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EP-4738679-A1 - POWER CONVERSION MODULE AND VEHICLE-MOUNTED CHARGER APPLYING SAME

EP4738679A1EP 4738679 A1EP4738679 A1EP 4738679A1EP-4738679-A1

Abstract

The present invention provides a power conversion module and a vehicle charger using same. The power conversion module includes: a casing , and a spatial water channel, a power mainboard, an input terminal, a signal terminal, a LVDC terminal, and an output terminal each disposed on the casing, wherein the input terminal, the signal terminal, the LVDC terminal, and the output terminal are arranged on the same side of the casing, and the input terminal and the output terminal are respectively at two ends on the same side of the casing opposite to each other; and further comprises: an input filtering circuit board and an output filtering circuit board, wherein the input filtering circuit board and the output filtering circuit board are respectively arranged on two adjacent sides of the casing where the input terminal and the output terminal are disposed, and are electrically connected to the input terminal and the output terminal, respectively; the power mainboard is disposed at the top of the casing and electrically connected respectively to the input filtering circuit board and the output filtering circuit board. In the present invention, by way of dividing the filtering mainboard into an input filtering circuit board and an output filtering circuit board with high integration and small size, and arranging all terminals and nozzles on the same side of the casing, it is possible to improve the overall power density and optimize heat dissipation and electrical distribution.

Inventors

  • FENG, Yingying
  • LUO, Yaowen
  • WANG, Guang
  • HE, Yao

Assignees

  • SHENZHEN VMAX NEW ENERGY (GROUP) CO., LTD

Dates

Publication Date
20260506
Application Date
20240509

Claims (10)

  1. A power conversion module, including a casing (1), and a spatial water channel (2), a power mainboard (3), an input terminal (4), a signal terminal (5), a LVDC terminal (7), and an output terminal (6) each disposed on the casing (1), wherein the input terminal (4), the signal terminal (5), the LVDC terminal (7), and the output terminal (6) are arranged on the same side of the casing (1), and the input terminal (4) and the output terminal (6) are respectively at two ends on the same side of the casing (1) opposite to each other; the power conversion module further comprises: an input filtering circuit board (8) and an output filtering circuit board (9), the input filtering circuit board (8) and the output filtering circuit board (9) are respectively arranged on two adjacent sides of the casing (1) where the input terminal (4) and the output terminal (6) are disposed, and are electrically connected to the input terminal (4) and the output terminal (6), respectively; the power mainboard (3) is disposed at the top of the casing (1) and electrically connected respectively to the input filtering circuit board (8) and the output filtering circuit board (9).
  2. The power conversion module according to claim 1, wherein the spatial water channel (2) is set in the middle of the casing (1) and lies between the input filtering circuit board (8) and the output filtering circuit board (9), and a water inlet nozzle (21) and a water outlet nozzle (22) of the spatial water channel (2) are set on the same side of the casing (1) where the input terminal (4), the signal terminal (5), the LVDC terminal (7), and the output terminal (6) are disposed.
  3. The power conversion module according to claim 2, wherein the power conversion module further comprises: a first shielding cover (81) arranged between the input filtering circuit board (8) and the power mainboard (3) and a second shielding cover (91) arranged between the output filtering circuit board (9) and the power mainboard (3).
  4. The power conversion module according to claim 2, wherein the signal terminal (5) and the LVDC terminal (7) lie between the input terminal (4) and the output terminal (6), and the signal terminal (5) and the LVDC terminal (7) are arranged one above another; the water inlet nozzle (21) lies between the input terminal (4) and the LVDC terminal (7), and the water outlet nozzle (22) lies between the output terminal (6) and the LVDC terminal (7).
  5. The power conversion module according to claim 2, wherein the power conversion module further comprises a planar water channel disposed at the bottom of the casing (1), and a plurality of adhesive filling cavities are formed among the spatial water channel (2), the casing (1), and the planar water channel, and a heating element of either the input filtering circuit board (8) or the output filtering circuit board (9) is accommodated in a corresponding adhesive filling cavity (11).
  6. The power conversion module according to any one of claims 1-5, wherein the input filtering circuit board (8) and the output filtering circuit board (9) are electrically connected to the power mainboard (3) respectively through a power connection copper column (92) and a signal connection copper pin (93).
  7. The power conversion module according to any one of claims 1-5, wherein the input terminal (4) is electrically connected to the input filtering circuit board (8) through a terminal pin (42) and the output terminal (6) is electrically connected to the output filtering circuit board (9) through a terminal pin (42).
  8. The power conversion module according to any one of claims 1-5, wherein the input terminal (4) is electrically connected to a terminal post (82) of the input filtering circuit board (8) through an adapter cable (41) and the output terminal (6) is electrically connected to a terminal post (82) of the output filtering circuit board (9) through an adapter cable (41).
  9. The power conversion module according to any one of claims 1-5, wherein the input filtering circuit board (8) is an AC input filtering circuit board, and the output filtering circuit board (9) is an HV output filtering circuit board, and the input terminal (4) is an AC input terminal, and the output terminal (6) is an HV output terminal.
  10. An on-board charger, wherein the on-board charger uses the power conversion module claimed in any one of claims 1-9.

Description

Technical Field The present invention relates to the technical field of charging vehicles and power conversion, in particular to a power conversion module and an on-board charger using same. Background of the Invention As a demand for energy conservation, emission reduction, and air pollution control is steadily on the increase, the motor industry needs to transform product's energy structure as soon as possible to achieve the goal of "carbon peaking" and "carbon neutrality". Currently, new energy vehicles are gradually being commercialized in the market, and electric vehicles are a mainstream model among them, which has huge potential for future development and market demand. Power conversion modules serving as an important component of an electric vehicle charging system (including EV charging piles, on-board chargers, voltage converter DCDC, and other related integrated products) will also have huge market demand in the future. Nowadays, as labor costs are continuously rising; in order to ensure stable product quality and consistency in production, how to automatically manufacture power conversion modules, such as OBC charging modules, has become an inevitable trend in this field. Currently, pursuing a lightweighting of automotive components has become a goal in the industry. Consequently, a size of OBC charging modules is gradually shrinking, and a large number of circuit components and electromagnetic devices are integrated inside an OBC charging module. However, for automatic manufacture of OBC charging modules, there is still a possibility of further optimizing structures and methods for installing such circuit components and electromagnetic devices. A traditional OBC charging module typically has a filtering mainboard and a power mainboard arranged with respect to each other up and down inside a casing, wherein a size of the filtering mainboard matches that of the power mainboard and the filtering mainboard is arranged above the power mainboard. This conventional arrangement where the filtering mainboard and the power mainboard are disposed separately, causes an increase in sizes of filtering circuit boards and a decrease in power density of OBC charging modules. In addition, such an arrangement complicates internal heat dissipation structures of OBC charging modules, and degrades heat dissipation effects of power device. In addition, for OBC charging modules employing such an arrangement, it is necessary to wire and assemble multiple power connectors with power devices in various positions separately inside the casing on the top and bottom of the casing, leading to relative decentralization of electrical distribution for OBC charging modules, which is unfavorable to automatically assembling OBC charging modules. Summary of the Invention In order to solve the problem existing in the prior art that an arrangement where a filtering mainboard and a power mainboard are disposed separately, causes an increase in sizes of filtering circuit boards and a decrease in power density of OBC charging modules, the present invention proposes a power conversion module with high integration and power density, and a vehicle-mounted charger using same. In order to solve the above problems, the technical scheme of the present invention is as follows: the present invention provides a power conversion module, including a casing, and a spatial water channel, a power mainboard, an input terminal, a signal terminal, a LVDC terminal, and an output terminal each disposed on the casing, the input terminal, the signal terminal, the LVDC terminal, and the output terminal are arranged on an the same side of the casing, and the input terminal and the output terminal are respectively at two ends on the same side of the casing opposite to each other;the power conversion module further comprises: an input filtering circuit board and an output filtering circuit board, the input filtering circuit board and the output filtering circuit board are respectively arranged on two adjacent sides of the casing where the input terminal and the output terminal are disposed, and are electrically connected to the input terminal and the output terminal, respectively;the power mainboard is disposed at the top of the casing and electrically connected respectively to the input filtering circuit board and the output filtering circuit board. Preferably, the spatial water channel is set in the middle of the casing and lies between the input filtering circuit board and the output filtering circuit board, and a water inlet nozzle and a water outlet nozzle of the spatial water channel are set on the same side of the casing where the input terminal, the signal terminal, the LVDC terminal, and the output terminal are disposed. Further, the power conversion module further comprises: a first shielding cover arranged between the input filtering circuit board and the power mainboard and a second shielding cover arranged between the output filtering circuit board a