Battery charger for a vehicle and related implementation process

Abstract

A battery charger (1) for a vehicle, comprising an outer container (2); electronic boards (3, 4) housed within the container (2), operatively connected to the vehicle's battery and configured for recharging the battery; at least one electrical component (5, 6) connected to the electronic boards (3, 4); and at least one support (7, 8) for housing the electrical component (5, 6); wherein the support (7, 8) includes electrical connection means (9, 10, 11) between the electrical component (5, 6) and the electronic boards (3, 4).

Description

Technical Field

[0001] The present invention relates to a battery charger for a vehicle and an implementation process associated therewith. Background Art

[0002] In particular, referring to the field of electric or hybrid motor vehicles, in order to convert the input voltage / current into a suitable output voltage / current, it is necessary to use power electronic devices installed on the vehicle, such as an OBC (on-board charger) battery charger or a DC-DC converter.

[0003] Known types of battery chargers for vehicles typically include one or more power supply or control boards, which are composed of one or more printed circuit boards.

[0004] The printed circuit board can 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.

[0005] It should be particularly noted that in the field of implementing battery chargers for vehicles, due to the heat dissipation characteristics of metals (usually aluminum), it is preferable to use printed circuit boards with metal supports in order to achieve high thermal efficiency.

[0006] The battery charger must include large electrical winding components (with power in the order of kW) composed of components such as transformers, filters, and inductors.

[0007] According to known solutions, these large electrical winding components are grouped in special modules including special housing supports. These additional modules are usually necessary precisely because the winding components are large in size and difficult to directly fix to the printed circuit board.

[0008] Similar considerations also apply to components such as large capacitors.

[0009] In fact, specifically, referring to a printed circuit board with an epoxy glass support, the fixing method of directly winding components on the support will result in low mechanical strength, poor effect, and will basically affect the life of the battery charger.

[0010] In addition, regarding the problem of low mechanical strength, using a printed circuit board with an IMS-type metal support also increases the fact that the fixing method of winding components on the support will require drilling the support itself, thus bringing a high risk of electrical short circuit.

[0011] In fact, known IMS-type supports include a metal plate usually made of aluminum, which is covered with a thin dielectric material layer on which copper tracks are made.

[0012] Therefore, drilling holes in the support for fixing the winding component means creating a possible electrical connection between the winding component itself and the aluminum of the support, thus causing a short circuit to occur.

[0013] Therefore, in known types of battery chargers, the module with the electrical winding component is connected to the printed circuit board through a special cable, and both are fixed in a special container or different containers.

[0014] However, this known solution has several drawbacks.

[0015] In fact, it is necessary to connect each winding component present on the module at precise and different points on the circuit board, but it is difficult to take out the wires of each winding component to make the correct connection.

[0016] Therefore, the complexity of these connections makes the assembly more difficult, and at the same time increases the possibility of connection errors, or anyway, during the normal use of the battery charger, there may be "loose" connections over time. Summary of the Invention

[0017] The main object of the present invention is to design a battery charger for a vehicle and the related implementation process, which allows simplifying the assembly operation of the battery charger itself, especially for large electrical components such as winding components or capacitors.

[0018] Another object of the present invention is to design a battery charger for a vehicle and the related implementation process, which allows avoiding connection errors of the electrical winding components.

[0019] Another object of the present invention is to design a battery charger for a vehicle and the related implementation process, which allows overcoming the above-mentioned drawbacks of the prior art in a simple, reasonable, easy, effective usage manner and with a low-cost solution.

[0020] The above object can be achieved by the battery charger for a vehicle according to claim 1.

[0021] The above object can also be achieved by the implementation process of the present invention of the battery charger for a vehicle according to claim 13. Brief Description of the Drawings

[0022] Other features and advantages of the present invention will be more prominent from the description of the preferred but non-exclusive embodiments of the battery charger for a vehicle and the related implementation process, and are shown in the form of indicative but non-limiting examples in the drawings, where:

[0023] Figure 1 is an overall view of a possible embodiment of the battery charger according to the present invention;

[0024] Figure 2 Is Figure 1 Exploded view of the battery charger;

[0025] Figure 3 Shows two supports for an electronic board and electrical components for a battery charger according to the present invention;

[0026] Figure 4 Shows a possible support for the electrical components for a battery charger according to the present invention, which is particularly suitable for supporting large winding components;

[0027] Figure 5 Shows a possible support for the electrical components for a battery charger according to the present invention, which is particularly suitable for supporting large capacitors. Detailed description of the invention

[0028] Specifically referring to these views, reference numeral 1 generally represents a battery charger for a vehicle, particularly a battery charger that can be installed on an electric vehicle, a hybrid vehicle or a similar vehicle and is adapted to recharge the battery of the vehicle.

[0029] The battery charger 1 includes an outer container 2, which is adapted to accommodate and protect the entire electronics of the battery charger itself and is adapted to be installed and fixed inside the vehicle.

[0030] The battery charger 1 further includes at least one electronic board 3, 4 housed in the container 2, and the electronic board 3 and the electronic board 4 are operably connected to the battery of the vehicle and are configured for recharging the battery itself.

[0031] Referring to the specific but non-limiting embodiment shown in the figure, the battery charger 1 includes a first power electronics board 3 and a second IMS electronics board 4 that are suitably connected to each other.

[0032] However, different embodiments of the battery charger 1 cannot be excluded, that is, different types and different numbers of electronic boards are used therein.

[0033] The battery charger 1 further includes at least one electrical component 5, 6 connected to at least one electronic board 3, 4, and at least one support 7, 8 for housing such at least one electrical component 5, 6.

[0034] In particular, each support 7, 8 used in the battery charger 1 is adapted to allow the support of one or more electrical components 5, 6 while simplifying the correct positioning inside the container 2.

[0035] The electrical components supported by means of the supports 7, 8 can consist of large winding components (such as transformers, inductors or filters) or large capacitors.

[0036] However, the use of supports for different types of electronic components cannot be excluded.

[0037] Advantageously, the supports 7, 8 used in the battery charger 1 according to the invention include electrical connection means 9, 10, 11 for connecting at least one electrical component 5, 6 to the electronic board 4.

[0038] In particular, the presence of the electrical connection means 9, 10, 11 allows the electrical components 5, 6 to be connected to one or more electronic boards 3, 4 in a quick and easy manner.

[0039] By referring particularly but not exclusively to the embodiments shown in the figures, the battery charger 1 includes a first support 7 adapted to support a plurality of capacitors 5 and a second support 8 adapted to support a plurality of winding components 6. Both the first support 7 and the second support 8 are associated with the power electronics board 3 and the IMS electronics board 4.

[0040] However, the use of a different number of supports connected to different electronic boards cannot be excluded, nor can the support of a different number and different types of electronic components through the supports.

[0041] Advantageously, the electrical connection means 9, 10, 11 include at least one first electrical terminal 9, at least one second electrical terminal 10 and at least one connection element 11, wherein the at least one first electrical terminal 9 is connected to at least one electrical component 5, 6, the at least one second electrical terminal 10 is connected to at least one electronic board 3, 4, and the at least one connection element 11 electrically connects the first electrical terminal 9 to the second electrical terminal 10.

[0042] Each of the electronic boards 3, 4 is provided with at least one corresponding connection terminal 12 for connecting the second electrical terminal 10.

[0043] The first electrical terminal 9, the second electrical terminal 10 and the connection element 11 are all formed on the supports 7, 8 themselves.

[0044] Referring to the specific embodiments shown in the figures, both the first support 7 and the second support 8 include corresponding electrical connection means 9, 10, 11.

[0045] In particular, the first support 7 includes a plurality of first electrical terminals 9 for connecting the respective capacitors 5, a plurality of second electrical terminals 10 for connection to the corresponding connection terminals 12 of the power electronics board 3 and the IMS electronics board 4, and a plurality of connection elements 11 for electrically connecting each first electrical terminal 9 to at least one corresponding second electrical terminal 10.

[0046] Similarly, the second support 8 includes a plurality of first electrical terminals 9 for connecting the respective winding components 6, a plurality of second electrical terminals 10 for connecting to the corresponding connection terminals 12 of the power electronics board 3 and the IMS electronics board 4, and a plurality of connection elements 11 for connecting each first electrical terminal 9 to at least one corresponding second electrical terminal 10.

[0047] Advantageously, each support 7, 8 includes at least one fixing frame 13 for fixing the electrical components 5, 6, which fixing frame 13 is provided with electrical connection means 9, 10, 11 and is suitably shaped to allow each electrical component 5, 6 to be correctly connected to precise and different points of the electronics boards 3, 4.

[0048] In particular, the fixing frame 13 includes at least one receiving seat for receiving the corresponding electrical components 5, 6.

[0049] Usefully, the first electrical terminals 9 are made on such receiving seats of the fixing frame 13.

[0050] Referring to the specific embodiment shown in the figures, each first electrical terminal 9 includes a connection pad for connecting the terminals of the corresponding electrical components 5, 6.

[0051] Advantageously, according to a preferred embodiment, the second electrical terminals 10 include a first electrical connector connected to a second electrical attachment connector 12 corresponding to the electronics board.

[0052] Preferably, the second electrical terminals 10 and the electrical attachment connectors 12 are made of Faston connectors to simplify and accelerate the assembly and connection operations to the electronics boards 3, 4.

[0053] Advantageously, according to a preferred embodiment, the connection elements 11 are composed of conductive tracks or specially wired conductive elements and are made directly on the fixing frame 13.

[0054] Advantageously, the fixing frame 13 is designed to accommodate a plurality of electrical components 5, 6 and includes electrical connection means 9, 10, 11 between each electrical component 5, 6 and each electronics board 3, 4.

[0055] In particular, each fixing frame 13 includes a plurality of receiving seats for a plurality of electrical components 5, 6.

[0056] Thus, in this way, each support 7, 8 can fix a plurality of corresponding electrical components 5, 6 and allows the electrical components themselves to be quickly and easily connected to each electronics board 3, 4.

[0057] Furthermore, the presence of the second electrical terminals 10 arranged on opposite sides of the fixing frame 13 allows the electronic components 5, 6 to be connected to the power electronics board 3 and the IMS electronics board.

[0058] Advantageously, according to a possible embodiment, the fixing frame 13 includes at least one interconnecting element 14 adapted to interconnect at least one contact 15 present on the first electronic board 3 to at least one corresponding contact present on the second electronic board 4.

[0059] Preferably, the interconnecting element 14 consists of an element that is substantially tubular and is adapted to receive the contacts of the first electronic board 4.

[0060] The implementation process of a battery charger for a vehicle includes at least the following steps:

[0061] - Fabricating at least one electronic board 3, 4 connectable to the vehicle's battery and configured to recharge the battery itself;

[0062] - Connecting at least one electrical component 5, 6 to the electronic boards 3, 4.

[0063] Advantageously, the connection of at least one electrical component 5, 6 to the electronic boards 3, 4 is carried out according to the following steps:

[0064] - Fabricating at least one support 7, 8 for receiving at least one electrical component 5, 6, wherein electrical connection means 9, 10, 11 are provided between the at least one electrical component 5, 6 and the electronic boards 3, 4.

[0065] - Associating at least one electrical component 5, 6 with the support 7, 8 and making an electrical connection between the electrical component 5, 6 and the electrical connection means 9, 10, 11;

[0066] - Associating the support 7, 8 with the electronic boards 3, 4 and making an electrical connection between the electrical connection means 9, 10, 11 and the electronic boards 3, 4.

[0067] Furthermore, the implementation process according to the present invention includes the following steps:

[0068] - Fabricating an external container 2;

[0069] - Accommodating and fixing the at least one electronic board 3, 4 and the at least one support 7, 8 provided with the electronic components 5, 6 within the container 2.

[0070] It cannot be excluded that the above-described supports used in the reference battery charger 1 are used in different applications to support, for example, the same or different types of electronic components.

[0071] In this example, the support includes electrical connection means similar to the above-described electrical connection means 9, 10, 11 and at least one fixing frame similar to the above-described fixing frame 13.

[0072] The described invention has actually been determined to be able to achieve the intended purpose.

[0073] It is particularly emphasized that the battery charger and implementation process according to the present invention can simplify the assembly operation, especially for assembling large electronic components, such as electric winding components or capacitors.

[0074] In addition, the battery charger and implementation process according to the present invention allow avoiding connection errors of electric winding components.

Claims

1. A battery charger (1) for a vehicle, comprising at least one outer container (2); at least one electronic board (3, 4) housed within said outer container (2), said electronic board (3, 4) being operatively connected to the vehicle's battery and configured for recharging said battery; at least one electrical component (5, 6) connected to said electronic board (3, 4); and at least one support (7, 8) for housing said at least one electrical component (5, 6); Among them, Said support (7, 8) includes electrical connection means (9, 10, 11) between said at least one electrical component (5, 6) and said electronic board (3, 4), characterized in that, Said electrical connection means (9, 10, 11) includes at least one first electrical terminal (9) connected to said at least one electrical component (5, 6), at least one second electrical terminal (10) connected to said electronic board (3, 4), and at least one connection element (11) connecting said first electrical terminal (9) and said second electrical terminal (10), said first electrical terminal (9), said second electrical terminal (10) and said connection element (11) being formed on said support (7, 8), wherein said support (7, 8) includes at least one fixing frame (13) for fixing said at least one electrical component (5, 6), said fixing frame (13) including at least one receiving seat for housing said at least one electrical component (5, 6), said first electrical terminal (9) being formed on said receiving seat, said second electrical terminal (10) at least includes a first electrical connector connected to a second electrical connector (12) corresponding to said electronic board (3, 4), and said connection element (11) includes at least one conductive element formed on said fixing frame (13).

2. The battery charger (1) according to claim 1, characterized in that, Said first electrical terminal (9) includes at least one pad for connecting the terminal of said at least one electrical component (5, 6).

3. The battery charger (1) according to claim 1, characterized in that, Said fixing frame (13) includes a plurality of receiving seats for housing a plurality of electrical components (5, 6).

4. The battery charger (1) according to claim 1, characterized in that, Said electrical component (5, 6) is a wound component (6).

5. The battery charger (1) according to claim 4, characterized in that, Said wound component (6) is constituted by one of a transformer, an inductor or a filter.

6. The battery charger (1) according to claim 1, characterized in that, Said electrical component (5, 6) is a capacitor (5).

7. A process for implementing a battery charger (1) for a vehicle according to any one of the preceding claims 1 - 6, comprising at least the following steps: - fabricating said electronic board (3, 4); - connecting at least one electrical component (5, 6) to said electronic board (3, 4); It is characterized in that Said connecting step at least includes the following steps: - fabricating said support (7, 8) for housing said at least one electrical component (5, 6); - associating said at least one electrical component (5, 6) with said support (7, 8) and making an electrical connection between said electrical component (5, 6) and said electrical connection means (9, 10, 11); - Associate the support members (7, 8) with the electronic boards (3, 4) and make electrical connections between the electrical connection means (9, 10, 11) and the electronic boards (3, 4).

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