Three-dimensional power supply device with circuit layer and construction technology thereof

Abstract

The invention relates to a three-dimensional power supply device with a circuit layer and a construction process thereof, the three-dimensional power supply device comprises a flexible metal-based copper-clad plate, a mounting hole, a fireproof silica gel coating and an electronic part, the flexible metal-based copper-clad plate is provided with the mounting hole, the electronic part is welded in a cavity of the flexible metal-based copper-clad plate, and the fireproof silica gel coating is arranged in the cavity of the flexible metal-based copper-clad plate. A fireproof silica gel coating is sprayed on the electronic part, a fixing structural member is arranged on the flexible metal-based copper-clad plate, a wire is inserted into the mounting hole, and a hexagon nut is in threaded connection with the flexible metal-based copper-clad plate. According to the invention, the electronic parts are directly attached to the surface of the flexible metal-based copper-clad plate, and heat generated during working can directly penetrate through the flexible metal-based copper-clad plate to be quickly dissipated, so that the heat conduction capability of the internal electronic parts is greatly improved, and the working efficiency of the whole power supply circuit is remarkably improved; and the driving working power can be improved under the same area, so that the energy-saving effect is realized.

Description

Technical Field

[0001] The present invention relates to the technical field of power supply devices, and specifically to a three-dimensional power supply device with a circuit layer and its construction technology. Background Art

[0002] Currently, the common structure of traditional power supply devices is to weld electronic components on a PCB substrate, and then add a metal shell or a plastic shell to achieve insulation protection and connect other fixing devices. However, this design has many drawbacks. If a plastic shell is used, the heat generated by the working of electronic components is difficult to dissipate due to the heat insulation characteristics of the plastic, resulting in poor heat dissipation effect, which affects the performance and stability of the power supply. If a metal shell is used, in order to avoid short circuits, an insulating layer needs to be added between the PCB board and the metal shell, and the electronic components need to reserve a large space or be wrapped with insulating sheets before assembly. This not only increases the assembly difficulty and cost, but also makes the heat unable to be effectively conducted out through the metal shell, also causing the problem of poor heat dissipation. At the same time, existing power supply devices must rely on an additional shell to achieve insulation protection, which further increases the complexity and cost of the device.

[0003] In the aspect of optoelectronic modules, existing linear optoelectronic modules and optical modules usually attach electronic components and LEDs to an aluminum substrate, and then use a transparent plastic shell for insulation protection. However, the material characteristics of the aluminum substrate limit its bending ability, and it can only be installed and fixed flatly. And when installed, the electronic components are exposed on the surface of the aluminum substrate and cannot be hidden inside the aluminum substrate, which to a certain extent limits the application scenarios and design flexibility of the optoelectronic module and cannot meet the diverse market demands. Therefore, a three-dimensional power supply device with a circuit layer and its construction technology are proposed to solve the above problems. Summary of the Invention

[0004] Aiming at the deficiencies of the prior art, the present invention provides a three-dimensional power supply device with a circuit layer and its construction technology, which has the advantages of improving the performance of the power supply device, simplifying the assembly process, enhancing the protection ability and expanding the application range, etc., and solves the problems of difficult heat dissipation, complex assembly structure, single insulation protection method and limited installation of optoelectronic modules in existing power supply devices.

[0005] To achieve the above object, the present invention provides the following technical solution: A three-dimensional power supply device with a circuit layer, including a flexible metal base copper clad laminate, mounting holes, a fireproof silicone coating and electronic components. Mounting holes are provided on the flexible metal base copper clad laminate. Electronic components are welded in the cavity of the flexible metal base copper clad laminate. A fireproof silicone coating is sprayed on the electronic components. Fixing structural members are provided on the flexible metal base copper clad laminate. An electronic component patch area is provided in the inner cavity of the flexible metal base copper clad laminate.

[0006] Further, the substrate of the flexible metal-based copper clad laminate is one or more of copper, iron, and aluminum. The flexible metal-based copper clad laminate undergoes stamping, spinning, and hemming machining operations to form a three-dimensional shell, and the electronic components are enclosed in the internal cavity.

[0007] Further, the material of the fireproof silicone coating is one or more of acrylic resin, polyurethane resin, silicone resin, epoxy resin, and parylene.

[0008] Further, the electronic components include isolation circuits, non-isolation circuits, linear drive circuits, and other control circuits. The flexible metal-based copper clad laminate is trimmed according to the designed dimensions using a cutting device.

[0009] Further, the mounting holes are divided into fixing holes and wire outlet holes. The hexagon nuts threadedly mount the flexible metal-based copper clad laminate on the fixed structural members through the fixing holes, and connect wires through the wire outlet holes for assembly with other electrical systems.

[0010] The construction process of a three-dimensional power supply device with a circuit layer, including the construction process of the three-dimensional power supply device with a circuit layer, is as follows:

[0011] Step 1: Select a flexible metal-based copper clad laminate

[0012] According to specific heat dissipation requirements, reasonably select the substrate of the flexible metal-based copper clad laminate. The commonly used substrate is aluminum. In scenarios with high heat dissipation requirements, give priority to using aluminum or copper-based copper clad laminates with excellent thermal conductivity; when there are special requirements for conductivity and strength, select copper-based or iron-based copper clad laminates.

[0013] Step 2: Fabricate the circuit

[0014] Adopt PCB manufacturing technology to form a circuit on the flexible metal-based copper clad laminate.

[0015] Step 3: Edge trimming

[0016] Use a professional cutting device to accurately trim the flexible metal-based copper clad laminate according to the designed dimensions to ensure that its edges are neat and the dimensions meet the requirements of subsequent processing.

[0017] Step 4: Solder the electronic components

[0018] Adopt the soldering process of reflow soldering or wave soldering to accurately solder the pre-prepared electronic components on the surface of the flexible metal-based copper clad laminate.

[0019] Step 5: Apply the fireproof silicone coating

[0020] Evenly apply the fireproof silicone coating on the electronic components in the cavity of the flexible metal-based copper clad laminate.

[0021] Step 6: Machining and assembly

[0022] The flexible metal-based copper-clad laminate is processed into a three-dimensional shape by using mechanical processing methods such as stamping, spinning and folding;

[0023] Step 7: Processing mounting holes and connections

[0024] Through drilling, punching and other mechanical processing methods, mounting holes or wire outlet holes are formed on the flexible metal-based copper-clad laminate, and the power supply device is firmly connected to other fixed structural parts through the mounting holes using connectors such as screws, hexagonal nuts or rivets; or wires are connected through the wire outlet holes and assembled with other electrical systems.

[0025] Furthermore, in the step of welding the electronic parts, the welding temperature and time are strictly controlled during the welding process to ensure the welding quality and avoid problems such as cold welding and short circuit.

[0026] Furthermore, during the machining process in the mechanical machining assembly step, attention is paid to controlling the machining parameters to ensure the structural strength and dimensional accuracy of the flexible metal-based copper-clad laminate. After the machining is completed, the electronic parts are wrapped in the internal cavity and assembled and fixed to form a shell.

[0027] Furthermore, in the step of applying the fireproof silicone coating, the coating is constructed by means of glue injection and potting to ensure that the coating covers the entire surface and has a uniform thickness, so as to achieve good insulation, fireproofing, waterproofing and corrosion resistance effects.

[0028] Compared with the prior art, the technical solution of this application has the following beneficial effects:

[0029] 1. The present invention directly attaches the electronic parts to the surface of the flexible metal-based copper-clad laminate. The heat generated during operation can be directly dissipated through the flexible metal-based copper-clad laminate, which greatly improves the heat conduction capacity of the internal electronic parts. This significantly improves the working efficiency of the entire power supply circuit, and can increase the driving working power under the same area, thereby achieving energy saving.

[0030] 2. The assembly structure of the present invention is simple, which reduces the number of material parts used and simplifies the assembly process, which not only reduces the production cost but also reduces the size of the power supply device, meeting the requirements of environmental protection and compact design.

[0031] 3. According to the design requirements, the present invention can weld different types of electronic devices, such as isolated circuits, non-isolated circuits and linear drive circuits, on the surface of a flexible metal-based copper-clad laminate. Moreover, the wiring on the flexible metal-based copper-clad laminate can be distributed in multiple directions after mechanical processing, which helps to further reduce the size of the electronic device, improve space utilization, and meet the usage requirements of different scenarios.

[0032] 4. The present invention has good fire prevention, waterproof, corrosion prevention and insulation protection performance. It is a power drive or electronic control device with protection, corrosion resistance and fluid resistance, and can operate stably in a variety of complex environments.

[0033] 5. The present invention has strong application flexibility. If a power cord is added, it can be used as an independent mobile power device. If an electronic wire is added and color painting is carried out on the outside of the base material, it can also be used as a power device for decorative hardware that shields the junction box, expanding its application fields. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 It is a process flow chart of the construction technology of a three-dimensional power device with a circuit layer according to the present invention;

[0035] Figure 2 It is a schematic structural diagram of a three-dimensional power device with a circuit layer according to the present invention;

[0036] Figure 3 It is a schematic structural diagram of the electronic component patch area of a three-dimensional power device with a circuit layer according to the present invention;

[0037] Figure 4 It is a schematic diagram of the second embodiment of a three-dimensional power device with a circuit layer according to the present invention;

[0038] Figure 5 It is a schematic diagram of the third embodiment of a three-dimensional power device with a circuit layer according to the present invention.

[0039] In the figure: 1. Flexible metal base copper clad laminate; 2. Mounting hole; 3. Fireproof silicone coating; 4. Electronic component; 5. Fixed structural member; 6. Conducting wire; 7. Hexagonal nut; 8. Electronic component patch area. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0040] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative work shall fall within the protection scope of the present invention.

[0041] Embodiment 1

[0042] Please refer to Figures 1-3, A three-dimensional power supply device with a circuit layer in this embodiment includes a flexible metal-clad laminate 1, mounting holes 2, a fireproof silicone coating 3, and electronic components 4. Mounting holes 2 are provided on the flexible metal-clad laminate 1. Electronic components 4 are welded inside the cavity of the flexible metal-clad laminate 1. A fireproof silicone coating 3 is potted on the electronic components 4. A fixing structure 5 is provided on the flexible metal-clad laminate 1. A wire 6 is inserted into the interior of the mounting hole 2. A hexagonal nut 7 is threadedly connected to the flexible metal-clad laminate 1. An electronic component patch area 8 is provided inside the cavity of the flexible metal-clad laminate 1.

[0043] In this embodiment, the base material of the flexible metal-clad laminate 1 is aluminum. The flexible metal-clad laminate 1 is subjected to stamping, spinning, and hemming machining operations to form a three-dimensional shell shape with a cavity inside, and the electronic components 4 are installed inside the cavity.

[0044] In this embodiment, the material of the fireproof silicone coating 3 is an acrylic resin raw material. The electronic components 4 include an isolation circuit, a non-isolation circuit, a linear drive circuit, and other control circuits. The flexible metal-clad laminate 1 is trimmed according to the designed size by a cutting device.

[0045] In this embodiment, the mounting holes 2 are divided into fixing holes and wire outlet holes. The hexagonal nut 7 threadedly mounts the flexible metal-clad laminate 1 on the fixing structure 5 through the fixing holes, and connects the wire 6 through the wire outlet holes for assembly with other electrical systems.

[0046] In this embodiment, the processing technology of the three-dimensional power supply device with a circuit layer is as follows:

[0047] 1) Adopt PCB manufacturing technology to form a circuit on the flexible metal-clad laminate 1;

[0048] 2) Perform trimming processing on the flexible metal-clad laminate 1;

[0049] 3) Weld the electronic components 4 on the surface of the flexible metal-clad laminate 1;

[0050] 4) Perform mechanical processing operations such as stamping, spinning, and hemming on the flexible metal-clad laminate 1, assemble and fix to form a shell and enclose the electronic components 4 inside the cavity;

[0051] 5) Apply a fireproof silicone coating 3 to the electronic components 4 inside the cavity of the flexible metal-clad laminate 1;

[0052] 6) Mechanically process the flexible metal-clad laminate 1 to form mounting holes 2 or wire outlet holes for assembly with other electrical systems or connection with other fixing parts.

[0053] The construction technology of a three-dimensional power supply device with a circuit layer includes the construction technology of the three-dimensional power supply device with a circuit layer, and the construction technology is specifically as follows:

[0054] Step 1: Select the flexible metal-based copper clad laminate 1

[0055] According to specific heat dissipation requirements, reasonably select the base material of the flexible metal-based copper clad laminate 1. Commonly used substrates are aluminum materials. In scenarios with high heat dissipation requirements, copper or aluminum-based copper clad laminates with excellent thermal conductivity are preferably selected; when there are special requirements for conductivity and strength, copper-based or iron-based copper clad laminates are selected;

[0056] Step 2: Fabricate the circuit

[0057] Adopt the PCB manufacturing process to form a circuit on the flexible metal-based copper clad laminate 1;

[0058] Step 3: Trim the edges

[0059] Use professional cutting equipment to accurately trim the flexible metal-based copper clad laminate 1 according to the designed dimensions to ensure that its edges are neat and the dimensions meet the requirements of subsequent processing;

[0060] Step 4: Solder electronic components

[0061] Adopt the soldering process of reflow soldering or wave soldering to accurately solder the pre-prepared electronic components 4 on the surface of the flexible metal-based copper clad laminate 1;

[0062] Step 5: Apply a fireproof silicone coating

[0063] Uniformly apply a fireproof silicone coating 3 on the electronic components 4 in the cavity of the flexible metal-based copper clad laminate 1;

[0064] Step 6: Machining and assembly

[0065] Use mechanical processing means such as stamping, spinning, and flanging to process the flexible metal-based copper clad laminate 1 into a three-dimensional shape;

[0066] Step 7: Process installation holes and connections

[0067] Through mechanical processing methods such as drilling and punching, form installation holes 2 or wire outlet holes on the flexible metal-based copper clad laminate 1. Use connectors such as screws, hex nuts 7 or rivets to firmly connect the power supply device to other fixed structural parts 5 through the installation holes 2; or connect wires through the wire outlet holes 6 and assemble with other electrical systems.

[0068] Example 2

[0069] Please refer to Figure 4, in this embodiment, a three-dimensional power supply device with a circuit layer in Embodiment 1 is installed at the lower part of mounting box C. The three-dimensional power supply device with a circuit layer is fixed to the lower part of mounting box C by hexagon nuts 7. The wire 6 passes through the box cover J. A nut K is provided on the box cover J. The inner thread of the nut K is connected to the first lifting ring H. A lifting chain L is installed on the lifting ring H. A second lifting ring M is installed on the lifting chain L. An electrical component is installed on the second lifting ring M.

[0070] In this embodiment, the construction process of the three-dimensional power supply device with a circuit layer is the same as that in Embodiment 1.

[0071] Embodiment 3

[0072] Please refer to Figure 5 , in this embodiment, a three-dimensional power supply device with a circuit layer in Embodiment 1 is installed on the cross-shaped fixing frame A. The hexagon nuts 7 fix the three-dimensional power supply device with a circuit layer and the cross-shaped fixing frame A. The wire 6 passes through the mounting box C. The cross-shaped fixing frame A is fixedly installed outside the mounting box C. A grounding wire is installed on the cross-shaped fixing frame A through screws. The wire 6 is connected to the electrical component.

[0073] In this embodiment, the construction process of the three-dimensional power supply device with a circuit layer is the same as that in Embodiment 1.

[0074] In summary, for the three-dimensional power supply device with a circuit layer and its construction process, the electronic component 4 can directly conduct heat through the flexible metal base copper clad laminate 1, improving the heat dissipation. The ability of the internal electronic component 4 to conduct heat externally can be enhanced, enabling the entire power supply circuit to operate more efficiently, relatively increasing the driving power per unit area, and thus achieving the effect of energy conservation. The assembly structure is simple, reducing the number of material parts and assembly processes, thereby reducing the size of the power supply, and further achieving the effect of environmental protection. The electronic devices can be designed according to the design requirements, and can be surface-mounted on the flexible metal base copper clad laminate 1, such as isolated circuits, non-isolated circuits, and linear drive circuits. The wiring on the flexible metal base copper clad laminate 1 can be machined mechanically, and the electronic components 4 are distributed in a multi-faceted manner to reduce the size of the electronic device, further achieving the effect of environmental protection, and meeting the requirements of fire prevention, waterproofing, corrosion prevention, and insulation protection. It is a protective, corrosion-resistant, and fluid-resistant power supply drive or electronic control device. Utilizing the machinable characteristics of the flexible metal base copper clad laminate 1, it is processed into a three-dimensional shape, and the electronic components 4 are distributed in a multi-faceted manner on the flexible metal base copper clad laminate 1, and connections with other fixing parts are formed. If a power cord is added, it is an independent mobile power supply device; if an electronic wire is added and color paint processing can be applied to the outside of the base material, it can be used as a power supply device for decorating the concealed junction box.

[0075] It should be noted that, in this document, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprising", "including" or any other variant thereof are intended to cover non-exclusive inclusion, such that a process, method, article or device comprising a series of elements not only includes those elements but also includes other elements not expressly listed, or elements inherent to such process, method, article or device. Without further limitation, an element defined by the statement "comprising an..." does not exclude the presence of additional identical elements in the process, method, article or device comprising said element.

[0076] Although the embodiments of the present invention have been shown and described, it will be understood by those of ordinary skill in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A three-dimensional power supply device with a circuit layer, comprising a flexible metal-based copper-clad laminate (1), a mounting hole (2), a fireproof silicone coating (3) and electronic parts (4), characterized in that: The flexible metal-based copper-clad laminate (1) is provided with a mounting hole (2), an electronic component (4) is welded in the cavity of the flexible metal-based copper-clad laminate (1), a fireproof silicone coating (3) is sprayed on the electronic component (4), a fixed structural component (5) is provided on the flexible metal-based copper-clad laminate (1), a conductor (6) connected to a load is inserted into the interior of the mounting hole (2), the conductor (6) is connected to a three-dimensional power supply device, a hexagonal nut (7) is threadedly connected to the flexible metal-based copper-clad laminate (1), the hexagonal nut (7) is externally connected to a tooth rod, and the tooth rod is externally connected to other mechanical parts, and an electronic component patch area (8) is provided in the inner cavity of the flexible metal-based copper-clad laminate (1).

2. A three-dimensional power supply device with a circuit layer according to claim 1, characterized in that: The substrate of the flexible metal-based copper-clad laminate (1) is one or more of copper, iron, and aluminum. The flexible metal-based copper-clad laminate (1) is subjected to stamping, spinning, and folding mechanical processing operations to form a three-dimensional shell, and the electronic parts (4) are coated in the internal cavity.

3. The three-dimensional power supply device with a circuit layer according to claim 1, characterized in that: The material of the fireproof silicone coating (3) is one or more of acrylic resin, polyurethane resin, silicone resin, epoxy resin, and polyparaxylene.

4. The three-dimensional power supply device with a circuit layer according to claim 1, characterized in that: The electronic component (4) comprises an isolation circuit, a non-isolation circuit, a linear drive circuit and other control circuits, and the flexible metal-based copper-clad laminate (1) is trimmed according to the designed size using a cutting device.

5. The three-dimensional power supply device with a circuit layer according to claim 1, characterized in that: The mounting hole (2) is divided into a fixing hole and a wire outlet hole. The hexagonal nut (7) is threadedly mounted on the fixed structure (5) through the fixing hole, and the wire (6) is connected through the wire outlet hole to be assembled with other electrical systems.

6. A construction process of a three-dimensional power supply device with a circuit layer, comprising the construction process of a three-dimensional power supply device with a circuit layer according to any one of claims 1 to 5, characterized in that: The construction process is as follows: Step 1: Select Flexible Metal-Based Copper Clad Laminate (1) According to the specific heat dissipation requirements, the base material of the flexible metal-based copper-clad laminate (1) is reasonably selected. Aluminum is commonly used as the base material. In scenarios with high heat dissipation requirements, aluminum or copper-based copper-clad laminates with excellent thermal conductivity are preferably selected; when there are special requirements for electrical conductivity and strength, copper or iron-based copper-clad laminates are selected; Step 2: Make the circuit A circuit is formed on a flexible metal-based copper-clad board (1) using a PCB manufacturing process; Step 3: Edge trimming Use professional cutting equipment to accurately cut the edges of the flexible metal-based copper-clad laminate (1) according to the designed dimensions to ensure that its edges are neat and its dimensions meet the requirements of subsequent processing; Step 4: Soldering electronic parts Using a reflow soldering or wave soldering process, the pre-prepared electronic components (4) are accurately soldered onto the surface of the flexible metal-based copper-clad laminate (1); Step 5: Apply fire-resistant silicone coating Uniformly applying a fireproof silicone coating (3) on an electronic component (4) in a cavity of a flexible metal-based copper-clad laminate (1); Step 6: Machining and assembly The flexible metal-based copper-clad laminate (1) is processed into a three-dimensional shape by using mechanical processing means such as stamping, spinning and folding; Step 7: Processing mounting holes and connections A mounting hole (2) or a wire outlet hole is formed on the flexible metal-based copper-clad laminate (1) by means of mechanical processing such as drilling and punching, and a connecting piece such as a screw, a hexagonal nut (7) or a rivet is used to firmly connect the power supply device to other fixed structural parts (5) through the mounting hole (2); or an electric wire is connected through the wire outlet hole (6) to assemble with other electrical systems.

7. The construction process of a three-dimensional power supply device with a circuit layer according to claim 1, characterized in that: In the step of welding the electronic parts, the welding temperature and time are strictly controlled during the welding process to ensure the welding quality and avoid problems such as cold welding and short circuit.

8. The construction process of a three-dimensional power supply device with a circuit layer according to claim 1, characterized in that: During the machining process in the mechanical machining and assembly step, attention is paid to controlling the machining parameters to ensure the structural strength and dimensional accuracy of the flexible metal-based copper-clad laminate (1). After the machining is completed, the electronic components (4) are wrapped in the internal cavity and assembled and fixed to form a shell.

9. The construction process of a three-dimensional power supply device with a circuit layer according to claim 1, characterized in that: In the step of applying the fireproof silicone coating, the coating is constructed by means of glue injection and potting to ensure that the coating has full coverage and uniform thickness, so as to achieve good insulation, fireproofing, waterproofing and corrosion resistance effects.

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