阅读说明：本技术 用于车辆的电池充电器和相关的实现过程 (Battery charger for a vehicle and related implementation process ) 是由 G·西蒙纳西 于 2019-03-05 设计创作，主要内容包括：用于车辆的电池充电器(1),包括一个外部容器(2)；容纳在容器(2)内的电子板(3、4),其可操作地连接到车辆的电池并配置为用于电池的再充电；连接到电子板(3、4)的至少一个电气部件(5、6)；以及用于容纳电气部件(5、6)的至少一个支撑件(7、8)；其中,支撑件(7、8)包括在电气部件(5、6)和电子板(3、4)之间的电连接装置(9、10、11)。(Battery charger (1) for vehicles, comprising external containers (2), an electronic board (3, 4) housed inside the container (2) operatively connected to the batteries of the vehicle and configured for recharging the batteries, at least electrical components (5, 6) connected to the electronic board (3, 4), and at least supports (7, 8) for housing the electrical components (5, 6), wherein the supports (7, 8) comprise electrical connection means (9, 10, 11) between the electrical components (5, 6) and the electronic board (3, 4).)

1. A battery charger (1) for vehicles, comprising at least external containers (2), at least electronic boards (3, 4) housed inside said containers (2), said electronic boards (3, 4) being operatively connected to the batteries of the vehicle and configured for recharging said batteries, at least electrical components (5, 6) connected to said electronic boards (3, 4), and at least supports (7, 8) for housing said at least electrical components (5, 6);

characterized in that said support (7, 8) comprises electrical connection means (9, 10, 11) between said at least electrical components (5, 6) and said electronic boards (3, 4).

2. Battery charger (1) according to claim 1, characterized in that said electrical connection means (9, 10, 11) comprise at least electrical terminals connected to said at least electrical components (5, 6), at least second electrical terminals (10) connected to said electronic board (3, 4), and at least connection elements (11) connected to said electrical terminals (9) and to said second electrical terminals (10), said electrical terminals (9), said second electrical terminals (10) and said connection elements (11) being made on said support (7, 8).

3. The battery charger (1) according to one or more of the preceding claims , characterized in that said supports (7, 8) comprise at least fixing frames (13) for fixing said at least electrical components (5, 6).

4. Battery charger (1) according to claim 3, characterized in that said fixed frame (13) comprises at least housing seats for housing said at least electrical components (5, 6).

5. Battery charger (1) according to claim 4, characterized by the fact that said th electric terminal (9) is made on said housing seat.

6., battery charger (1) according to claims 2-5, characterized in that the electrical terminals (9) comprise at least pads (9) for connecting the terminals of the at least electrical components (5, 6).

7., battery charger (1) according to claims 2 to 6, characterized in that said second electric terminals (10) comprise at least a electric connector (10) connected to a second electric connector (12) corresponding to said electronic board (3, 4).

8., the battery charger (1) according to claims 2 to 7, characterized in that the connecting element (11) comprises at least conductive elements (11) made on the fixed frame (13).

9., battery charger (1) according to claims 3 to 8, characterized in that the fixed frame (13) comprises a plurality of housing seats for housing a plurality of electrical components (5, 6).

10. Battery charger (1) according to one or more of the preceding claims , characterized in that said electric component (5, 6) is a winding component (6).

11. Battery charger (1) according to claim 10, characterized in that said winding member (6) is constituted by of transformers, inductors or filters.

12. The battery charger (1) according to one or more of the preceding claims , characterized in that said electrical component (5, 6) is a capacitor (5).

13. Process for implementing a battery charger (1) for a vehicle, comprising at least the following steps:

-making at least electronic boards (3, 4), said electronic boards (3, 4) being connectable to a battery of a vehicle and configured for recharging of said battery;

-connecting at least electrical components (5, 6) to the electronic board (3, 4);

characterized in that the connecting step comprises at least the following steps:

-making at least supports (7, 8) for housing said at least electrical components (5, 6), said supports (7, 8) being provided with electrical connection means (9, 10, 11) between said at least electrical components (5, 6) and said electronic boards (3, 4);

-associating said at least electrical components (5, 6) with said support (7, 8) and making an electrical connection between said electrical components (5, 6) and said electrical connection means (9, 10, 11);

-associating said support (7, 8) with said electronic board (3, 4) and making an electrical connection between said electrical connection means (9, 10, 11) and said electronic board (3, 4).

14. Support (7, 8) for electrical components, comprising at least fixed frames (13), said fixed frames (13) being provided with at least housing seats for housing at least electrical components (5, 6), characterized in that it comprises electrical connection means (9, 10, 11) between said at least electrical components (5, 6) and at least electronic boards (3, 4), said connection means (9, 10, 11) being made on said fixed frames (13).

Technical Field

The invention relates to battery chargers for vehicles and implementation processes related thereto.

Background

In particular, with reference to the field of electric or hybrid motor vehicles, in order to convert an input voltage/current into a suitable output voltage/current, it is necessary to use power electronics installed on the vehicle, such as an OBC (on-board charger) battery charger or a DC-DC converter.

Known types of battery chargers for vehicles typically include or more power supplies or control boards, which consist of or more printed circuit boards.

The printed circuit board may be made on a support made of an electrically insulating material such as epoxy glass or on a metal support of the IMS (insulated metal substrate) type.

It should be noted in particular that in the field of realising battery chargers for vehicles, printed circuit boards with metal supports are preferably used due to the heat dissipation characteristics of metal (usually aluminium), in order to achieve high thermal efficiency.

The battery charger must include large electrical winding components (power on the order of kW) consisting of components such as transformers, filters and inductors.

According to known solutions, these large electrical spooled parts are grouped in purpose-built modules comprising special housing supports. These additional modules are often necessary precisely because of the large size of the winding members, which make direct attachment to the printed circuit board difficult.

Similar considerations apply to components such as large capacitors.

In fact, with reference to printed circuit boards with epoxy glass supports in particular, the fixing of the components directly wound on the support would make the printed circuit board mechanically weak, ineffective and substantially affect the life of the battery charger.

Furthermore, as regards the problem of low mechanical strength, the use of printed circuit boards with metallic supports of the IMS type also increases the fact that the way in which the components are wound on the support will require the drilling of the support itself, which therefore entails a high risk of electrical short circuits.

In fact, a support of the IMS type is known, comprising a metal plate, generally made of aluminum, covered with a thin layer of dielectric material on which copper tracks are made.

Drilling the support for fixing the winding member therefore means that a possible electrical connection is made between the winding member itself and the aluminium of the support, causing a short circuit to occur.

In known types of battery chargers, therefore, the module with the electric winding components is connected to the printed circuit board by means of special cables and both are fixed in a special container or in different containers.

However, this known solution has several drawbacks.

In practice, it is necessary to connect the various spooled parts present on the module at the exact point and at different points on the circuit board, but the wires of the various spooled parts are difficult to take out for a correct connection.

The complexity of these connections thus makes assembly more difficult, while also increasing the likelihood of connection errors, or in any event, there may be an insufficiently "robust" connection over time during normal use of the battery charger.

Disclosure of Invention

The main object of the present invention is to devise battery chargers for vehicles and the related realisation process that allow to simplify the assembly operations of the battery charger itself, in particular for large electrical components, such as winding components or capacitors.

Another object of the invention is to devise battery chargers for vehicles and related implementations that allow avoiding connection errors of the electric winding parts.

Another object of the invention is to devise battery chargers for vehicles and related realisations that allow to overcome the above mentioned drawbacks of the prior art in a simple, rational, easy, effective way of use and low cost solution.

The above object is achieved by a battery charger for a vehicle according to claim 1.

The above object is also achieved by the implementation of the invention for a battery charger for a vehicle according to claim 13.

Drawings

Further characteristics and advantages of the invention will emerge more clearly from the description of a preferred but not exclusive embodiment of a battery charger for vehicles and a related implementation procedure, illustrated by way of an indicative but non-limiting example in the accompanying drawings, wherein:

fig. 1 is an overall view of a possible embodiment of a battery charger according to the invention;

FIG. 2 is an exploded view of the battery charger of FIG. 1;

figure 3 shows an electronic board and two supports for the electrical components of the battery charger according to the invention;

figure 4 shows a possible support for the electrical components of the battery charger according to the invention, particularly suitable for supporting large winding components;

fig. 5 shows a possible support for the electrical components of a battery charger according to the invention, which is particularly suitable for supporting large capacitors.

Detailed Description

With particular reference to these figures, reference numeral 1 generally indicates a battery charger for a vehicle, in particular a battery charger that can be mounted on an electric vehicle, a hybrid vehicle or the like and is suitable for recharging the battery of the vehicle.

The battery charger 1 comprises an external container 2, which external container 2 is adapted to house and protect the entire electronics of the battery charger itself and to be mounted and fixed inside the vehicle.

The battery charger 1 also comprises at least electronic boards 3, 4 housed inside the container 2, the electronic boards 3 and 4 being operatively connected to the batteries of the vehicle and configured for recharging the batteries themselves.

With reference to the specific but non-limiting embodiment shown in the figures, the battery charger 1 comprises a th power electronic board 3 and a second IMS electronic board 4, suitably connected to each other.

However, different embodiments of the battery charger 1, i.e. in which different types and different numbers of electronic boards are used, cannot be excluded.

The battery charger 1 further comprises at least electrical components 5, 6 connected to at least electronic boards 3, 4, and at least supports 7, 8 for accommodating such at least electrical components 5, 6.

In particular, each support 7, 8 used in the battery charger 1 is adapted to allow or more electrical components 5, 6 to be supported, while simplifying the correct positioning inside the container 2.

The electrical components supported by means of the supports 7, 8 may consist of large wound components (e.g. transformers, inductors or filters) or large capacitors.

However, the use of supports for different types of electronic components cannot be excluded.

Advantageously, the support 7, 8 used in the battery charger 1 according to the invention comprises electrical connection means 9, 10, 11 for connecting at least electrical components 5, 6 to the electronic board 4.

In particular, the presence of the electrical connection means 9, 10, 11 allows to connect the electrical components 5, 6 to or more electronic boards 3, 4 in a quick and easy manner.

By referring in particular, but not exclusively, to the embodiment shown in the figures, the battery charger 1 comprises a -th support 7 adapted to support a plurality of capacitors 5, and a second support 8 adapted to support a plurality of winding members 6, the -th support 7 and the second support 8 are both associated with the power electronic board 3 and with the IMS electronic board 4.

However, the use of different numbers of supports connected to different electronic boards cannot be excluded, and the support of different numbers of different types of electronic components by the supports cannot be excluded.

Advantageously, the electrical connection means 9, 10, 11 comprise at least fourth electrical terminals 9, at least 0 second electrical terminals 10 and at least connection elements 11, wherein the at least fourth electrical terminals 9 are connected to at least electrical components 5, 6, the at least second electrical terminals 10 are connected to at least electronic boards 3, 4, the at least connection elements 11 electrically connect the fifth electrical terminals 9 to the second electrical terminals 10.

Each electronic board 3, 4 is provided with at least respective connection terminals 12 for connecting second electrical terminals 10.

The th electrical terminal 9, the second electrical terminal 10 and the connecting element 11 are all made on the support 7, 8 itself.

With reference to the particular embodiment shown in the figures, the th support 7 and the second support 8 each comprise respective electrical connection means 9, 10, 11.

In particular, the -th support 7 comprises a plurality of -th electric terminals 9 for connecting the respective capacitors 5, a plurality of second electric terminals 10 for connecting with respective connection terminals 12 of the power and IMS electronics boards 3, 4, and a plurality of connection elements 11 for electrically connecting each -th electric terminal 9 to at least respective second electric terminals 10.

Similarly, the second support 8 comprises a plurality of electrical terminals 9 for connecting each winding member 6, a plurality of second electrical terminals 10 for connecting with respective connection terminals 12 of the power and IMS electronics boards 3, 4, and a plurality of connection elements 11 for connecting each electrical terminal 9 to at least respective second electrical terminals 10.

Advantageously, each support 7, 8 comprises at least fixing frames 13 for fixing the electrical components 5, 6, the fixing frames 13 being provided with electrical connection means 9, 10, 11 and being suitably shaped to allow each electrical component 5, 6 to be correctly connected to a precise and distinct point of the electronic board 3, 4.

In particular, the fixed frame 13 comprises at least housing seats for housing the respective electrical components 5, 6.

Usefully, the th electric terminal 9 is made on such a housing seat of the fixed frame 13.

With reference to the particular embodiment shown in the figures, each -th electrical terminal 9 comprises a connection pad for connecting a terminal of a respective electrical component 5, 6.

Advantageously, according to a preferred embodiment, the second electrical terminal 10 comprises an th electrical connector connected to a second electrical attachment connector 12 corresponding to an electronic board.

Preferably, the second electrical terminals 10 and the electrical attachment connector 12 are constituted by a Faston connector, to simplify and speed up the assembly and connection operations of the electronic boards 3, 4.

Advantageously, according to a preferred embodiment, the connection element 11 consists of a conductive track or a specially wired conductive element and is made directly on the fixed frame 13.

Advantageously, the fixed frame 13 is designed to house a plurality of electrical components 5, 6 and comprises electrical connection means 9, 10, 11 between each electrical component 5, 6 and each electronic board 3, 4.

In particular, each fixed frame 13 comprises a plurality of housing seats for a plurality of electrical components 5, 6.

In this way, therefore, each support 7, 8 can fix a plurality of respective electrical components 5, 6 and allow the electrical components themselves to be connected quickly and easily to each electronic board 3, 4.

Furthermore, the presence of the second electrical terminals 10 arranged on the opposite side of the fixed frame 13 allows the connection of the electronic components 5, 6 to the power electronic board 3 and to the IMS electronic board.

Usefully, according to a possible embodiment, the fixed frame 13 comprises at least interconnection elements 14, the interconnection elements 14 being adapted to interconnect at least contacts 15 present on the th electronic board 3 to at least corresponding contacts present on the second electronic board 4.

Preferably, the interconnection element 14 consists of a substantially tubular element suitable for housing the contact of the th electronic board 4.

The implementation of a battery charger for a vehicle comprises at least the following steps:

-making at least electronic boards 3, 4, the electronic boards 3, 4 being connectable to the batteries of the vehicle and configured to recharge the batteries themselves;

connecting at least electrical components 5, 6 to the electronic boards 3, 4.

Advantageously, the connection of at least electrical components 5, 6 to the electronic boards 3, 4 is performed according to the following steps:

-making at least supports 7, 8 for accommodating at least electrical components 5, 6, wherein the supports 7, 8 are provided with electrical connection means 9, 10, 11 between at least electrical components 5, 6 and the electronic boards 3, 4.

Associating at least electrical components 5, 6 with the supports 7, 8, making electrical connections between the electrical components 5, 6 and the electrical connection means 9, 10, 11;

associating the support 7, 8 with the electronic board 3, 4, making an electrical connection between the electrical connection means 9, 10, 11 and the electronic board 3, 4.

Furthermore, the implementation process according to the invention comprises the following steps:

-making an outer container 2;

-housing and fixing inside said container 2 said at least electronic boards 3, 4 and said at least supports 7, 8, said supports 7, 8 being provided with said electronic components 5, 6.

It cannot be excluded to use the above-described support described with reference to the battery charger 1 in different applications, for example to support the same or different types of electronic components.

In this example, the support comprises electrical connection means similar to the electrical connection means 9, 10, 11 described above and at least fixed frames similar to the fixed frames 13 described above.

The described invention has been determined in practice to be able to achieve the intended aim.

It is particularly emphasized that the battery charger and the implementation process according to the invention enable assembly operations to be simplified, in particular the assembly of large electronic components, such as electrical winding components or capacitors.

Furthermore, the battery charger and implementation process according to the invention allow to avoid connection errors of the electric winding components.