Power supply module

Abstract

The utility model relates to the field of power supply devices, in particular to a power supply module. Comprising a power supply metal shell assembly, a main circuit board assembly and a filter circuit board assembly, the power supply metal shell assembly defines an independent cavity, the filter circuit board assembly is arranged in the independent cavity, and the main circuit board assembly is arranged on the power supply metal shell assembly and connected with the filter circuit board assembly. The filter circuit board is provided with a through-flow stud, a filter device and a protective tube, and the through-flow stud and / or the protective tube are / is sleeved with an insulation structure. According to the invention, the insulation reliability between the through-flow devices in the power supply module and between the through-flow devices and the power supply metal shell assembly is improved.

Description

Technical Field

[0001] This application relates to the field of power supply devices, and more particularly to a power supply module. Background Technology

[0002] On-board chargers, on-board DC / DC converters, and other power supplies are evolving towards higher voltage, higher current, and higher shock resistance levels. Their dimensions and volume are becoming smaller, while their power density is increasing, leading to a denser arrangement of electronic components inside the power supply. This significantly improves the performance and efficiency of power supply equipment. However, with the increase in component density, the efficient use of space within the power supply becomes extremely critical. How to rationally arrange various electronic components within a limited space to ensure their normal operation has become an important challenge.

[0003] Existing power modules contain many exposed current-carrying components, such as metal studs and fuses used for current conduction between the main circuit board and the filter circuit board, which are very close together. This has a significant impact on the overall insulation performance of the power supply, and the insulation reliability between current-carrying components and between current-carrying components and the power supply's metal casing is low.

[0004] Therefore, based on the above problems, existing technologies need to be improved. Utility Model Content

[0005] The purpose of this application is to provide a power module.

[0006] The above-mentioned technical objective of this application is achieved through the following technical solution: a power module, including a power metal housing assembly, a main circuit board assembly, and a filter circuit board assembly, wherein the power metal housing assembly forms an independent cavity, the filter circuit board assembly is disposed in the independent cavity, the main circuit board assembly is disposed on the power metal housing assembly and connected to the filter circuit board assembly, the filter circuit board assembly includes a filter circuit board, the filter circuit board is provided with a current-passing stud, a filtering device, and a fuse, and the current-passing stud and / or the fuse are fitted with an insulating structure.

[0007] By adopting the above technical solution, the power module's filter circuit board is equipped with current-carrying studs, filtering components, and fuses. The current-carrying studs and / or fuses are fitted with insulating structures, significantly improving the insulation between current-carrying components and between the current-carrying components and the power supply's metal casing. This enhances the overall insulation reliability and withstand voltage performance of the power supply. Simultaneously, this structure effectively prevents the risk of short circuits caused by high voltage and high current, ensuring the normal operation of the power supply in high-vibration environments.

[0008] Optionally, the insulation structure includes a first insulating shell and a second insulating shell, and a plurality of flow-through studs are provided, with adjacent flow-through studs spaced apart by the first insulating shell.

[0009] By adopting the above technical solution, adjacent current-carrying studs are separated by a first insulating shell, effectively avoiding the risk of short circuits between current-carrying studs under high voltage and high current conditions, and improving the insulation reliability and safety of the power module. At the same time, this structure also enhances the mechanical stability between current-carrying studs, reduces the impact of vibration and shock on the studs, and improves the overall vibration resistance of the power module.

[0010] Optionally, a plurality of fuses are provided, with adjacent fuses spaced apart by the second insulating housing.

[0011] By adopting the above technical solution, adjacent fuses are separated by a second insulating shell, effectively preventing the risk of short circuits between fuses and improving the overall insulation effect and reliability of the power module. At the same time, the design of the second insulating shell also protects the fuse's fine filament leads, preventing breakage in vibrating working environments and enhancing the fuse's mechanical strength and stability.

[0012] Optionally, the second insulating housing is provided with a pin, which is hollow and used to avoid the pin of the fuse. The pin is installed with an interference fit to the through hole on the filter circuit board.

[0013] By adopting the above technical solution, the hollow design of the pin on the second insulating shell can effectively avoid the fuse pins, preventing damage to the fuse pins during assembly. At the same time, the pin is installed with an interference fit with the through hole on the filter circuit board, ensuring the stability of the fuse and the reliability of the electrical connection, thereby improving the vibration resistance and long-term stability of the power module in high vibration environments.

[0014] Optionally, the flow stud is made of copper.

[0015] By adopting the above technical solution, the current-carrying studs are made of copper, which ensures excellent conductivity, reduces resistance loss during current transmission, and improves current transmission efficiency. At the same time, copper also possesses good mechanical strength and corrosion resistance, enabling it to maintain stable performance in high-voltage, high-current, and high-vibration-resistance operating environments, thus extending the service life of the power module.

[0016] Optionally, the insulating structure is made of insulating plastic material.

[0017] By adopting the above technical solution, the insulation structure is made of insulating plastic material, which can effectively improve the insulation performance between the current-carrying studs and fuses and the power supply metal shell, prevent short circuits caused by high voltage and high current, and thus enhance the overall insulation reliability and safety of the power module.

[0018] Optionally, one end of the flow-through stud is provided with a threaded connection structure, and the other end of the flow-through stud away from the threaded connection structure is a pin structure.

[0019] By adopting the above technical solution, one end of the current-carrying stud has a threaded connection structure, which facilitates reliable mechanical connection with other components, ensuring that the current-carrying stud is not easily loosened or detached in a vibration environment, thus improving the stability of the connection. Simultaneously, the other end of the current-carrying stud away from the threaded connection structure is a pin structure, which can be effectively inserted into the through-hole on the filter circuit board, preventing radial movement of the stud during vibration and impact, enhancing the circuit board's shear resistance, avoiding solder joint cracking, and thereby improving the reliability and safety of the entire power module.

[0020] In summary, this application has at least the following beneficial effect:

[0021] 1. By installing insulating structures on the current-carrying studs and fuses, the insulation effect between current-carrying devices and between current-carrying devices and the power supply metal casing is effectively improved, significantly enhancing the overall insulation reliability and withstand voltage performance of the power supply;

[0022] 2. The flow-through stud adopts a design with a threaded structure on one end and a pin structure on the other end. The pin structure can prevent the stud from moving radially during vibration and impact, increase the circuit board's shear resistance, avoid solder joint breakage, and improve the stability of the power supply in a vibration environment.

[0023] 3. The insulation structure is made of insulating plastic, which has excellent insulation properties. It can not only prevent short circuits caused by high voltage and high current, but also protect the fine wire leads of the fuse soldered on the circuit board from breaking, thus enhancing the reliability of the internal electronic components of the power supply. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of a power module.

[0025] Figure 2 This is a schematic diagram of the filter circuit board assembly;

[0026] Figure 3 This is an exploded view of the flow-through stud and the first insulating shell;

[0027] Figure 4 This is an exploded view of the fuse and the second insulating housing.

[0028] Figure Labels

[0029] 1. Power supply metal housing assembly; 2. Main circuit board assembly; 3. Filter circuit board assembly; 31. Filter circuit board; 32. Current-passing stud; 33. Filtering components; 34. Fuse; 4. Insulation structure; 41. First insulating housing; 42. Second insulating housing. Detailed Implementation

[0030] The present application will be further described in detail below with reference to the accompanying drawings.

[0031] Example 1

[0032] In this embodiment, refer to Figure 1 A power module includes a power metal housing assembly 1, a main circuit board assembly 2, and a filter circuit board assembly 3. The power metal housing assembly 1 forms an independent cavity, and the filter circuit board assembly 3 is disposed in the independent cavity. The main circuit board assembly 2 is disposed on the power metal housing assembly 1 and connected to the filter circuit board assembly 3. The filter circuit board assembly 3 includes a filter circuit board 31, which is provided with a current-passing stud 32, a filtering component 33, and a fuse 34. An insulating structure 4 is fitted on the current-passing stud 32 and / or the fuse 34.

[0033] Specifically, refer to Figure 1 The power supply metal housing assembly 1 includes side walls, a bottom plate, and a top cover. The side walls and bottom plate together form an independent cavity, and the top cover is connected to the side walls to form a closed power module housing. The main circuit board assembly 2 includes a main circuit board and various electronic components connected to it. The main circuit board is fixed to the side wall of the power supply metal housing assembly 1 with screws. The filter circuit board assembly 3 includes a filter circuit board 31, a current-carrying stud 32, a filtering component 33, and a fuse 34. The filter circuit board 31 is fixed to the bottom plate of the power supply metal housing assembly 1 with screws.

[0034] Reference Figures 2-4 The insulating structure 4 includes a first insulating shell 41 and a second insulating shell 42. The first insulating shell 41 is fitted onto the current-carrying stud 32, and the second insulating shell 42 is fitted onto the fuse 34. The first insulating shell 41 is made of insulating plastic with a thickness of approximately 1 mm to 3 mm to prevent short circuits caused by high voltage and high current. The second insulating shell 42 is also made of insulating plastic with a thickness of approximately 1 mm to 3 mm to ensure complete coverage of the fuse 34 and prevent lead breakage.

[0035] The first insulating housing 41 and the second insulating housing 42 can be manufactured using a thermoplastic injection molding process to ensure a seamless fit between the metal and the plastic. The interior of the first insulating housing 41 has a groove that matches the outer contour of the flow-through stud 32, and the interior of the second insulating housing 42 has a groove that matches the outer contour of the fuse 34, ensuring a tight fit between the two and enhancing the insulation effect.

[0036] Reference Figure 3Several current-passing studs 32 are provided, and adjacent current-passing studs 32 are separated by a first insulating shell 41 to improve the insulation reliability between adjacent current-passing studs 32. Each current-passing stud 32 includes a copper body, a threaded connection structure at one end, and a pin structure at the other end. The pin structure is used to insert into a through-hole on the filter circuit board 31 to achieve a secure connection. The length and diameter of the current-passing studs 32 can be adjusted according to actual needs.

[0037] Reference Figure 4 Several fuses 34 are provided, with adjacent fuses 34 spaced apart by a second insulating housing 42. A hollow pin is provided on the second insulating housing 42 to avoid the leads of the fuses 34, protecting the leads from breakage or bending. The pin is interference-fitted with a through-hole on the filter circuit board 31. The diameter of the pin is slightly smaller than the diameter of the through-hole on the filter circuit board 31, and its length is slightly longer than the depth of the through-hole, ensuring that the pin is fully inserted into the through-hole for a secure connection.

[0038] Reference Figure 2 The filter circuit board assembly 3 also includes a filter component 33, which is fixed to the filter circuit board 31 by soldering and is used to filter out high-frequency noise in the power supply. The type and quantity of the filter component 33 can be selected according to actual needs. For example, components such as capacitors and inductors can be selected, and the quantity can be selected between 1 and 10.

[0039] The implementation principle of this embodiment is as follows: By mounting an insulating structure 4 on the current-carrying stud 32 and the fuse 34, the contact between the current-carrying stud 32 and the fuse 34 and other metal components is effectively isolated, avoiding short circuits caused by high voltage and high current, and significantly improving the insulation effect of the power module. The pin structure of the current-carrying stud 32 is inserted into the through hole on the filter circuit board 31, which can prevent the radial movement of the stud when vibration and impact occur, increasing the shear resistance of the circuit board and preventing solder joint breakage. At the same time, the pin structure of the fuse 34 is interference-fitted with the through hole on the filter circuit board 31, ensuring that the fuse 34 will not loosen in the vibration environment, protecting the extremely fine pins soldered on the circuit board from breakage. By integrating the current-carrying stud 32 and the fuse 34 on the filter circuit board 31 and protecting them with the insulating structure 4, the structure of the entire power module is more compact, saving internal space and improving space utilization.

[0040] Example 2

[0041] The difference between this embodiment and the above embodiment is that the material of the insulation structure 4 is changed to ceramic material, which has higher temperature resistance and better insulation performance.

[0042] Specifically, both the first insulating shell 41 and the second insulating shell 42 are made of ceramic material with a thickness of approximately 1 mm to 3 mm. Ceramic material has high temperature resistance, maintaining good insulation performance in high-temperature environments, making it suitable for high-power-density power modules. Furthermore, ceramic material also possesses good mechanical strength, capable of withstanding greater mechanical stress, thus enhancing the reliability and stability of the power module.

[0043] The interiors of the first insulating housing 41 and the second insulating housing 42 are provided with grooves that match the outer contours of the flow-through stud 32 and the fuse 34, ensuring a tight fit and enhancing the insulation effect. The exterior of the first insulating housing 41 is provided with reinforcing ribs to increase its structural strength and prevent deformation under high-temperature conditions. The exterior of the second insulating housing 42 is provided with heat sinks to increase the heat dissipation area, reduce temperature, and extend service life.

[0044] The implementation principle of this embodiment is as follows: Ceramic materials have higher temperature resistance and better insulation properties, which can more effectively isolate the current-carrying studs 32 and fuses 34 from contact with other metal components, avoiding short circuits caused by high voltage and high current, and further improving the insulation effect of the power module. Ceramic materials have high temperature resistance, maintaining good insulation performance in high-temperature environments, making them suitable for high-power-density power modules, thus improving the applicability and reliability of the power module. Ceramic materials have good mechanical strength, able to withstand greater mechanical stress, enhancing the stability and reliability of the power module, especially in high-temperature and vibration environments.

[0045] Example 3

[0046] The difference between this embodiment and the above embodiment is that the material of the current-carrying stud 32 is changed to aluminum alloy. Aluminum alloy has good conductivity and lightweight characteristics, making it suitable for high power density power modules.

[0047] Specifically, the current-carrying stud 32 is made of aluminum alloy, with a threaded connection structure at one end and a pin structure at the other. Aluminum alloy has excellent electrical conductivity, effectively conducting current, while also being lightweight, reducing the weight of the power module and making it suitable for automotive applications. The length and diameter of the current-carrying stud 32 can be adjusted according to actual needs; for example, the length can be selected between 10mm and 50mm, and the diameter between 2mm and 5mm.

[0048] The insulation structure 4 is still made of insulating plastic with a thickness of about 1mm to 3mm. The interior of the first insulating housing 41 and the second insulating housing 42 is provided with grooves that match the outer contours of the flow stud 32 and the fuse 34, ensuring that the two fit tightly and enhancing the insulation effect.

[0049] The implementation principle of this embodiment is as follows: Aluminum alloy has good electrical conductivity, which can effectively conduct current and improve the transmission efficiency of the power module. At the same time, aluminum alloy is lightweight, reducing the weight of the power module and making it suitable for automotive applications. By mounting an insulating structure 4 on the current-carrying stud 32 and fuse 34, contact between the current-carrying stud 32 and fuse 34 and other metal components is effectively isolated, avoiding short circuits caused by high voltage and high current, and significantly improving the insulation effect of the power module. By integrating the current-carrying stud 32 and fuse 34 onto the filter circuit board 31 and protecting them with the insulating structure 4, the entire power module structure is more compact, saving internal space and improving space utilization.

[0050] Example 4

[0051] The difference between this embodiment and the above embodiments is that the filter circuit board assembly 3 also includes a temperature sensor, which is used to monitor the internal temperature of the power module to ensure that the power module operates within a safe range.

[0052] Specifically, the temperature sensor is soldered and fixed to the filter circuit board 31, located near the filter component 33, for real-time monitoring of the internal temperature of the power module. The type of temperature sensor can be selected according to actual needs; for example, a thermistor or thermocouple can be chosen. The temperature sensor signal is transmitted to the control unit on the main circuit board via wires. The control unit adjusts the operating state of the power module according to the temperature signal to ensure that the power module operates within a safe range.

[0053] The implementation principle of this embodiment is as follows: By adding a temperature sensor to the filter circuit board 31, the internal temperature of the power module is monitored in real time to ensure that the power module operates within a safe range. The control unit adjusts the operating state of the power module according to the temperature signal to prevent overheating damage.

[0054] Example 5

[0055] The difference between this embodiment and the above embodiments is that the sidewalls and bottom plate of the power supply metal housing assembly 1 are made of composite material. Composite material has good thermal insulation performance and mechanical strength, and is suitable for high power density power supply modules.

[0056] Specifically, the sidewalls and base plate of the power supply metal housing assembly 1 are made of composite material, which is composed of glass fiber and epoxy resin, possessing excellent thermal insulation properties and mechanical strength. The composite material is approximately 1mm to 3mm thick, effectively isolating heat inside the power module and preventing heat conduction to the external environment, thus improving the safety of the power module. Simultaneously, the composite material has good mechanical strength, capable of withstanding greater mechanical stress, enhancing the stability and reliability of the power module.

[0057] The implementation principle of this embodiment is as follows: Composite materials have excellent thermal insulation properties, effectively isolating heat inside the power module and preventing heat conduction to the external environment, thus improving the safety of the power module. The thermal insulation performance of composite materials is particularly important in high-power-density applications. Mechanical strength: Composite materials have good mechanical strength, capable of withstanding greater mechanical stress, enhancing the stability and reliability of the power module, especially under high-temperature and vibration environments.

[0058] The embodiments described in this specific implementation are preferred embodiments of this application and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A power module, characterized by The power supply metal shell assembly (1) encloses an independent cavity, the filter circuit board assembly (3) is arranged in the independent cavity, the main circuit board assembly (2) is arranged on the power supply metal shell assembly (1) and connected with the filter circuit board assembly (3), the filter circuit board assembly (3) comprises a filter circuit board (31), the filter circuit board (31) is provided with a through-flow stud (32), a filter device (33) and a fuse tube (34), the through-flow stud (32) and / or the fuse tube (34) is sleeved with an insulation structure (4).

2. A power module according to claim 1, characterized in that The insulation structure (4) comprises a first insulation shell (41) and a second insulation shell (42), the through-flow stud (32) is provided with a plurality of through-flow studs, adjacent through-flow studs (32) are spaced apart by the first insulation shell (41).

3. A power module according to claim 2, characterized in that The fuse tube (34) is provided with a plurality of fuse tubes, adjacent fuse tubes (34) are spaced apart by the second insulation shell (42).

4. A power module according to claim 3, characterized in that The second insulation shell (42) is provided with a pin, the pin is hollowly arranged and used for avoiding the pin of the fuse tube (34), the pin and the through hole on the filter circuit board (31) are mounted in interference fit.

5. The power module of claim 1, wherein, The through-flow stud (32) is made of copper material.

6. A power module according to claim 1, characterized in that The insulation structure (4) is made of insulating plastic material.

7. The power module of claim 1, wherein, One end of the through-flow stud (32) is provided with a threaded connection structure, the other end of the through-flow stud (32) away from the threaded connection structure is a pin structure.

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