42 and the main body 41 in both directions are not overlapped, on one hand, the heat dissipation area can be increased, so that the heat dissipation performance of the power tube 30 is improved, on the other hand, the arrangement mode of the extension portion 42 can enable the arrangement mode of the connection terminal (such as the power supply positive electrode input end 81, the a-phase output end 821, the B-phase output end 822 and the C-phase output end 823 described below) of the electric vehicle controller 100 to be more flexible, and the connection terminal can be arranged at any position only by changing the extension direction and the extension form of the extension portion 42.

In addition, in the present application, the power supply positive electrode input and the motor three-phase output of the electric vehicle controller 100 can be electrically connected to the corresponding power tube 30 through the respective thermal relays 40, and it is unnecessary to provide a wiring for connecting these terminals on the circuit board 20, reducing the heat generation amount of the circuit board 20. The heat generated by the current passing through the thermal relay 40 can be directly transferred to the housing 10 and directly dissipated to the outside of the electric vehicle controller 100, and the technical problem of heat generated by the conduction of the thermal relay 40 is solved.

It will be appreciated that, when the power tube 30 is in operation, heat generated by the power tube 30 can be rapidly transferred to the housing 10 of the electric vehicle controller 100 through the thermal relay 40 to absorb heat generated instantaneously by the power tube 30, thereby ensuring that the power tube 30 can be within a safe temperature range.

Meanwhile, since the thermal relay 40 can quickly absorb and draw out the heat instantaneously generated by the power tube 30, the overcurrent capacity of the power tube 30 can be further improved to improve the power, and the manufacturing cost is reduced without arranging more power tubes 30 or adopting higher-specification power tubes 30 for improving the power.

From another perspective, in the electric vehicle controller 100 provided with the thermal relay 40 in the embodiment of the present application, when the same number of power tubes 30 is adopted, the power tubes 30 can carry a larger overcurrent to increase the power because the heat generated by the power tubes 30 can be quickly transferred to the thermal relay 40 to cool the power tubes 30.

That is, in the case of using the same number and the same specification of the power tubes 30, the technical solution in the embodiment of the present application can increase the power compared to the technical solution in the prior art. Under the condition of the same power, compared with the scheme in the prior art, the technical scheme of the power supply device can reduce the use quantity of the power tubes 30, so that the manufacturing cost is reduced, for example, the power of 9 power tubes or even 12 power tubes in the prior art can be achieved by adopting 6 power tubes 30.

In summary, in the embodiment of the present application, the heat dissipation capability of the power tube 30 can be improved by adopting the arrangement of the thermal relay 40 with the metal connecting piece in the embodiment of the present application, so as to improve the power of the three-phase motor 200 and reduce the cost, and meanwhile, the layout position of the connection terminal of the electric vehicle controller 100 can be more flexible and the heat productivity of the circuit board 40 can be reduced.

More specifically, in embodiments of the present application, the thickness of the body 41 and the extension 42 may be greater than the thickness of the metal back plate 31 of the power tube 30. In this way, the body 41 and the extension 42 can absorb more heat to rapidly cool the metal back plate 31.

In embodiments of the present application, the body 41 may completely cover the back side of the metal back plate 31, i.e., the size of the body 41 may be the same as or larger than the size of the back side of the metal back plate 31). The back surface of the metal back plate 31 may be substantially rectangular, that is, the contact surface of the metal back plate 31 with the main body 41 may be substantially rectangular. Of course, it will be appreciated that in other embodiments, the body 41 may be slightly smaller than the metal back plate 31, and is not limited thereto

In addition, in this document, the term "electrically conductive thermal connection" is understood to mean that the two are in direct contact with each other and can conduct electricity and heat, or that the two are indirectly in contact with each other through other elements to achieve indirect electrical connection and indirect heat conduction, and the same description will be referred to herein below.

In embodiments of the present application, the body 41 may preferably be in direct contact with the metal back plate 31 to effect an electrically conductive thermal connection, i.e., at least one planar surface of the body 41 is in direct abutting contact with the metal back plate 31.

It will be appreciated, of course, that in some possible embodiments, an electrically conductive element with better heat conductivity may be disposed between the main body 41 and the back surface of the metal back plate 31 to achieve the electrically conductive thermal connection therebetween, for example, with a silicone grease with better heat conductivity and electrical conductivity, which is not limited herein.

It should be noted that, in this context, an "insulating thermal connection" is understood to mean that the two elements are insulated from each other but can be thermally transferred by other heat conducting elements, that is, in this application, the body 41 and/or the extension 42 are insulated from each other and thermally connected to the housing 10 of the electric vehicle controller 100, and in the following, the same description will be given with reference thereto.

Example two

Referring to fig. 4, in some embodiments, at least 6 power tubes 30 may be configured as A, B, C three-phase upper leg power tubes and A, B, C three-phase lower leg power tubes.

Specifically, power tube 30 may include an a-phase upper leg power tube 301, an a-phase lower leg power tube 302, a B-phase upper leg power tube 303, a B-phase lower leg power tube 304, a C-phase upper leg power tube 305, and a C-phase lower leg power tube 306. The number of the power tubes 30 of the a-phase upper arm power tube 301, the a-phase lower arm power tube 302, the B-phase upper arm power tube 303, the B-phase lower arm power tube 304, the C-phase upper arm power tube 305 and the C-phase lower arm power tube 306 is at least 1.

Referring to fig. 5 and 6, the number of thermal relays 40 is at least 4, and specifically, thermal relay 40 may include an upper leg thermal relay 43 and a lower leg thermal relay 44. The number of upper arm thermal relays 43 is at least 1, and the number of lower arm thermal relays 44 is at least 3.

At least one upper bridge arm thermal relay 43 is electrically and thermally connected with the metal backboard 31 of the upper bridge arm power tube of at least two phases in a common conduction way;

the metal back plate 31 of the lower leg power tube of each phase is electrically and thermally connected to at least one lower leg thermal relay 44.

The upper arm thermal relay 43 is connected to a positive input of a power supply of the electric vehicle controller 100, and/or the lower arm thermal relay 44 is connected to a three-phase output of a motor of the electric vehicle controller 100.

In this way, the upper arm thermal relay 43 can radiate heat from the upper arm power tube and can also realize the positive input of the electric vehicle controller 100, and the lower arm thermal relay 44 can radiate heat from the lower arm power tube and can also realize the three-phase output of the electric vehicle controller 100. Meanwhile, the metal back plate 31 of the upper bridge arm heat relay body 43 corresponding to at least two phases of upper bridge arm power tubes can reduce the use quantity of the upper bridge arm heat relay bodies 43, reduce the manufacturing cost and also facilitate the installation.

Specifically, it is understood that, in the electric vehicle controller 100, the number of the power tubes 30 is at least 6, and herein, the number of the power tubes 30 is 6 as an example, and as shown in fig. 4, the number of the power tubes 30 is 6, and is 1 a-phase upper arm power tube 301, 1 a-phase lower arm power tube 302, 1B-phase upper arm power tube 303, 1B-phase lower arm power tube 304, 1C-phase upper arm power tube 305, and 1C-phase lower arm power tube 306, respectively.

It can be understood that, in the electric vehicle controller 100, since the drains of all the upper bridge arm power tubes of the three-phase half-bridge driving circuit are required to be connected with the positive input of the power supply, all the upper bridge arm power tubes can be electrically and commonly mounted on the same upper bridge arm thermal relay 43, and only at least 3 main bodies 41 are required to be arranged on the upper bridge arm thermal relay 43 for electrically and thermally connecting with the metal back plates 31 of different upper bridge arm power tubes, so that all the upper bridge arm power tubes can be connected with the positive input of the power supply together.

Therefore, as shown in fig. 5 and 6, in the embodiment of the present application, the upper arm thermal relay 43 may have only 1 block, and 3 spaced main bodies 41,3 main bodies 41 formed on the upper arm thermal relay 43 may be connected together by the connection portion 45 and connected to the extension portion 42, and at least one upper arm power tube is provided on each main body 41.

In addition, in the three-phase half-bridge driving circuit, since the drain electrode of the lower bridge arm power tube is electrically connected with the source electrode of the upper bridge arm power tube and three-phase output is required at the same time, in order to avoid mutual conduction between the two lower bridge arm power tubes, each lower bridge arm power tube corresponding to each phase needs to be separately corresponding to at least one lower bridge arm thermal relay 44.

Therefore, as shown in fig. 5 and 6, in the embodiment of the present application, the number of lower arm thermal relays 44 is at least 3, the lower arm thermal relay 44 corresponding to the a-phase lower arm power tube 302 may be correspondingly connected to the a-phase output of the three-phase motor control 100, the lower arm thermal relay 44 corresponding to the B-phase lower arm power tube 304 may be correspondingly connected to the B-phase output of the three-phase motor control 100, and the lower arm thermal relay 44 corresponding to the C-phase lower arm power tube 306 may be correspondingly connected to the C-phase output of the three-phase motor control 100.

The number of power tubes 40 is 6, the number of upper arm thermal relays 43 is 1, and the number of lower arm thermal relays 44 is 3.

Specifically, as shown in fig. 5 and 6, the upper leg thermal relay 43 may include 3 main bodies 41 and 1 extension 42,3 lower leg thermal relays 44 may be an a-phase lower leg thermal relay, a B-phase lower leg thermal relay, and a C-phase lower leg thermal relay, respectively. The extension 42 of the upper arm thermal relay 43 is connected to the positive power input, and the upper arm thermal relay 43 is thermally connected to the housing 10 in an insulating manner; the metal back plates 31 of the a-phase upper arm power tube 301, the B-phase upper arm power tube 303 and the C-phase upper arm power tube 305 are respectively connected with the 3 main bodies 41 of the 3 upper arm heat relays 43 in a corresponding conductive and thermal manner, the extension parts 42 of the respective lower arm heat relays 44 are correspondingly connected with the three output ends of the three-phase output of the motor, and meanwhile, the respective lower arm heat relays 44 are also connected with the housing 10 in an insulating and thermal manner.

More specifically, the 3 lower leg thermal relays 44 are electrically and thermally connected to the metal back plate 31 of the a-phase lower leg power tube 302, the B-phase lower leg power tube 304, and the C-phase lower leg power tube 306, respectively, and are:

the main body 41 on the A-phase lower bridge arm thermal relay body is in conductive thermal connection with the back surface of the metal back plate 31 of the A-phase lower bridge arm power tube 301, and the extension part 42 on the A-phase lower bridge arm thermal relay body is in output connection with the A-phase of three-phase output;

the main body 41 on the B-phase lower bridge arm thermal relay body is in conductive thermal connection with the back surface of the metal back plate 31 of the B-phase lower bridge arm power tube 301, and the extension part 42 on the B-phase lower bridge arm thermal relay body is in output connection with the B-phase output of the three-phase output;

the main body 41 on the C-phase lower arm thermal relay is electrically and thermally connected to the back surface of the metal back plate 31 of the C-phase lower arm power tube 301, and the extension 42 on the C-phase lower arm thermal relay is connected to the C-phase output of the three-phase output.

As shown in fig. 4, in the embodiment shown in fig. 4, the upper arm power tubes and the lower arm power tubes are alternately arranged in sequence along the arrangement of 6 power tubes 30. In this case, as shown in fig. 5 and 6, it is preferable that the spacing distance between the adjacent two bodies 41 on the upper leg heat relay body 43 be set to be larger than the width of the bodies 41 of the lower leg heat relay body 44, so that the bodies 41 of the lower leg heat relay body 44 corresponding to the lower leg power tube can be disposed between the adjacent two bodies 41 of the upper leg heat relay body 43 to optimize the layout between the respective heat relay bodies 40, that is, so that the bodies 41 of the respective heat relay bodies 40 can also be disposed in a row.

In addition, referring to fig. 10 to 12, in the embodiment of the present application, the main body 41 of each thermal relay 40 may be located below the metal back plate 31 of the corresponding power tube 30, and the extension portion 42 of each thermal relay 40 may be bent relative to the main body 41 and extend in a plane parallel to the circuit board 20.

The 3 main bodies 41 of the upper arm thermal relay 43 are connected together by the connection portions 45 and then connected to the extension portions 42, and the extension portions 42 are folded and extended with respect to the connection portions 43 in a plane parallel to the circuit board 20.

In this way, the extension 42 of each heat relay body 40 is provided in a bent form with respect to the main body 41 of each heat relay body 40, and the length of each extension 42 can be increased in a fixed space to increase the heat dissipation area and improve the heat dissipation efficiency.

As shown in fig. 5 and 6, in the embodiment of the present application, it is preferable that all upper arm power transistors share 1 upper arm thermal relay 43 in order to save manufacturing processes and reduce mounting processes. That is, the metal back plates 31 of all the upper arm power tubes are electrically and thermally connected together with 1 upper arm thermal relay 43.

Of course, it should be understood that in some embodiments, the number of upper arm thermal relays 43 may be multiple, for example, 2 blocks, 3 blocks, or the like, and when the number is 2 blocks, two main bodies 41 may be disposed on one of the blocks and corresponding to two upper arm power tubes, and one main body 41 may be disposed on the other block and corresponding to one upper arm power tube, and of course, each upper arm power tube may correspond to multiple upper arm thermal relays 43, and then all upper arm thermal relays 43 are connected with the positive input of the power source, which is not limited herein.

Furthermore, in some embodiments, the number of lower leg thermal relays 44 may be greater than 3, for example, each lower leg power tube may correspond to one or more lower leg thermal relays 44, which is not limited herein.

In addition, in the illustrated example, the number of the power tubes 30 of the electric vehicle controller 100 is 6, and in the example in which 6 power tubes 30 are arranged in a row in the figure, the 6 power tubes 30 may be disposed at an edge position of the circuit board 20, and three pins 32 of the power tubes 30 are welded at an edge of the circuit board 20.

Specifically, in some embodiments, the plurality of power tubes 30 may be arranged at edge positions of the circuit board 20 in a direction parallel to the circuit board 20, and the metal back plate 31 of the power tube 30 may be arranged parallel to the circuit board 20 and at least partially exposed from the edge of the circuit board 20, and the back surface of the metal back plate 31 faces the lower housing 12, which may be referred to as a horizontal mounting. In such a case, the top surface of the body 41 of the thermal relay 40 may be in direct contact with the back surface of the metal back plate 31 to form an electrically conductive thermal connection.

It will be appreciated that referring to fig. 13, in other embodiments, the power tube 30 may be mounted on the circuit board 20 in an upright manner or mounted on the circuit board 20 in an inclined manner, and the metal back plate 31 of the power tube 30 may be perpendicular to the circuit board 20 (i.e. mounted vertically) or at an inclined angle (i.e. mounted obliquely). In this case, the body 41 of the thermal relay 40 may protrude from the circuit board 20, and the side surface of the body 41 is electrically and thermally connected to the back surface of the metal back plate 31. The specific arrangement of the power tube 30 is not limited herein, and may be specifically selected according to practical situations.

In addition, only 6 power tubes 30 are illustrated herein as an example, and it is understood that in some embodiments, the number of power tubes 30 may be 9, 12, 18, etc., and is not limited in particular herein.

In addition, in the embodiment shown in fig. 4 to 6, the power tubes 30 may be arranged in a row, and the main bodies 41 of the respective thermal relays 40 are also arranged in a row. It will be appreciated that in other embodiments, the power tubes 30 may be arranged in two rows, four rows, six rows, etc., and are not limited in this regard.

For example, as shown in fig. 14, in the example shown in fig. 14, the number of power tubes may be 6 and arranged in two rows, all the upper arm power tubes may be arranged in one row and share one upper arm thermal relay 43, and all the lower arm power tubes may be arranged in another row and each upper arm power tube corresponds to one lower arm thermal relay 44.

It should be understood that, in the embodiment of the present application, no matter how many power tubes are, all the upper bridge arm power tubes may be disposed on one upper bridge arm thermal relay 43, and only a plurality of corresponding main bodies 41 need to be formed on the upper bridge arm thermal relay 43, or each upper bridge arm power tube may correspond to one upper bridge arm thermal relay 43 or two or more upper bridge arm power tubes corresponding to one upper bridge arm thermal relay 43, which is not limited herein.

For the lower bridge arm power tubes, when the number of each corresponding lower bridge arm power tube is more than 1, all the a-phase lower bridge arm power tubes 302 may be connected in parallel and simultaneously correspond to one lower bridge arm thermal relay 44, or each a-phase lower bridge arm power tube 302 may correspond to one lower bridge arm thermal relay 44; all the B-phase lower bridge arm power tubes 304 may be connected in parallel and simultaneously correspond to one lower bridge arm thermal relay 44, or each B-phase lower bridge arm power tube 304 may correspond to one lower bridge arm thermal relay 44; all the C-phase lower leg power tubes 306 may be connected in parallel and correspond to one lower leg thermal relay 44, or each C-phase lower leg power tube 306 may correspond to one lower leg thermal relay 44, which is not limited herein.

In addition, referring to fig. 11 to 14, in the illustrated embodiment, each thermal relay 40 is electrically and thermally connected to the back surface of the metal back plate 31 of the corresponding power tube 30. It will be appreciated that in other embodiments, as shown in fig. 15, each thermal relay 40 may also be conductively thermally coupled to the front side of the metal back plate 31 of the corresponding power tube 30. In this context, the back surface of the metal back plate 31 refers to a surface of the metal back plate 31 opposite to the surface on which the plastic package is disposed, and the front surface of the metal back plate 31 refers to a surface of the metal back plate 31 in the same direction as the surface on which the plastic package is disposed.

Furthermore, it is to be understood that in some possible embodiments, each thermal relay 40 may also be conductively thermally coupled to a side of the metal back plate 31, particularly without limitation. That is, in the present application, each thermal relay 40 may be electrically and thermally connected to at least one of the front, side and back surfaces of the metal back plate 31 of the corresponding power tube 30, and the specific arrangement manner may be selected according to practical situations.

In addition, it should be understood that, in some embodiments, only the upper arm thermal relay 43 may be correspondingly connected to the positive power input of the electric vehicle controller 100, and the three-phase motor output of the electric vehicle controller 100 may be configured on the circuit board 20, or the lower arm thermal relay 44 may be correspondingly connected to the three-phase motor output of the electric vehicle controller 100, and the positive power input may be configured on the circuit board 20, which is not limited herein.

Example III

In the embodiment of the present application, the metal connection member (i.e., each thermal relay 40) may be made of a material having a thermal conductivity greater than 50W/m·k, for example, the metal connection member may be made of at least one of metal materials having a good thermal conductivity such as copper, aluminum, copper-aluminum composite (e.g., copper-aluminum alloy), and the like, which may be preferably made of aluminum.

In some embodiments, the body 41 may be integrally formed with the extension 42.

Thus, the body 41 and the extension 42 are integrally formed, so that the manufacturing process of the metal connecting piece can be simplified, the two parts do not need to be connected after being manufactured respectively, and the manufacturing process is simplified. Meanwhile, the two parts are integrally formed, so that the extension part 42 is not required to be installed later, the manual installation cost is saved, and the production efficiency is improved.

Specifically, in such an embodiment, the main body 41 and the extension portion 42 may preferably be manufactured together using a casting process that enables at least partial misalignment of projection areas formed by orthographic projections of the extension portion 42 and the main body 41 in the a direction and the B direction in fig. 7. In this way, the extension 42 may be bent with respect to the main body 41 to increase the extension length of the extension 42 within the effective space of the housing 10, thereby increasing the heat dissipation area.

In a preferred embodiment, the metal connector may be cast from aluminum, particularly without limitation. Furthermore, it will be appreciated that in some embodiments, the metal connector may be partially or entirely formed by a casting process, and is not limited in this respect, so long as the body 41 and the extension 42 can be smoothly formed.

Example IV

Referring to fig. 2 to 3 and 10 to 12, in some embodiments, the housing 10 may include an upper housing 11 and a lower housing 12, the upper housing 11 and the lower housing 12 may be fitted together up and down to form a complete housing 10, and the circuit board 20 may be installed in a space formed by the upper housing 11 and the lower housing 12.

In some embodiments, each thermal relay 40 may be configured to be electrically and thermally connected to the lower housing 12, and in order to improve the heat dissipation performance, the lower housing 12 may be made of metal, and the heat dissipation body may be a part of the lower housing 12 directly, or the heat dissipation body may be made of metal and thermally connected to the lower housing 12 through other arrangements. Meanwhile, in order to improve the heat dissipation effect, a plurality of heat dissipation teeth may be further formed on the outer surface of the lower case 12.

In this way, the upper bridge arm thermal relay 43 and the lower bridge arm thermal relay 44 can respectively absorb heat generated by the upper bridge arm power tube and the lower bridge arm power tube rapidly and transfer the heat to the lower shell 12 so as to emit the heat through external air convection, and further cool down and dissipate the heat of the upper bridge arm power tube and the lower bridge arm power tube so as to improve the overcurrent capacity of the upper bridge arm power tube and the lower bridge arm power tube.

Of course, it will be appreciated that in some embodiments, each thermal relay 40 may also be configured for insulated thermal connection with the upper housing 11. Furthermore, in some embodiments, each thermal relay 40 may also be configured to be electrically and thermally coupled to both the lower housing 12 and the upper housing 11, particularly without limitation herein. Hereinafter, each of the thermal relays 40 is described as being configured to be electrically and thermally connected with the lower case 12, but this should not be construed as limiting the present application.

Further, referring to fig. 11 and 12, in the illustrated embodiment, the bottom surface of the entire thermal relay 40 is parallel to the inner surface of the lower housing 12, and the bottom surface of the entire thermal relay 40 is the heat transfer surface 421 of the thermal relay 40, and the heat transfer surface 421 is electrically and thermally connected to the casing 10. The thickness of the body 41 may be greater than the thickness of the extension 42, i.e., the body 41 protrudes upward from the extension 42, in which case the heat transfer surface 421 is composed of the bottom surface of the body 41 and the bottom surface of the extension 42, and the heat transfer surface 421 is thermally connected with the housing 10 in an insulating manner.

Meanwhile, the thickness of the main body 41 is greater than that of the extension portion 42, so that a certain interval exists between the extension portion 42 and the circuit board 20, interference between the extension portion 42 and the circuit board 20 during power-on is avoided, and reliability and stability of the electric vehicle controller 100 are improved.

Of course, it will be appreciated that in other embodiments, the heat transfer surface 421 may comprise only the bottom surface of the body 41, in which case the bottom surface of the body 41 is thermally and electrically isolated from the housing 10, and the extension 42 may be spaced from the lower shell 11. In addition, in some embodiments, the heat transfer surface 421 may include only the bottom surface of the extension 42, in which case the bottom surface of the extension 42 is thermally insulated from the housing 10, and the bottom surface of the main body 41 is spaced from the lower housing 11, which is not limited herein.

Example five

Referring to fig. 3 and 12, in some embodiments, in order to achieve insulating thermal connection of each thermal relay 40 with the housing 10, the electric vehicle controller 100 may further include an insulating member 50, the insulating member 50 may be disposed inside the lower case 12, and the heat transfer surface 421 of each thermal relay 40 may abut against the insulating member 50.

In this way, the insulating member 50 can realize rapid heat transfer, and avoid electric leakage caused by conduction between each heat relay body 40 and the housing 10, and avoid conduction between the upper arm heat relay body 43 and the lower arm heat relay body 44, and conduction between each lower arm heat relay body 44.

Specifically, in such an embodiment, the insulating member 50 may be a kind of chip package made of an insulating thermal interface material such as a metal substrate (e.g., an aluminum substrate), a silicon wafer, an imine film, an insulating cloth, a high thermal conductivity interface material, or the like.

It will be appreciated that in some embodiments, the shape of the insulator 50 may be configured to correspond to the geometry of the heat transfer surface 421 of the thermal relay, or the insulator 50 may be configured directly to cover the entire inner surface of the lower housing 12.

In some embodiments, the insulating member 50 may preferably be an aluminum substrate, which may include an aluminum base layer and an insulating layer laminated on the aluminum base layer, and a copper foil layer provided on the insulating layer, and the copper foil layer may cover an area corresponding to each of the thermal relays 40, that is, the aluminum substrate may not have the copper foil layer except for an area corresponding to each of the thermal relays 40. For example, the upper bridge arm thermal relays 43 may correspond to one copper foil area, each lower bridge arm thermal relay 44 may correspond to one copper foil area individually, and each thermal relay 40 may be soldered to the corresponding copper foil area, so that the positioning and limiting of each thermal relay 40 may be performed while ensuring heat transfer efficiency through the provision of an aluminum substrate.

Example six

Referring to fig. 3, 12, 16 and 17, in some embodiments, the electric vehicle controller 100 may further include a positioning structure 70, where the positioning structure 70 may be used to position and assemble the main body 41 of each thermal relay 40 with the metal back plate 31 of the corresponding power tube 30, and/or to position and assemble the thermal relay 40 with the housing 10.

In this way, the positioning structure 70 can limit the relative positions of each thermal relay 40 and the metal back plate 31 of the power tube 30 and the housing 10, so as to ensure the stability of the conductive thermal connection between each main body 41 and the metal back plate 31 and the installation stability of each thermal relay 40 and the housing 10, thereby improving the reliability of the electric vehicle controller 100.

It is to be understood that, herein, the "positioning structure 70 may be used to position and assemble the main body 41 of each thermal relay 40 with the metal back plate 31 of the corresponding power tube 30, and/or, the" to position and assemble the thermal relay 40 with the housing 10 "may be understood that the positioning structure 70 may position and limit the main body 41 of each thermal relay to ensure that the main body 41 can maintain stable conductive thermal connection with the metal back plate 31 of the corresponding power tube 30 and/or ensure that the relative position between each thermal relay 40 and the housing 10 is stable, so as to avoid the positional deviation of each thermal relay 40, which may cause the main body 41 to fail to achieve stable conductive thermal connection with the back surface of the metal back plate 31.

Specifically, in the embodiment of the present application, the positioning structure 70 may be disposed in the lower housing 12, the positioning structure 70 may be an insulating bracket 71, and the insulating bracket 71 may be made of an insulating and temperature-resistant material such as plastic.

As shown in fig. 16 and 17, a plurality of limiting grooves 711 may be formed on the insulating support 71, and each of the thermal relays 40 may be disposed in each of the limiting grooves 711 on the insulating support 71, and the limiting grooves 711 may contact the outer edge profile of each of the thermal relays 40, respectively, to thereby position and limit each of the thermal relays 40.

That is, in the embodiment of the present application, the positioning structure 70 may position and limit each thermal relay 40, and when each thermal relay 40 is installed, the circuit board 20 with the power tube 30 may be directly covered on the positioning structure 70 to achieve conductive thermal connection between each main body 41 and the metal back plate 31 of each power tube 30.

Further, the outer contour of the insulating support 71 may correspond to the inner contour of the lower housing 12 so that the insulating support 71 is just capable of being mounted in the lower housing 12 in a complete fit.

Referring to fig. 16 to 18, in some embodiments, the insulating support 71 may be formed with a first positioning protrusion 712, and a first positioning hole 123 may be formed at the bottom of the lower housing 12, and the first positioning protrusion 712 cooperates with the first positioning hole 123 to position the insulating support 71 on the lower housing 12.

Thus, the positions of the insulating holders 71 are fixed, the positions of the respective thermal relays 40 are also relatively fixed, and during the assembly process, only the insulating holders 71 need to be positioned and mounted on the lower case 12 through the first positioning protrusions 712 and the first positioning holes 123, then the respective thermal relays are placed in the corresponding limiting grooves 711, and then the circuit board 20 with the power tube 30 is placed on the lower case 12 so that the metal back plate 31 can be in contact with the corresponding main body 41 to achieve conductive thermal connection.

Of course, it is understood that in some embodiments, the first positioning hole may be formed on the insulating support 71, the first positioning protrusion may be formed on the lower housing 12, or the first positioning hole and the first positioning protrusion may be formed on the insulating support 71, and the first positioning protrusion and the first positioning hole may also be formed on the lower housing 12, where the positioning holes and the positioning protrusions on the two correspond one to one, and in particular, the present invention is not limited thereto.

Still further, referring to fig. 16 and 17, in some embodiments, a second positioning protrusion 713 may be further formed on the insulating support 71, and a second positioning hole 21 may be formed on the circuit board 20, where the second positioning hole 21 cooperates with the second positioning protrusion 713 to position and mount the circuit board 20 on the insulating support 71, so that the metal back plate 31 of each power tube 30 on the circuit board 20 corresponds to the main body 41 of the corresponding thermal relay 40 to achieve conductive thermal connection.

In this case, at the time of assembly, the insulating brackets 71 may be first installed in the lower case 12 through the first positioning protrusions 712 and the first positioning holes 123, then each of the thermal relays 40 is placed in the limit grooves 711 on the corresponding insulating brackets 71 and is in contact with the insulator 50, and then the circuit board 20 with the power tubes 30 may be installed on the insulating brackets 71 through the second positioning protrusions 713 and the second positioning holes 21 to directly achieve the alignment and conductive thermal connection of the main body 41 of each of the thermal relays 40 with the metal back plate 31 of the corresponding power tube 30, with high assembly efficiency.

Of course, it is understood that in some embodiments, the second positioning protrusion may be formed on the circuit board 20, the second positioning hole may be formed on the insulating support 71, or the second positioning hole and the second positioning protrusion may be formed on the insulating support 71, and the second positioning protrusion and the second positioning hole may also be formed on the circuit board 20, where the positioning holes and the positioning protrusions on the two correspond to each other, which is not limited herein.

It should be further understood that, in some embodiments, the positioning structure 70 is not limited to the insulating support 71 shown in the drawings, but may also include positioning posts, positioning slots, positioning buckles, etc. disposed on the lower housing 12, and is not limited herein, and it is only necessary to be able to position and limit each thermal relay 40 to maintain a stable conductive thermal connection with the metal back plate 31.

For example, in some embodiments, a plurality of insulating posts may be formed on the second housing 12, and positioning holes corresponding to the insulating posts may be formed on each thermal relay 40, and positioning and limiting of each thermal relay 40 may be achieved by cooperation of the insulating posts and the positioning holes when each thermal relay 40 is installed.

As another example, in some embodiments, the metal substrate (aluminum substrate) described above may also be used to provide insulating thermal connection while also enabling positioning of each thermal relay 40 through a copper foil layer on the metal substrate.

Example seven

Referring to fig. 3-6 and 15, in some embodiments, the extension 42 may be configured to connect with the terminal 80. Terminal 80 provides a power positive input or a motor three-phase output of the electric vehicle controller 100.

In this way, the thermal relay 40 can realize rapid heat dissipation of the power tube 30 and can also be used as a conductive element to realize connection between each upper bridge arm power tube and the positive input of the power supply or as a conductive element to realize connection between the lower bridge arm power tube and the three-phase output of the motor, thereby realizing multiplexing of functions and simplifying the circuit structure on the circuit board 20.

Specifically, as shown in fig. 4 to 6, the terminal 80 may include a power supply positive input terminal 81 and a motor three-phase output terminal 82, and the motor three-phase output terminal 82 may include an a-phase output terminal 821, a B-phase output terminal 822, and a C-phase output terminal 823.

The power supply positive electrode input end 81 can be electrically connected with the extension part 42 of the upper bridge arm thermal relay 43 so as to be electrically connected with each upper bridge arm power tube 30 of the electric vehicle controller 100;

the a-phase output terminal 821, the B-phase output terminal 822, and the C-phase output terminal 823 are electrically connected to the extension portions 42 of the three lower arm thermal relays 44, respectively. The a-phase output terminal 821, the B-phase output terminal 822 and the C-phase output terminal 823 may be arranged in parallel at intervals on the same side of the electric vehicle controller 100, and the positive power input terminal may be disposed on the other side of the electric vehicle controller 100.

That is, in the embodiment of the present application, the upper arm thermal relay 43 may implement the power supply positive input while implementing the rapid heat dissipation of the upper arm power tube, without providing a power supply positive input line on the circuit board 20 and then providing a power supply positive input terminal on the circuit board 20 for the power supply positive input.

The lower bridge arm thermal relay 44 can realize three-phase output of the electric vehicle controller 100 while realizing rapid heat dissipation of the lower bridge arm power tube, and three-phase output is realized without arranging a circuit on the circuit board 20 and then arranging a motor three-phase output end 82 on the circuit board 20, so that multiplexing of functions is realized, and a circuit arrangement structure on the circuit board 20 is simplified.

Furthermore, it can be appreciated that in the embodiment of the present application, since the terminals 80 are disposed on the extension portions 42 of the respective thermal relays 40, only the length, the extension direction, and the extension form of the extension portions 42 need to be changed to dispose the terminals 80 at any position of the electric vehicle controller 100, thereby meeting different requirements to adapt to different application scenarios.

For example, in the embodiment shown in fig. 4 to 6, the extension portion 42 of the upper arm heat relay 43 may be bent and extended toward one side of the circuit board 20 with respect to the main body 41, and the extension portion 42 of the lower arm heat relay 44 may be bent and extended toward the other side of the circuit board 20 with respect to the main body 41, respectively, so that the power positive input terminal 81 and the motor three-phase output terminal 82 may be located in two different directions of the circuit board 20 for the user to wire.

Of course, it will be appreciated that in some embodiments, the power supply positive input terminal 81 and the motor three-phase output terminal 82 may be located on two adjacent sides of the electric vehicle controller 100, or both types of terminals may be located on the same side of the electric vehicle controller 100, and the specific arrangement manner may be selected according to the actual specific requirements and the layout requirements of the components on the circuit board 20 of the electric vehicle controller 100.

It will be appreciated that no matter where the terminals are required to be located, only the direction and form of extension of the thermal relay need be reasonably changed, and no wiring layout on the circuit board 20 is required.

Of course, in some embodiments, the terminal 80 electrically connected to the thermal relay may include only the positive power input 81 of the electric vehicle controller 100, and the three-phase motor output 82 is output through a circuit on the circuit board 20, or the terminal 80 connected to the thermal relay may include only the three-phase motor output 82, and the positive power input 81 is output through a circuit on the circuit board 20, which is not limited herein.

In addition, referring to fig. 4 to 6, in some embodiments, the electric vehicle controller 100 may further include a power negative input end 83, the power negative input end 83 and the power positive input end 81 are arranged side by side, a negative wiring member 84 is connected to the bottom of the power negative input end 83, a negative copper foil is formed on the circuit board 20, one end of the negative wiring member 84 is provided with the power negative input end 83, and the other end is welded with the negative copper foil on the circuit board 20 or connected together by a fastener such as a screw to achieve the electrical connection. In this way, the negative power input can be achieved by the negative connection 84 without requiring additional negative input lines to be provided by the circuit board 20.

Example eight

In some embodiments, the terminal 80 may be integrally formed with the extension 42.

Thus, the terminal 80 and the extension 42 can be integrally formed without separately manufacturing two elements and then connecting the two elements, so that the cost is saved, and meanwhile, the terminal 80 can be integrally formed without being mounted subsequently, the manual mounting cost is saved, and the production efficiency is improved.

Specifically, in such an embodiment, the main body 41, the extension portion 42 and the terminal 80 may be die-cast integrally through a die-casting process, so that the production efficiency can be effectively improved, and there is no need to additionally install a separate terminal 80 on the extension portion 42, so that the investment of the terminal 80 and the steps of manual assembly are reduced, and the production cost can be effectively reduced.

More specifically, power supply positive input 81 may be integrally formed with extension 42 of upper leg thermal relay 43, and a-phase output 821, B-phase output 822, and C-phase output 823 may be integrally formed with extension 42 of corresponding lower leg thermal relay 44, respectively.

Of course, it should be understood that in other embodiments, the terminal 80 and the extension 42 may be detachably connected, for example, the two may be plugged together by a plugging structure to achieve electrical connection, or the terminal 80 may be snapped onto the extension 42 by a snap-fit structure, or the terminal 80 may be detachably fixed onto the extension 42 by a fastening element such as a screw or a bolt, which is not particularly limited herein, and may be selected according to practical needs.

Example nine

Further, referring to fig. 5, 6 and 11 and 12, in some embodiments, in order to achieve conductive thermal connection between the metal back plate 31 and the main body 41, mounting holes 311 may be formed on the back surface of the metal back plate 31 of each power tube 30, and fixing holes 411 may be formed on the main body 41 for connection with the metal back plate 31 of the power tube 30.

In this way, the metal backboard 31 and the main body 41 can be connected and installed only by penetrating the fastening elements matched with the mounting holes 311 and the fixing holes 411, so that the metal backboard 31 is fixed with the main body 41 and simultaneously electrically conductive and thermally connected, and the implementation mode is simple, and the installation is convenient and quick.

Specifically, in such an embodiment, the fixing hole 411 may be a threaded hole, and when assembled, the main body 41 and the metal back plate 31 of the power tube 30 may be assembled and fixed by being engaged with the fixing hole 411 after passing through the mounting hole 311 of the metal back plate 31 by a screw, a bolt or other threaded connection, and at the same time, conductive thermal connection is also achieved.

It will be appreciated that in some embodiments, the threaded connection member such as the screw may be made of a metal material, so that on one hand, the strength of the connection structure between the main body 41 and the metal back plate 31 may be improved, and on the other hand, the electrical connection between the metal back plate 31 and the main body 41 may be realized by the screw, so that the assembly process is simple.

Of course, in other embodiments, the metal back plate 31 and the main body 41 may be electrically and thermally connected by welding and/or riveting or electrically and thermally connecting the metal back plate 31 of each power tube 30 and the main body 41 of each thermal relay 40.

In addition, in some embodiments, the metal back plate 31 and the main body 41 may be connected by pressure fastening, such as, but not limited to, compression fastening by a pressing bar and elastic pressing by an elastic member.

For example, in some examples, an elastic member or a holding portion may be provided on the upper case 11, and when the upper case 11 and the lower case 12 are combined together, the elastic member or the holding portion may be held against the front surface of the power tube 30 so that the back surface of the metal back plate 31 of the power tube 30 and the main body 41 are tightly fitted together to achieve conductive thermal connection therebetween.

Of course, some embodiments may also be combined by using a screw compression, a screw fit, other devices compression, and an elastic member compression of a restorable elastic force to achieve the conductive thermal connection between the main body 41 and the metal back plate 31, which is not limited herein.

Examples ten

In some embodiments, the metal back plate 31 and the main body 41 are also compressed by the cooperation of the upper housing 11 and the lower housing 12 to achieve a conductive thermal connection.

Specifically, as shown in fig. 2 and 3, in the illustrated embodiment, the catching parts 111 may be formed on four sides of the upper case 11, catching grooves 1111 may be formed on the catching parts 111, and catching protrusions 122 may be correspondingly formed on four sides of the lower case 12. As shown in fig. 12, the upper case 11 may be provided with a pressing protrusion 112.

When the upper case 11 and the lower case 12 are fastened together by the fastening protrusion 122 and the fastening portion 111, the abutting protrusion 112 on the upper case 11 abuts against the power tube 30 to generate a pressing force so as to tightly attach the metal back plate 31 of the power tube 30 to the main body 41 to achieve conductive thermal connection (as shown in fig. 12).

That is, in such an embodiment, the metal back plate 31 is supported by the main body 41 and is abutted by the abutment convex portion 112 on the upper case 11 to form a stable conductive thermal connection with the main body 41.

Specifically, in such an embodiment, the upper housing 11 may be made of an insulating material such as plastic, so that it is possible to avoid that the electric vehicle controller 100 cannot work normally due to leakage of the holding protrusion 112 on the upper housing 11 when the power tube 30 is held.

It will be understood, of course, that in some embodiments, the upper housing 11 may be made of a metal material, in which case the supporting protrusion 112 on the upper housing 11 may be configured to support an insulating portion on the power tube 30, for example, may support a plastic package on the metal back plate 31 of the power tube 30, or, of course, an insulating pad may be disposed above the power tube 30, where the supporting protrusion 112 on the upper housing 11 supports against the insulating pad to achieve supporting and compressing of the power tube 30.

In addition, referring to fig. 3, 12 and 19, in order to avoid the direct hard contact between the supporting protrusion 112 on the upper housing 11 and the power tube 30, which is easy to damage during assembly, in some embodiments, the electric vehicle controller 100 may further include a buffer member 60, where the buffer member 60 may be an insulating buffer member.

The buffer member 60 may be a rubber pad, a foam pad, or other element capable of deforming to a certain extent under an external force to absorb an impact force, the buffer member 60 may cover the front surface of the power tube 30, and when the upper and lower cases 11 and 12 are assembled together, the supporting protrusion 112 on the upper case 11 may abut against the buffer member 60 to indirectly abut against the power tube 30 so as to tightly attach the metal back plate 31 of each power tube 30 to the main body 41 of each thermal relay.

Of course, it should be noted that more implementations for electrically conductive thermal connection of the main body 41 and the metal back plate 31 are provided above, and it should be understood that in some embodiments, the above-mentioned various connection methods may exist separately or simultaneously, and are not limited herein. For example, the metal back plate 31 and the main body 41 are connected by screws, and the power tube 30 can be held by forming the holding convex part 112 on the upper housing 11, so that the connection and contact between the two can be more stable.

Example eleven

Referring to fig. 5, 6 and 11, in some embodiments, the extension 42 extends in a plane parallel to the circuit board 20 of the electric vehicle controller 100.

In this way, the bottom surfaces of the extending portions 42 are all in the same plane parallel to the circuit board 20, and when the bottom surfaces of the extending portions 42 are used as the heat transfer surfaces 421, the heat transfer surfaces 421 can be all abutted against the lower housing 12, so as to improve the contact area between the two surfaces, thereby improving the heat dissipation efficiency.

Specifically, in general, the circuit board 20 is disposed in a form parallel to the inner surface of the lower case 12, and the heat transfer surface 421 is thermally connected with the inner surface of the lower case 12 in an insulating manner, and therefore, in order to increase the heat transfer area of each heat relay with the lower case 12, in this application, it is preferable that the extension 42 is disposed to extend in a plane (i.e., a horizontal plane) parallel to the circuit board 20 so that the heat transfer surface 421 of the extension 421 can be integrally fitted with the lower case 12 to increase the heat dissipation area.

In the embodiments of the present application, the body 41 may be disposed to extend in a plane perpendicular to the circuit board 20, i.e., the body 41 may be disposed perpendicular to the circuit board 20 and the inner surface of the lower case 12, while the extension plane of the extension portion 42 is perpendicular to the body 41.

As shown in fig. 11 and 12, taking the power tube 30 as a horizontal installation example, the main bodies 41 of the three lower arm thermal relays 44 may be respectively located below the metal back plates 31 of the three lower arm power tubes, and the extension portions 42 of the respective lower arm thermal relays 44 are bent with respect to the respective main bodies 41 and extend in a plane parallel to the circuit board 20. Of course, it is understood that in other embodiments, the main body 41 may not be disposed perpendicular to the circuit board 20, for example, the main body 41 may be disposed in an inclined, bent, or the like manner.

It will be appreciated that in some embodiments the extension 42 may not extend entirely in a plane parallel to the circuit board 20, for example, the extension 42 may extend a section in a plane parallel to the circuit board 20 and then extend a further section downwardly, such as to circulate to form a wave-shaped extension 42.

Of course, in other embodiments, the extension 42 may have other shapes, for example, the extension 42 may have a circular, oval, triangular, etc. protrusion structure, and the lower housing 12 may have a recess corresponding to the structure.

Further, as shown in fig. 12, in the embodiment shown in fig. 12, the back surface of the metal back plate 31 of the power tube 30 is electrically and thermally connected to the side surface of the main body 41, and the extension portion 42 also extends along a plane parallel to the circuit board 20. It will be appreciated that in other embodiments, the extension 42 may extend in a plane perpendicular to the circuit board 20 where heat dissipation requirements are met, and is not limited in this regard.

Example twelve

In some embodiments, the thermal relay 40 includes a heat transfer surface 421 in insulated thermal communication with the housing 10, the heat transfer surface 421 including a bottom surface of the body 41 and a bottom surface of the extension 42. The bottom surface of the body 41 and the bottom surface of the extension 42 lie on the same plane.

In this way, the heat transfer surfaces 421 of the heat relay bodies 40 are all located on the same plane, and the manufacturing and molding are easy.

Specifically, as described above, in such embodiments, the heat transfer surface 421 formed by the combination of the bottom surface of the main body 41 and the bottom surface of the extension 42 may be located on a plane parallel to the circuit board 20 and the inner surface of the lower case 12, and the heat transfer surface 421 may be tightly fitted with the inner surface of the lower case 12 when mounted to achieve efficient heat conduction.

Of course, it is understood that in other embodiments, the heat transfer surface 421 may have at least one curved or folded surface thereon in order to increase the heat transfer area. For example, as described above, the bottom surface of the extension 42 may have a convex structure having a circular, oval, triangular, etc. shape to form a curved surface or a folded surface, and the lower case 12 may have grooves corresponding to the structures, which cooperate to increase the heat conductive area.

Example thirteen

In some embodiments, the surface areas of the heat transfer surfaces 421 of at least 3 lower leg thermal relays 44 are similar or equal.

In this way, the areas of the heat transfer surfaces 421 of the lower bridge arm thermal relays 44 are similar or equal, so that the cooling speed of each lower bridge arm power tube is basically kept consistent, and the working temperature between the lower bridge arm power tubes is kept within the same or similar range, so as to effectively improve the stability of the electric vehicle controller 100.

Specifically, under normal conditions, the heat productivity of the A, B, C three-phase lower arm power tubes of the electric vehicle controller 100 is large and close, and in order to balance the performances of the a-phase lower arm power tube 302, the B-phase lower arm power tube 304, and the C-phase lower arm power tube 306, the surface areas of the heat transfer surfaces of the respective lower arm thermal relays 44 are set to be similar or equal, so that the respective lower arm power tubes are kept at a substantially same working temperature, thereby improving stability.

Examples fourteen

Referring to fig. 2, 10 and 21 and 22, in some embodiments, the upper housing 11 may be provided with a first wiring portion 115, the first wiring portion 115 is provided with a positive wiring groove 1151 and a negative wiring groove 1152 with open top and side portions, the power positive wiring terminal 81 may penetrate through the bottom of the positive wiring groove 1151 to extend into the positive wiring groove 1151, and the power negative wiring terminal 84 penetrates through the bottom of the negative wiring groove 1152 to extend into the negative wiring groove 1152.

Thus, when the positive electrode and the negative electrode of the power supply are connected, the ends of the two connecting wires can be positioned only by arranging the ends of the positive connecting wire and the negative connecting wire in the positive connecting wire groove 1151 and the negative connecting wire groove 1152 respectively, so that the connecting wires are convenient to connect with the positive electrode input end 81 and the negative electrode input end 83 of the power supply.

Specifically, in such an embodiment, the first wire portion 115 may be made of an insulating material, for example, it may be made of a plastic material. When the upper housing 11 is made of an insulating material, the first wire connection portion 115 may be integrally formed with the upper housing 11, and when the upper housing 11 is made of a metal material, the first wire connection portion 115 may be formed separately from the upper housing 11, and the first wire connection portion 115 may be directly disposed on the upper housing 11 through another mating structure, which is not limited herein.

Still further, referring to fig. 2, 10 and 21 and 22, in some embodiments, the upper housing 11 may further be provided with a second wire connection portion 116, the second wire connection portion 116 and the first wire connection portion 115 may be located at opposite ends of the upper housing 11, the second wire connection portion 116 is provided with an a-phase wire connection groove 1161, a B-phase wire connection groove 1162 and a C-phase wire connection groove 1163, which are both open at top and side, the three wire connection grooves are arranged side by side, the a-phase output terminal 821 may be penetrating the a-phase wire connection groove 1161 and extend into the a-phase wire connection groove 1161, the B-phase output terminal 822 may be penetrating the B-phase wire connection groove 1162 and extend into the B-phase wire connection groove 1162, and the C-phase output terminal 823 may be penetrating the C-phase wire connection groove 1163 and extend into the C-phase wire connection groove 1163.

In this way, when the three-phase windings of the three-phase motor 200 are connected, the ends of the three connecting wires can be positioned only by placing the ends of the a-phase connecting wire, the B-phase connecting wire and the C-phase connecting wire in the a-phase connecting wire slot 1161, the B-phase connecting wire slot 1162 and the C-phase connecting wire slot 1163 respectively, so that the three-phase connecting wires are convenient to connect with the a-phase output terminal 821, the B-phase output terminal 822 and the C-phase output terminal 823.

Specifically, in such an embodiment, the second wire connection portion 116 may also be made of an insulating material, for example, it may be made of a plastic material, where the upper housing 11 is made of an insulating material, the second wire connection portion 116 may be integrally formed with the upper housing 11, where the upper housing 11 is made of a metal material, the second wire connection portion 116 may be separately formed with the upper housing 11, and the second wire connection portion 116 may be directly disposed on the upper housing 11 through another mating structure, which is not limited herein.

Example fifteen

Referring to fig. 19 and 20, in some embodiments, the electric vehicle controller 100 may further include a sealing member 90, and the sealing member 90 may be provided on an upper surface of the lower case 12 to seal a gap between the upper case 11 and the lower case 12 when the two are mated to improve waterproof and moisture-proof properties.

Specifically, referring to fig. 19, in such an embodiment, the sealing member 90 may be made of a rubber material, the sealing member 90 may include a sealing body 91, a first sealing portion 92 and a second sealing portion 93, the sealing body 91 may have a rectangular ring shape, the specific shape of which may be matched with the shape of the upper surface of the lower case 12, and the first sealing portion 92 and the second sealing portion 93 may be coupled to the sealing body 91 and protrude toward the inside of the sealing body 91.

Referring to fig. 20, a first through hole 921 and a second through hole 922 may be formed on the first sealing portion 92, the power positive input end 81 is penetrated through the first through hole 921, the power negative input end 83 is penetrated through the second through hole 922, as shown in fig. 4 and 9, step surfaces are formed on the power positive input end 81 and the power negative input end 83, the first sealing portion 92 is carried on the step surfaces, a third through hole 931, a fourth through hole 931 and a fifth through hole 933 are formed on the second sealing portion 93, the a-phase output end 821 is penetrated through the third through hole 931, the B-phase output end 822 is penetrated through the fourth through hole 931, the C-phase output end 823 is penetrated through the fifth through hole 933, and step surfaces are also formed on three output ends of the a-phase output end 821, the B-phase output end 822 and the C-phase output end 823, respectively, the second sealing portion 93 is carried on the step surfaces.

During assembly, the bottom of the first connection part 115 may compress the first sealing part 92 against the step surfaces of the positive power input end 81 and the negative power input end 83 to seal the positive power input end 81 and the negative power input end 83, and the bottom of the second connection part 116 compresses the second sealing member 90 against the step surfaces of the a-phase output end 82, the B-phase output end 83 and the C-phase output end 84 to seal the a-phase output end 82, the B-phase output end 83 and the C-phase output end 84, thereby further improving the waterproof and moistureproof performances.

Sixteen implementations

Further, referring to fig. 20, in some embodiments, the sealing member 90 may be integrally formed with the buffer member 60, for example, both may be made of rubber, and both may be integrally formed through the same mold, so as to improve the processing efficiency and the assembly efficiency, and the sealing member 90 may be positioned through each connection terminal, which may position the buffer member 60 while positioning the sealing member 90, so that the positioning difficulty of the buffer member 60 during the assembly process may be reduced.

In the description of the present specification, reference to the terms "some embodiments," "illustrative embodiments," "examples," "specific examples," or "other embodiments," etc., means that a particular feature, structure, material, or characteristic described in connection with the embodiments or examples is included in at least one embodiment or example of the present application. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiments or examples. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

Furthermore, the foregoing description of the preferred embodiment is provided for the purpose of illustration only, and is not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.

Claims (12)

1. The utility model provides a metal connecting piece for electric motor car controller, its characterized in that, metal connecting piece is used for connecting the anodal input of power or the motor three-phase output of electric motor car controller, metal connecting piece includes:

the main body is used for conducting and electrically connecting with a metal backboard of the power tube, and the power tube is provided with a plurality of pins which are arranged at intervals along the same direction; and

the extension part is connected with the main body, the orthographic projection areas of the extension part and the main body in the arrangement direction of the pins are at least partially misaligned, and the orthographic projection areas of the extension part and the main body in the arrangement direction perpendicular to the pins are at least partially misaligned.

2. The metal connector of claim 1, wherein the body and the extension are integrally formed.

3. The metal connector of claim 1, wherein the extension is configured to connect with a terminal of the electric vehicle controller;

The terminal provides the positive input of the power supply or the three-phase output of the motor.

4. A metal connector according to claim 3, wherein the terminal is detachably connected to the extension or integrally formed therewith.

5. The metal connector of claim 1, wherein the body is provided with a fixing hole for connection with the metal back plate.

6. The metal connector of claim 1, wherein the extension extends in a plane parallel to a circuit board of the electric vehicle controller.

7. The metal connector of claim 1, wherein the extension portion includes a first extension portion and a second extension portion, the first extension portion being connected to the main body and extending in a direction perpendicular to the arrangement direction of the pins, the second extension portion extending in the arrangement direction of the pins.

8. An electric vehicle controller employing a metal connector, comprising:

a housing;

a circuit board mounted within the housing;

at least 6 power tubes welded on the circuit board;

a plurality of thermal relays employing the metal connector of any one of claims 1-7;

The heat relay body is connected with the power supply positive electrode input of the electric vehicle controller or the three-phase output of the motor, the main body is electrically and thermally connected with the metal backboard of the power tube, and the heat relay body is in insulating thermal connection with the shell.

9. The electric vehicle controller of claim 8, wherein at least 6 of the power transistors are configured as a A, B, C three-phase upper leg power transistor and a A, B, C three-phase lower leg power transistor;

the thermal relay comprises at least one upper bridge arm thermal relay body and at least three lower bridge arm thermal relay bodies;

at least one upper bridge arm thermal relay is jointly and electrically connected with the metal backboard of the upper bridge arm power tube of at least two phases;

the metal backboard of the lower bridge arm power tube of each phase is in conductive thermal connection with at least one lower bridge arm thermal relay;

the upper bridge arm thermal relay is connected with the power supply positive electrode input of the electric vehicle controller, and/or the lower bridge arm thermal relay is connected with the motor three-phase output of the electric vehicle controller.

10. The electric vehicle controller of claim 9, wherein the thermal relay includes a heat transfer surface in insulative thermal communication with the housing, and wherein the heat transfer surfaces of at least three of the lower leg thermal relays have similar or equal surface areas.

11. The electric vehicle controller of claim 10, wherein the thermal relay includes a heat transfer surface in insulative thermal communication with the housing, the heat transfer surface including a bottom surface of the body and a bottom surface of the extension;

the bottom surface of the main body and the bottom surface of the extension part are positioned on the same plane; and/or

The heat transfer surface has at least one curved or folded surface thereon.

12. An electric vehicle comprising an electric vehicle controller as claimed in any one of claims 8 to 11, the electric vehicle being provided with a three-phase motor, a three-phase interface of the three-phase motor being electrically connected to a motor three-phase output of the electric vehicle controller.

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