Battery charger for vehicle

Abstract

A battery charger (1) for a vehicle, comprising an outer container (2); an electronic device (3) contained in the container (2), which is operably connected to a battery of the vehicle and is configured for recharging the battery; and at least one cooling circuit (4) for the electronic device (3), wherein the electronic device (3) comprises at least one electronic board (5), which is provided with an insulating metal substrate (5a) associated with the cooling circuit (4), an electrically insulating material layer (5b) is formed on at least a portion of the insulating metal substrate (5a), and at least one electronic circuit (5c) is formed on the electrically insulating material layer (5b), wherein the electronic board (5) comprises at least one conductive metal strip (7) for transmitting and distributing electric current, the conductive metal strip (7) being electrically connected to the electronic circuit (5c) and having a portion in direct contact with a surface portion of the electronic board (5) for cooling the conductive metal strip (7) via the cooling circuit (4).

Description

Technical Field

[0001] The present invention relates to a battery charger for a vehicle. Background Art

[0002] In particular, referring to the field of electric or hybrid vehicles, in order to convert input voltage / current into a suitable output voltage / current, power electronics installed on the vehicle must be used, such as an OBC (On-Board Charger) battery charger or a DC-DC converter.

[0003] Battery chargers of known type for vehicles typically include one or more power supply or control boards consisting 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 noted in particular that in the field of realizing battery chargers for vehicles, it is preferred to use printed circuit boards with metal supports due to the heat dissipation properties of metal (usually aluminum), thereby achieving high thermal efficiency.

[0006] It is also known to use so-called "busbars" on electronic boards of known types of battery chargers, these busbars consisting of special metal strips which can be connected to different points of the electronic board and are of suitable dimensions allowing the transport and distribution of high currents.

[0007] However, the known solutions still have some disadvantages.

[0008] Indeed, the busbars mounted on battery chargers of known type must be able to transmit high currents between different points of the electronic board and therefore they need to be of relatively large dimensions compared to the other electronic components mounted on the electronic board.

[0009] As a result, this involves the problem that the busbars used take up a non-negligible amount of space, which, considering the growing demand for small battery chargers, also creates several complexities in the design and arrangement of the internal electronics of the battery charger. Summary of the invention

[0010] The main object of the invention is to devise a battery charger for a vehicle which is small in size and which at the same time can be assembled simply and quickly.

[0011] Another object of the present invention is to design a battery charger for a vehicle that can be effectively maintained at an ideal operating temperature.

[0012] Another object of the present invention is to devise a battery charger for vehicles that allows overcoming the above-mentioned drawbacks of the prior art with a simple, rational, easy, effective way of use and low-cost solution.

[0013] The above objects are achieved by a battery charger for a vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Other features and advantages of the invention will emerge more clearly from the description of a preferred but not exclusive embodiment of a battery charger for a vehicle, illustrated by way of indicative but non-limiting example in the accompanying drawings, in which:

[0015] Figure 1 is an overall view of a possible battery charger according to the present invention;

[0016] Figure 2 yes Figure 1 Exploded view of the battery charger;

[0017] Figure 3 is a view of an IMS (Insulated Metal Substrate) electronic board of a battery charger according to the present invention;

[0018] Figure 4 Shows Figure 3 Detail of the IMS electronics board. DETAILED DESCRIPTION

[0019] With particular reference to these views, reference numeral 1 generally indicates a battery charger for a vehicle, and 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.

[0020] The battery charger 1 comprises an external container 2 suitable for housing and protecting the entire electronics of the battery charger itself and suitable for being mounted and fixed inside a vehicle.

[0021] The battery charger 1 comprises an electronic device, indicated in the figures by reference numeral 3 , housed in a container 2 , operatively connected to the battery of the vehicle and configured for recharging the battery itself.

[0022] The battery charger further comprises a cooling circuit 4 to limit the temperature of the electronic device 3 during use of the battery charger 1 .

[0023] For example, the cooling circuit 4 may consist of a conventional liquid cooling circuit.

[0024] According to a particular but not exclusive embodiment shown in the figures, the cooling circuit 4 is made directly on the bottom of the container 2 .

[0025] The electronic device 3 comprises at least one electronic board 5 provided with an insulated metal substrate (IMS) 5 a associated with a cooling circuit 4 .

[0026] The electronic board 5 further includes an electrically insulating material layer 5b formed on at least a portion of the insulating metal substrate 5a, and at least one electronic circuit 5c made on the electrically insulating material layer 5b.

[0027] The electronic device 3 may comprise several electronic boards.

[0028] For example, with reference to the particular but non-limiting embodiment shown in the figures, the electronic device 3 comprises two electronic boards 5 and 6 , wherein, in particular, the electronic board 5 is an IMS type electronic board.

[0029] The electronic board 5 comprises at least one conductive metal strip 7 for transmitting and distributing electric current, which conductive metal strip 7 is electrically connected to the electronic circuit 5c.

[0030] This conductive metal strip 7 is the so-called "busbar" and is used to allow the transmission and distribution of high currents to several different points of the electronic board.

[0031] Advantageously, the conductive metal strip 7 is provided with at least one portion arranged in direct contact with at least one surface portion of the electronic board 5 .

[0032] In this way, the conductive metal strips 7 can be cooled during use of the battery charger 1 and thus kept at a lower operating temperature. In practice, the cooling circuit 4 allows cooling of the insulating metal substrate 5a of the electronic board 5 and cooling of the conductive metal strips 7 by thermal conduction.

[0033] The fact that the conductive metal strip 7 is positioned directly on the electronic board 5 and is cooled by heat conduction through the cooling circuit 4, the insulating metal substrate 5a of the electronic board itself, allows the use of conductive metal strips 7 of reduced dimensions compared to known types of strips.

[0034] In particular, the conductive metal strip 7 is provided with a lower surface arranged in direct contact with at least one surface portion of the electronic board 5 .

[0035] Preferably, the conductive metal strip 7 is substantially plate-shaped and comprises an upper surface opposite a lower surface associated with the electronic board 5 .

[0036] Furthermore, the conductive metal strip 7 preferably has a substantially elongated shape.

[0037] However, it cannot be excluded that the conductive metal strip 7 has a different shape.

[0038] With reference to the particular embodiment shown in the figures, the electronic board 5 comprises a plurality of conductive metal strips 7 arranged at different parts of the electronic board itself and suitable for connecting different points.

[0039] Each conductive metal strip 7 extends over at least a portion of the electronic board 5 , over the layer 5 b of electrically insulating material.

[0040] Advantageously, each conductive metal strip 7 comprises electrical coupling connection means 8 connecting at least one electrical connection element. The electrical connection element, not shown in the figures, may comprise, for example, a special cable suitable for carrying a predetermined current on the conductive metal strip 7.

[0041] The electrical coupling connection device 8 is constituted by, for example, an electrical terminal made at at least a portion of the conductive metal strip 7 .

[0042] As shown, the terminal extends from the upper surface of the conductive metal strip 7 .

[0043] The electronic board 5 described above is used in a battery charger 1 for an electric vehicle.

[0044] However, the use of an electronic board similar to the electronic board 5 described above, which is provided with at least one conductive metal strip 7 , cannot be excluded in different applications.

[0045] The described invention has in fact been determined to achieve the intended purposes.

[0046] Particular emphasis is placed on the small dimensions of the battery charger according to the invention, combined with a simple and quick assembly.

[0047] In fact, the fact that the conductive metal strip 7 is positioned directly on the electronic board 5 and is cooled by thermal conduction through the cooling circuit 4, the insulating metal substrate 5a of the electronic board itself, allows the use of conductive metal strips 7 of reduced dimensions compared to known types of strips.

[0048] Furthermore, the very cooling of the electrically conductive metal strips used allows the ideal operating temperature to be maintained in an efficient manner.

Claims

1. A battery charger (1) for a vehicle, comprising at least one external container (2); at least one electronic device (3) contained in the container (2), the electronic device (3) being operably connected to a battery of the vehicle and configured for recharging the battery; and at least one cooling circuit (4) for the electronic device (3), wherein the electronic device (3) comprises at least one electronic board (5), the electronic board (5) being provided with an insulating metal substrate (5a) associated with the cooling circuit (4), an electrically insulating material layer (5b) being formed on at least a portion of the insulating metal substrate (5a), and at least one electronic circuit (5c) being formed on the electrically insulating material layer (5b), characterized in that The electronic board (5) comprises at least one conductive metal strip (7) for transmitting and distributing electric current, the conductive metal strip (7) being electrically connected to the electronic circuit (5c) and having a lower surface in direct contact with at least one surface portion of the electronic board (5), and the conductive metal strip (7) extending over at least a portion of the electronic board (5) and over the layer of electrically insulating material (5b) for cooling the conductive metal strip (7) by means of the cooling circuit (4).

2. The battery charger (1) according to claim 1, characterized in that The conductive metal strip (7) is substantially in the shape of a plate.

3. The battery charger (1) according to claim 1, characterized in that The conductive metal strip (7) comprises an upper surface opposite the lower surface associated with the electronic board (5).

4. The battery charger (1) according to claim 1, characterized in that The conductive metal strip (7) has a substantially elongated shape.

5. The battery charger (1) according to claim 3, characterized in that The conductive metal strip (7) comprises an electrical coupling connection device (8) for connecting at least one electrical connection element.

6. The battery charger (1) according to claim 5, characterized in that The electrical coupling connection device (8) comprises at least one electrical terminal made at at least a portion of the conductive metal strip (7).

7. The battery charger (1) according to claim 6, characterized in that The at least one electrical terminal extends from the upper surface of the conductive metal strip (7).

8. An electronic board (5), comprising an insulating metal substrate (5a) associated with a cooling circuit (4), a layer of electrically insulating material (5b) formed on at least a portion of the insulating metal substrate (5a), and at least one electronic circuit (5c) manufactured on the layer of electrically insulating material (5b), characterized in that It comprises at least one conductive metal strip (7) for transmitting and distributing electric current, the conductive metal strip (7) being electrically connected to the electronic circuit (5c) and having a lower surface in direct contact with at least one surface portion of the electronic board (5), and the conductive metal strip (7) extending over at least a portion of the electronic board (5) and over the electrically insulating material layer (5b) for cooling the conductive metal strip (7) by means of the cooling circuit (4).

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