Electric vehicle inverter module capacitors

Patent metadata

Field	Value
Publication number	US-10600577-B2
Application number	US-201816110475-A
Country	US
Kind code	B2
Filing date	Aug 23, 2018
Priority date	Apr 26, 2018
Publication date	Mar 24, 2020
Grant date	Mar 24, 2020

Abstract

Provided herein is a capacitor module of an inverter module of an electric vehicle. The capacitor module can include a capacitor housing. The capacitor module can include a plurality of positive terminals coupled with a first surface of the capacitor housing and extending from the first surface at a first angle. The capacitor module can include a plurality of negative terminals coupled with the first surface of the capacitor housing and extending from the first surface at the first angle. The capacitor module can include a divider coupled with the first surface of the capacitor housing. The divider can be disposed between the plurality of positive terminals and the plurality of negative terminals. The divider can electrically isolate the plurality of positive terminals from the plurality of negative terminals. The capacitor module can include a plurality of mounting holes formed on an outer surface of the capacitor housing.

First claim

What is claimed is:

1. A capacitor module of an inverter module to provide electrical power to an electric vehicle, comprising:
a capacitor housing;
a plurality of positive terminals coupled with a first surface of the capacitor housing and extending from the first surface at a first angle;
a plurality of negative terminals coupled with the first surface of the capacitor housing; a divider coupled with the first surface of the capacitor housing, the divider disposed between the plurality of positive terminals and the plurality of negative terminals, and the divider electrically isolates the plurality of positive terminals from the plurality of negative terminals;
a plurality of mounting holes formed on an outer surface of the capacitor housing;
an extension portion of the divider, the extension portion disposed between the plurality of positive terminals and the plurality of negative terminals to electrically insulate the plurality of positive terminals from the plurality of negative terminals, and wherein the plurality of positive terminals are adjacent to a first side surface of the extension portion and the plurality of negative terminals are adjacent to a second side surface of the extension portion;
a first divider support member to hold the plurality of positive terminals and the plurality of negative terminals; and
a second divider support member to hold the plurality of positive terminals and the plurality of negative terminals.

2. The capacitor module of claim 1 , comprising:
a dielectric gel tray coupled with capacitor housing through the plurality of mounting holes, the dielectric gel tray defining an inner region, the inner region having the plurality of positive terminals, the plurality of negative terminals, and the divider disposed therein.

3. The capacitor module of claim 1 , comprising:
the extension portion disposed perpendicular with respect to the first surface of the capacitor housing, wherein the extension portion extends at a same angle as the divider with respect to the first surface of the capacitor housing.

4. The capacitor module of claim 1 , comprising:
the extension portion having a height in a range from 1 mm to 4 mm.

5. The capacitor module of claim 1 , comprising:
a plurality of separating elements formed on the divider; and
a second plurality of separating elements formed on the divider.

6. The capacitor module of claim 1 , comprising:
a plurality of separating elements formed on at least one side surface of the divider, each of the plurality of separating elements formed at a height in a range from 18 mm to 22 mm with respect to a bottom end of the divider.

7. The capacitor module of claim 1 , comprising:
the plurality of positive terminals including a positive base portion and a plurality of positive leads, the plurality of positive leads extending from the positive base portion.

8. The capacitor module of claim 1 , comprising:
each of the plurality of positive terminals including at least one positive lead, each of the positive leads having a thickness in a range from 0.5 mm to 1.5 mm.

9. The capacitor module of claim 1 , comprising:
the plurality of negative terminals including a negative base portion and a plurality of negative leads, the plurality of negative leads extending from the negative base portion.

10. The capacitor module of claim 1 , comprising:
each of the plurality of negative terminals including at least one negative lead, each of the negative leads having a thickness in a range from 0.5 mm to 1.5 mm.

11. The capacitor module of claim 1 , comprising:
the capacitor module disposed in an inverter module of a drive train unit, the drive train unit having multiple inverter modules.

12. The capacitor module of claim 1 , comprising:
the capacitor module disposed in an inverter module of a drive train unit, the drive train unit disposed in an electric vehicle.

13. A method for providing a capacitor module of an inverter module of an electric vehicle, the method comprising:
providing a capacitor housing of a capacitor module;
coupling a plurality of positive terminals with a first surface of the capacitor housing such that the plurality of positive terminals extend from the first surface at a first angle;
coupling a plurality of negative terminals with the first surface of the capacitor housing; disposing a divider between the plurality of positive terminals and the plurality of negative terminals, the divider coupled with the first surface of the capacitor housing, and the divider electrically isolates the plurality of positive terminals from the plurality of negative terminals;
forming a plurality of mounting holes on an outer surface of the capacitor housing;
coupling a first divider support member with a first edge surface of the divider using a first adhesive layer, the first divider support member to hold the plurality of positive terminals and the plurality of negative terminals; and
coupling a second divider support member with a second edge surface of the divider using a second adhesive layer, the second divider support member to hold the plurality of positive terminals and the plurality of negative terminals, wherein the second edge surface is an opposite end of the divider with respect to the first edge surface.

14. The method of claim 13 , comprising:
forming a plurality of separating elements on a first side surface of the divider; and
forming a plurality of separating elements on a second side surface of the divider.

15. The method of claim 13 , comprising:
coupling an extension portion with the divider, the extension portion disposed between the plurality of positive terminals and the plurality of negative terminals to electrically insulate the plurality of positive terminals from the plurality of negative terminals.

16. The method of claim 13 , comprising:
coupling the first divider support member with the first edge surface of the divider; and
coupling the second divider support member with the second edge surface of the divider, wherein the plurality of positive terminals and the plurality of negative terminals are disposed between the first divider support member and the second divider support member.

17. The method of claim 13 , comprising:
disposing the capacitor module in an inverter module of a drive train unit, the drive train unit having multiple inverter modules.

18. The method of claim 13 , comprising:
providing the capacitor module in an inverter module of a drive train unit; and
providing the drive train unit in an electric vehicle.

19. An electric vehicle, comprising:
a capacitor module of an inverter module of an electric vehicle, the capacitor module comprising:
a capacitor housing;
a plurality of positive terminals coupled with a first surface of the capacitor housing and extending from the first surface at a first angle;
a plurality of negative terminals coupled with the first surface of the capacitor housing;
a divider coupled with the first surface of the capacitor housing, the divider disposed between the plurality of positive terminals and the plurality of negative terminals, and the divider electrically isolates the plurality of positive terminals from the plurality of negative terminals;
a plurality of mounting holes formed on an outer surface of the capacitor housing;
an extension portion of the divider, the extension portion disposed between the plurality of positive terminals and the plurality of negative terminals to electrically insulate the plurality of positive terminals from the pl

Assignees

• Sf Motors Inc
• Chongqing Jinkang New Energy Vehicle Co Ltd

Inventors

• Song Yunan
• Mao Kangwei
• Nie zhong
• Wang Duanyang
• Tang Yifan

Classifications

• H01G9/0029

  Processes of manufacture · CPC title

• H01G9/008 Primary

  Terminals · CPC title

• H01G9/08

  Housing; Encapsulation · CPC title

• H01G9/07

  Dielectric layers · CPC title

• H02M7/003

  Constructional details, e.g. physical layout, assembly, wiring or busbar connections · CPC title