Power converter
By externalizing the filter element and fixing it in combination with conductive components, the problem of EMC performance degradation caused by vibration in power converters in new energy vehicles is solved, achieving higher vibration resistance and signal stability.
Patent Information
- Application Number
- CN202520324371.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-02-26
- Publication Date
- 2026-01-23
- Estimated Expiration
- 2035-02-26
AI Technical Summary
Existing power converters in new energy vehicles suffer from EMC performance issues due to the failure of filter components caused by vibration, leading to signal loss and vehicle safety problems.
By placing the filter element outside the circuit board and combining it with the conductive parts inside the housing to form an integral structure, the fixing strength and vibration resistance are enhanced.
This improves the vibration resistance and EMC performance of the power converter, ensures signal stability, and enhances vehicle safety and reliability.
Smart Images
Figure CN223829239U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of power supply technology, and more particularly to a power converter. Background Technology
[0002] A DC-DC (Direct Current to Direct Current) converter, as a power converter, can convert DC voltage to a lower DC voltage (i.e., a buck DC-DC converter), a higher DC voltage (i.e., a boost DC-DC converter), or the same DC voltage (i.e., a regulated DC-DC converter). To filter out the high-frequency components generated during the operation of the DC-DC converter and keep the output voltage stable within a certain range, a corresponding filtering device is usually provided, which includes inductive or capacitive elements. This filtering device can be constructed as a single-stage, two-stage, or multi-stage filter.
[0003] It should be noted that the content described herein is only to provide background information in relation to this disclosure and does not necessarily belong to the prior art. Utility Model Content
[0004] The purpose of this application is to provide a power converter equipped with a corresponding filtering device, which has improved vibration resistance in mechanical aspects while ensuring the filtering function.
[0005] In addition, this application aims to solve or alleviate other technical problems existing in the prior art.
[0006] The power converter proposed in this application includes:
[0007] A housing that encloses a receiving cavity;
[0008] A circuit board, the circuit board being used to receive a first voltage signal and output a second voltage signal;
[0009] Connector, which is electrically connected to an external wiring harness;
[0010] A filtering assembly includes a first filtering element disposed outside the circuit board, the first filtering element having a first conductive element at its input terminal to receive the second voltage signal, and a second conductive element at its output terminal to output the filtered second voltage signal to the connector.
[0011] The assembly is fixed to the first filter element, the first conductive element and the second conductive element respectively, and is fixed as a whole in the receiving cavity.
[0012] Optionally, in the power converter proposed according to this application, the assembly includes a main body that sequentially includes a first end region, a middle region, and a second end region, wherein the first conductive element is fixed at the first end region, the second conductive element is fixed at the second end region, and the first filter element is fixed at the middle region.
[0013] In the power converter proposed according to this application, optionally, the first end region of the main body is plastic-coated on the outer surface of the end of the first conductive element for electrical connection with the first filter element;
[0014] And / or, the second end region of the main body is plastic-coated on the outer surface of the end of the second conductive element for electrical connection with the first filter element.
[0015] In the power converter proposed according to this application, optionally, the assembly is pre-molded together with the first conductive element and the second conductive element.
[0016] In the power converter proposed according to this application, optionally, the first filter element is fixed in the middle region of the main body by potting compound.
[0017] Optionally, in the power converter proposed according to this application, the assembly further includes a protrusion extending outward from the main body, the protrusion being fixed to the shield of the power converter, the shield being fixed to the housing and providing electromagnetic shielding for the circuit board.
[0018] In the power converter proposed according to this application, optionally, the first conductive element and the second conductive element are located on the side of the shield facing away from the circuit board.
[0019] Optionally, in the power converter proposed according to this application, a receiving groove is provided on one side of the shield, and the first filter element is fixed in the receiving groove by potting compound.
[0020] Optionally, in the power converter proposed in this application, the filtering assembly further includes a second filtering element disposed on the circuit board, one end of which is connected to the circuit board and the other end of which is connected to the first filtering element through the first conductive element.
[0021] In the power converter proposed according to this application, optionally, the filtering component can switch between a first filtering mode and a second filtering mode.
[0022] In the first filtering mode, the second voltage signal output by the circuit board is transmitted to the connector after being filtered by the second filtering element.
[0023] In the second filtering mode, the second voltage signal output by the circuit board is transmitted to the connector after being filtered by the second filtering element and the first filtering element in sequence.
[0024] By integrating the filter components and their associated conductive parts located outside the circuit board and fixing them as a whole, the power converter according to this application has higher fixing strength and improved vibration resistance. Attached Figure Description
[0025] Referring to the accompanying drawings, the above and other features of this application will become apparent, wherein,
[0026] Figure 1 A partial illustration of a power converter according to this application is shown;
[0027] Figure 2 It shows according to Figure 1 A partial illustration of the power converter with the corresponding components removed;
[0028] Figure 3 Shown separately according to Figure 1 The power converter assembly and the corresponding conductive parts fixed thereto. Detailed Implementation
[0029] The present application will now be described more fully with reference to the accompanying drawings, which illustrate exemplary embodiments thereof. However, the present application may be implemented in various forms and should not be construed as being limited to the embodiments given herein. The foregoing embodiments are intended to make the disclosure herein complete and thorough, so as to more fully convey the scope of protection of the present application to those skilled in the art.
[0030] In this specification, terms such as “comprising” and “including” indicate that, in addition to having the units and steps that are directly and explicitly stated in the specification and claims, the technical solution of this application does not exclude the presence of other units and steps that are not directly or explicitly stated.
[0031] Unless otherwise specified, terms such as “first” and “second” do not indicate the order of units in terms of time, space, size, etc., but are merely used to distinguish between units.
[0032] In power converters equipped with filtering components, especially multi-stage filtering components, the increased mass and insufficient fixing strength can affect vibration resistance. For example, in power converters used in new energy vehicles, vibration may cause the filtering components to fail, affecting their EMC (Electromagnetic Compatibility) performance, leading to signal loss and subsequent vehicle safety issues. Therefore, it is urgent to improve the vibration resistance of power converters.
[0033] refer to Figure 1 , Figure 2 and Figure 3 ,in, Figure 1 One embodiment of the power converter according to this application is illustrated in partial figures. Figure 2 In order to present the basis Figure 1 The internal structure of the power converter was modified by removing shielding and other related components. Figure 3 The power converter assembly and its conductive components are presented separately. The power converter 100 presented herein includes a housing 110, a circuit board 120, a connector 130, a filter assembly 140, an assembly 150, and a shield 160.
[0034] The power converter 100 can be the aforementioned DC-DC converter, AC-AC (Alternating Current-Alternating Current) converter, AC-DC (Alternating Current-Direct Current) converter, or DC-AC (Direct Current-Alternating Current) converter. For clarity, the following description primarily focuses on the DC-DC converter; however, its description can be similarly extended to other types of converters.
[0035] The housing 110 forms a receiving cavity for accommodating the circuit board 120, filter assembly 140, assembly 150, and shielding member 160. One end of the connector 130 extends into the receiving cavity to connect with the filter assembly 140, and the other end extends out of the receiving cavity to connect to the outside of the power converter. Exemplarily, a top cover is provided on one side of the receiving cavity, and a bottom plate is provided on the other side, together forming a closed receiving cavity. The housing 110 may be integrally formed, for example, or composed of multiple independent components. Furthermore, the material of the housing 110 may be, but is not limited to, plastic, metal, or other materials. Here, in the embodiments according to this application, the shape and structure of the housing 110 are not limited.
[0036] The circuit board 120 includes a power module for processing the received first voltage signal and outputting a second voltage signal. Here, the voltage value of the first voltage signal may be greater than, less than, or equal to the second voltage signal, and the first and second voltage signals may be the same or different in type; this is not limited in the embodiments according to this application.
[0037] Overall, the input terminal of the filter component 140 is electrically connected to the circuit board 120 to receive the unfiltered second voltage signal, and the output terminal of the filter component 140 is electrically connected to the connector 130 to output the filtered second voltage signal to the outside. The connector 130 is electrically connected to an external electrical device via an external wiring harness. For example, when the power converter is used in a vehicle, the electrical device is an on-board electronic device requiring a stable DC voltage.
[0038] Specifically, in combination Figure 1 and Figure 2 The filtering assembly 140 includes a first filtering element 141, which is external to the circuit board 120, meaning it is not electrically connected to the circuit board via wiring and is not mechanically fixed to the circuit board. Externalizing the first filtering element simplifies the circuit board wiring design. In the illustrated embodiment, the first filtering element 141 is implemented as an LC filter circuit, comprising an inductor coil 1411 external to the circuit board 120 and a capacitor 1412 connected in parallel with the inductor coil 1411. Specifically, the inductor coil 1411 has a first conductive element 170 at its input terminal to receive a second voltage signal; and a second conductive element 180 at its output terminal, one end of which is electrically connected to the capacitor 1412, and the other end of which is electrically connected to the connector 130 to output the filtered second voltage signal to the outside.
[0039] Here, the first conductive element 170 and the second conductive element 180 may be conductive busbars made of copper, aluminum, or other conductive materials. The first conductive element 170 and the second conductive element 180 may be welded to the inductor coil 1411 or electrically connected in other reliable ways.
[0040] from Figure 2 It can also be deduced that the filter assembly 140 further includes a second filter element 142, which is mechanically fixed to and electrically connected to the circuit board 120 to receive the second voltage signal. In the illustrated embodiment, the second filter element is two inductors or includes two inductors. It should be understood that the second filter element 142 may be or include one or more inductors (e.g., three or more), and this is not limited in the embodiments according to this application. Furthermore, the inductors may be fixed to the circuit board 120 by soldering, adhesive bonding, or threaded fasteners, and this is not limited in the embodiments according to this application.
[0041] In one feasible implementation, the first filter element 141 and the second filter element 142 form a two-stage filtering function. The unfiltered initial second voltage signal is first filtered by the second filter element 142 arranged on the circuit board 120. The second voltage signal after primary filtering is transmitted through the first conductive element 170 to the first filter element 141 located outside the circuit board 120 for secondary filtering. The second voltage signal after secondary filtering is output to the outside through the connector 130 via the second conductive element 180.
[0042] In another feasible implementation, the first filter element 141, external to the circuit board 120, can be selectively activated, meaning the filter assembly 140 can switch between a first filtering mode and a second filtering mode. In the first filtering mode, the unfiltered initial second voltage signal is filtered by the second filter element 142 arranged on the circuit board 120 before being transmitted to the connector 130; that is, only the second filter element 142 is active, while the first filter element 141 external to the circuit board 120 is inactive, i.e., a single-stage filtering function. In the second filtering mode, the unfiltered initial second voltage signal is filtered sequentially by the second filter element 142 arranged on the circuit board 120 and the first filter element 141 external to the circuit board 120 before being transmitted to the connector 130; that is, both the first and second filter elements are active simultaneously, i.e., the aforementioned two-stage filtering function.
[0043] For example, the switchability between the first filtering mode (i.e., single-stage filtering mode) and the second filtering mode (i.e., two-stage filtering mode) is achieved by a switching element, which may be located between the second filtering element 142 and the first conductive element 170 on the circuit board 120. Specifically, by closing the switching element, the first filtering element 141, external to the circuit board 120, is connected for secondary filtering. Alternatively, by opening the switching element, the first filtering element 141, external to the circuit board 120, is disconnected, meaning only the second filtering element 142 on the circuit board 120 performs filtering, while the first filtering element 141 is inactive. Here, single-stage or two-stage filtering of the second voltage signal can be selected as needed, thereby improving its application flexibility.
[0044] The switching element mentioned herein should not be interpreted in a restrictive way; it refers to any element, unit, or circuit that can realize electrical connection and disconnection, and is not specifically limited in the embodiments of this application.
[0045] It should also be understood that the above-described embodiments regarding the structure and filtering order of the filtering components, particularly the first and second filtering elements, are merely exemplary and not restrictive, and can be modified as needed. Furthermore, the first and second filtering elements can have different or the same filtering parameters, and this is not limited in the embodiments according to this application. Moreover, the filtering component is not limited to the structure capable of two-stage filtering described above; for example, it can also achieve more stages of filtering, i.e., it includes more filtering elements, some of which are arranged on the circuit board and others are external to the circuit board. Of course, the embodiments of this application do not exclude the possibility of having only a first filtering element external to the circuit board while satisfying the filtering function.
[0046] Combination Figure 1 and Figure 3 The diagram shows, in a perspective view, the electrical connection between the first filter element 141 and the first conductive element 170 and the second conductive element 180. The shielding element 160 completely or at least partially covers the circuit board 120 to isolate the components on the circuit board 120 from the outside environment. The shielding element 160 extends to the housing 110 on the right side to be secured to the housing 110 by threaded fasteners. It should be understood that the shielding element 160 may also be soldered to the housing 110. The material of the shielding element 160 may be, but is not limited to, copper, aluminum, alloys, or other materials with electromagnetic interference shielding properties.
[0047] from Figure 1 As can be seen, a first conductive element 170, a second conductive element 180, and an inductor coil 1411 of the first filter element 141 are provided on the side of the shield 160 facing away from the circuit board 120. Specifically, the first part of the shield 160 is used for the circuit board 120 and covers the circuit board 120 from above, wherein the first conductive element 170 and the second conductive element 180 are provided on the side of the second part facing away from the circuit board 120. The second part of the shield 120 is outside the circuit board 120 and is laid below the first filter element 141. Here, the first part and the second part can be independent of each other or integrally formed.
[0048] For the first portion of the shield 160, the first conductive element 170 is electrically connected to the circuit board 120, or to the output terminal of the second filter element 142 located thereon, via a connector passing through the through-hole of the shield 160. The output terminal of the second conductive element 180 is electrically connected to the capacitor 1412 located thereon via a connector passing through the through-hole of the shield 160.
[0049] The second portion of the shield 160 also has a receiving groove (not shown) on one side, in which a first filter element 141, specifically an inductor coil 1411, is fixedly received. Exemplarily, the inductor coil 1411 is fixed in the receiving groove by potting compound, such as an insulating colloid with thermal conductivity and fixing properties.
[0050] Instead of fixing the first filter element 141, which is external to the circuit board 120, to the second portion of the shield 160, in another alternative embodiment, the first filter element 141 is fixed to a carrier plate, i.e., the carrier plate replaces the second portion. The carrier plate may be part of the housing 110, or the carrier plate may be fixed thereto as a component independent of the housing 110. Exemplarily, the first filter element 141, external to the circuit board 120, may also be fixed in a receiving groove of the carrier plate by potting compound.
[0051] The assembly 150 is fixed to the first filter element 141 (especially the inductor coil 1411), the first conductive element 170, and the second conductive element 180, which are external to the circuit board 120, respectively, so that they are fixed as a whole in the receiving cavity formed by the housing 110. The assembly improves the fixing strength of the first filter element 141 and thereby improves the vibration resistance of the power converter.
[0052] according to Figure 3 The assembly 150 includes a main body 151 and a protrusion 152 extending outward from the main body. The main body 151 covers the inductor coil 1411 of the first filter element 141, and the protrusion 152 is fixed to the shield 160. The assembly 150 can be made of, but is not limited to, plastic; it can also be made of other insulating materials.
[0053] In the accompanying drawings, the main body 151 has two protrusions 152, which are respectively fixed to the shield 160 by threaded fasteners. It should be understood that the main body may also include only one, three, or more of the aforementioned protrusions, which can be fixed to the shield 160 in any other feasible manner.
[0054] The main body 151 of the assembly 150 includes a first end region (the lower end region in the drawings), a second end region (the upper end region in the drawings), and an intermediate region located therebetween. The end of the first conductive member 170 is fixed at the first end region; the end of the second conductive member 180 is fixed at the second end region; and the inductor coil 1411 is fixed at the intermediate region, for example, by means of the aforementioned potting compound, on the surface of the intermediate region.
[0055] In one feasible embodiment, the first end region of the main body 151 is fixed in a plastic-coated manner to the outer surface of the end of the first conductive member 170 for electrical connection with the first filter element 141, wherein the output end of the first conductive member 170 protrudes therefrom to be electrically connected to the input end of the inductor coil 1411 of the first filter element 141.
[0056] In another feasible embodiment, the second end region of the main body 151 is fixed in a plastic-coated manner to the outer surface of the end of the second conductive member 180 for electrical connection with the first filter element 141, wherein the input end of the second conductive member 180 protrudes therefrom to be electrically connected to the output end of the inductor coil 1411 of the first filter element 141.
[0057] Here, by integrating the first filter element 141, which is external to the circuit board 120, and the conductive element thereto, the fixing strength in the housing cavity is improved and the vibration resistance of the power converter is enhanced.
[0058] In the following embodiment, the first end region and the second end region of the main body 151 are respectively fixed to the first conductive element 170 and the second conductive element 180 by means of plastic coating. It is feasible that the assembly 150 can be pre-molded together with the first conductive element 170 and the second conductive element 180 and then the middle region of the main body 151 is fixed to the inductor coil 1411 of the first filter element.
[0059] Alternatively, the first end region of the main body 151 of the assembly 150 can be glued to the first conductive member 170, or the second end region of the main body 151 of the assembly 150 can be glued to the second conductive member 180.
[0060] In the power converter according to this application, the internal fixing strength, vibration resistance, and EMC performance can be improved by using the assembly. In one embodiment of this application, by placing a portion of the filtering components outside the circuit board, the compatibility of its structural design and ease of maintenance can be improved. In one embodiment of this application, the switchability of the power converter between different modes can improve its flexibility in achieving different EMC performance levels. In one embodiment of this application, by pre-molding the assembly and the conductive components associated with the first filtering component placed outside the circuit board, the assembly process can be simplified and internal parts management optimized.
[0061] The embodiments and examples presented herein are provided to illustrate embodiments of this application and its specific applications, thereby enabling those skilled in the art to implement and use this application. However, those skilled in the art should understand that the above description and examples are provided for ease of illustration and example only. The descriptions presented are not intended to cover all aspects of this application or to limit this application to the precise forms disclosed.
Claims
1. A power converter (100), characterized in that, It includes: A housing (110) that encloses a receiving cavity; Circuit board (120), the circuit board is used to receive a first voltage signal and output a second voltage signal; Connector (130), which is electrically connected to an external wiring harness; A filter assembly (140) includes a first filter element (141) disposed outside the circuit board (120), the first filter element having a first conductive element (170) at its input end to receive the second voltage signal, and a second conductive element (180) at its output end to output the filtered second voltage signal to the connector (130). The assembly (150) is fixed to the first filter element (141), the first conductive element (170) and the second conductive element (180) respectively, and is fixed as a whole in the receiving cavity.
2. The power converter (100) according to claim 1, characterized in that, The assembly (150) includes a main body (151), which includes a first end region, a middle region and a second end region in sequence. The first conductive element (170) is fixed at the first end region, the second conductive element (180) is fixed at the second end region, and the first filter element (141) is fixed at the middle region.
3. The power converter (100) according to claim 2, characterized in that, The first end region of the main body (151) is plastically wrapped around the outer surface of the end of the first conductive element (170) for electrical connection with the first filter element (141). And / or, the second end region of the main body (151) is plastic-coated on the outer surface of the end of the second conductive element (180) for electrical connection with the first filter element (141).
4. The power converter (100) according to claim 3, characterized in that, The assembly (150) is pre-molded together with the first conductive element (170) and the second conductive element (180).
5. The power converter (100) according to claim 2, characterized in that, The first filter element (141) is fixed in the middle area of the main body (151) by potting compound.
6. The power converter (100) according to claim 2, characterized in that, The assembly (150) also includes a protrusion (152) extending outward from the main body (151), the protrusion being fixed to the shield (160) of the power converter, the shield being fixed to the housing (110) and providing electromagnetic shielding for the circuit board (120).
7. The power converter (100) according to claim 6, characterized in that, The first conductive element (170) and the second conductive element (180) are respectively located on the side of the shield (160) away from the circuit board (120).
8. The power converter (100) according to claim 6, characterized in that, A receiving groove is provided on one side of the shield (160), and the first filter element (141) is fixed in the receiving groove by potting compound.
9. The power converter (100) according to claim 1, characterized in that, The filtering assembly (140) further includes a second filtering element (142) disposed on the circuit board (120), one end of which is connected to the circuit board (120) and the other end is connected to the first filtering element (141) through the first conductive element (170).
10. The power converter (100) according to claim 9, characterized in that, The filtering component (140) can switch between a first filtering mode and a second filtering mode. In the first filtering mode, the second voltage signal output by the circuit board (120) is transmitted to the connector (130) after being filtered by the second filtering element (142). In the second filtering mode, the second voltage signal output by the circuit board (120) is transmitted to the connector (130) after being filtered by the second filtering element (142) and the first filtering element (141) in sequence.