Three-phase bridge type charging module printed circuit board
By designing a three-phase bridge charging module printed circuit board, the problems of uneven heat dissipation, low efficiency, and high cost of traditional charging modules are solved. This achieves efficient energy conversion and heat dissipation, improves the stability and efficiency of the module, and reduces switching losses.
Patent Information
- Application Number
- CN202520156611.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-01-23
- Publication Date
- 2026-03-20
- Estimated Expiration
- 2035-01-23
AI Technical Summary
Traditional high-power charging modules suffer from uneven heat dissipation, low efficiency, high cost, and complex manufacturing processes. They are particularly prone to overheating during high-power charging, which affects stability and safety.
The three-phase bridge charging module printed circuit board design divides the printed circuit board into three areas, which are responsible for input, power conversion and output functions respectively. Silicon carbide MOSFETs and LLC capacitors are used to optimize current processing and power conversion. Combined with DSP control module and heat sink, efficient energy conversion and heat dissipation are achieved.
It improves the working efficiency, heat dissipation performance and stability of the charging module, reduces switching losses, ensures long-term efficient and stable operation, and reduces costs.
Smart Images
Figure CN224021924U_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the field of circuit board design, in particular to a three-phase bridge charging module printed circuit board. BACKGROUND
[0002] With the advancement of electrification, electric vehicles have gradually become the mainstream of transportation tools, and the construction of charging piles has become a necessary condition for the popularization of electric vehicles. In the design of charging piles, the charging module as one of the key components directly affects the charging efficiency and the reliability of the charging facility. In recent years, with the increasing demand for electric vehicle charging, especially the increasing demand for high-power charging, traditional charging modules face certain challenges in efficiency, heat dissipation, size and cost.
[0003] At present, the power modules used for high-power charging on the market mostly adopt traditional design methods, and there are generally the following problems. High-power charging modules generate a large amount of heat when working, and traditional design is difficult to effectively dissipate heat, which easily leads to overheating of the module, affecting its long-term stability and safety; the switching tubes of traditional charging modules are mostly made of silicon material, which has large power loss, resulting in low energy efficiency; the existing power printed circuit board design often lacks reasonable circuit layout, causing uneven heat dissipation, low module efficiency, and even partial circuit failure due to excessive current; the manufacturing process of existing charging modules is complex, and the required raw materials and circuit layout are relatively expensive, resulting in high cost.
[0004] In order to solve these problems, especially to improve the working efficiency and heat dissipation capacity of high-power charging modules, a new charging module design scheme is urgently needed, which can realize efficient power transmission, low power loss and high-efficiency heat dissipation, while also reducing cost and simplifying production process. CONTENT OF THE INVENTION
[0005] The utility model provides a three -phase bridge type charging module printed circuit board. Can solve the above -mentioned problems existing in related technical field. The technical scheme is as follows:
[0006] The present application provides a three-phase bridge charging module printed circuit board, which is suitable for 40KW charging module, comprising:
[0007] The printed circuit board is provided with a first printing area, a second printing area and a third printing area connected by a circuit from left to right.
[0008] The first printing area is provided with an input port, a first LLC electrolytic capacitor and a silicon carbide MOS tube.
[0009] The second printing area is provided with an LLC resonant inductor, an LLC resonant capacitor, an LLC resonant transformer, a second Y capacitor, a current transformer and a DSP control module 29.
[0010] The third printed area is provided with three-zone LLC electrolytic capacitor, three-zone Y capacitor, relay 36, rectifier diode heat sink, common mode inductor, differential mode inductor 41, output filter capacitor 42, anti-reverse diode heat sink, discharge circuit 50, CAN circuit 51 and output terminal 48.
[0011] Optionally, in the first printed area, the input port includes a first input port 1 and a second input port 8; the one-zone LLC electrolytic capacitor includes a one-zone first capacitor 2, a one-zone second capacitor 3, a one-zone third capacitor 4, a one-zone fourth capacitor 9, a one-zone fifth capacitor 10 and a one-zone sixth capacitor 11; the silicon carbide MOS tube includes a first MOS tube 5, a second MOS tube 6 and a third MOS tube 7.
[0012] Optionally, in the second printed area, the LLC resonant inductor includes a first resonant inductor 13, a second resonant inductor 15 and a third resonant inductor 27; the LLC resonant capacitor includes a first resonant capacitor 12, a second resonant capacitor 14 and a third resonant capacitor 26; the LLC resonant transformer includes a first transformer 18, a second transformer 19, a third transformer 21, a fourth transformer 22, a fifth transformer 24 and a sixth transformer 25; the two-zone Y capacitor includes a two-zone first Y capacitor 16 and a two-zone second Y capacitor 17; the current transformer includes a first transformer 20, a second transformer 23 and a third transformer 28.
[0013] Optionally, in the third printed area, the three-zone LLC electrolytic capacitor includes a three-zone first capacitor 30, a three-zone second capacitor 31, a three-zone third capacitor 32, a three-zone fourth capacitor 33, a three-zone fifth capacitor 34 and a three-zone sixth capacitor 35; the three-zone Y capacitor includes a three-zone first Y capacitor 44 and a three-zone second Y capacitor 45; the rectifier diode heat sink includes a first rectifier heat sink 37, a second rectifier heat sink 38, a third rectifier heat sink 39 and a fourth rectifier heat sink 40; the common mode inductor includes a first common mode inductor 43 and a second common mode inductor 47; the anti-reverse diode heat sink includes a first anti-reverse heat sink 46 and a second anti-reverse heat sink 49.
[0014] Optionally, the first printed area is further provided with a first input port 1 and a second input port 8;
[0015] The first input port 1 and the second input port 8 are respectively connected with the one-zone first capacitor 2, the one-zone second capacitor 3, the one-zone third capacitor 4, the one-zone fourth capacitor 9, the one-zone fifth capacitor 10 and the one-zone sixth capacitor 11;
[0016] The first input port 1 and the second input port 8 are also connected with the first MOS tube 5, the second MOS tube 6 and the third MOS tube 7 respectively.
[0017] Optionally, each capacitor of the three-zone LLC electrolytic capacitor is connected in parallel with each rectification fin of the rectification diode fin.
[0018] Optionally, each resonant capacitor of the LLC resonant capacitor, each resonant inductor of the LLC resonant inductor and each transformer of the LLC resonant transformer are connected with the silicon carbide MOS tube of the first printed area in sequence.
[0019] Optionally, the first mutual inductor 20, the second mutual inductor 23 and the third mutual inductor 28 are connected with the second transformer 19, the fourth transformer 22 and the sixth transformer 25 of the LLC resonant transformer.
[0020] Optionally, in the third printed area, the first common mode inductor 43, the second common mode inductor 47, the differential mode inductor 41, the output filter capacitor 42, the first anti-reverse fin 46, the second anti-reverse fin 49, the discharge circuit 50 and the CAN circuit 51 are arranged from top to bottom, and the output terminal 48 is arranged at the rightmost side.
[0021] The technical scheme provided by the utility model has at least the following beneficial effects:
[0022] The utility model discloses a kind of three-phase bridge type charging module printed circuit board, belong to circuit board design field.Through the design of optimized three-phase bridge type charging module printed circuit board, the overall performance of charging module is improved.The design divides printed circuit board into three areas, respectively undertake input, power conversion and output function, ensure current stability and efficient energy conversion.The first printed area is configured with silicon carbide MOS tube and LLC capacitor, improves the current processing capacity of input end.The second printed area is arranged with LLC resonant inductor, capacitor and transformer, realizes efficient power conversion, and cooperates with DSP control module, ensures the accurate regulation of power supply.The third printed area is focused on current rectification, filtering and output, and the heat dissipation capacity and electrical stability of module are enhanced by the optimized configuration of capacitor, fin and inductor.In addition, 6 silicon carbide MOS tubes are used to reduce switching loss, further improve the overall efficiency of module, reduce energy waste.This structural design effectively improves the working efficiency, heat dissipation performance and stability of charging module, ensures its long-time efficient and stable operation. BRIEF DESCRIPTION OF DRAWINGS
[0023] In order to more clearly illustrate the technical solutions in the present application, the drawings needed in the embodiment description will be briefly introduced. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative effort.
[0024] Figure 1 Figure 1 is a structural schematic diagram of a three-phase bridge charging module printed circuit board provided by an illustrative embodiment of the present application. DETAILED DESCRIPTION
[0025] In order to make the purpose, technical solutions and advantages of the present application more clear, the following will further describe the embodiments of the present application in combination with the drawings.
[0026] Embodiment 1
[0027] Please refer to Figure 1 Figure 1 is a structural schematic diagram of a three-phase bridge charging module printed circuit board provided by an illustrative embodiment of the present application.
[0028] The three-phase bridge charging module printed circuit board provided by the present application is suitable for a 40KW charging module, comprising a printed circuit board, wherein a first printed area, a second printed area and a third printed area are sequentially arranged on the printed circuit board and connected by a line.
[0029] The first printed area is provided with an input port, a first LLC electrolytic capacitor and a silicon carbide MOS tube.
[0030] The second printed area is provided with an LLC resonant inductor, an LLC resonant capacitor, an LLC resonant transformer, a second Y capacitor, a current transformer and a DSP control module 29.
[0031] The third printed area is provided with a third LLC electrolytic capacitor, a third Y capacitor, a relay 36, a rectifier diode heat sink, a common mode inductor, a differential mode inductor 41, an output filter capacitor 42, an anti-reverse diode heat sink, a discharge circuit 50, a CAN circuit 51 and an output terminal 48.
[0032] In summary, embodiment 1 describes a structure of a three-phase bridge charging module printed circuit board. According to the structural analysis, the technical effects of the design are as follows.
[0033] The structure optimization and electrical connection are realized. The printed circuit board is divided into three regions, each of which bears different functional electronic components, ensuring the stability of current flow and the efficient operation of the module. The first printed region realizes efficient access of the input end through the configuration of silicon carbide MOS tubes, LLC capacitors and other elements, enhancing the current processing capacity of the input port. The second printed region contains key LLC resonant inductors and capacitors and carries a DSP control module, providing efficient power conversion control and ensuring efficient and precise control of the power module. The third printed region focuses on current rectification, filtering and output, further enhancing the stable output of electrical energy and ensuring the reliability of the charging module.
[0034] The efficient heat dissipation design is realized. In the charging module, the reasonable layout of silicon carbide MOS tubes and heat sinks improves the heat dissipation efficiency, reduces the temperature rise during module operation, prolongs the service life of components, and improves the stability and efficiency of the charging module.
[0035] The module efficiency is realized. By using 6 silicon carbide MOS tubes, the switching loss is reduced, thereby improving the overall efficiency of the charging module, reducing energy waste, and achieving the effect of energy saving and emission reduction.
[0036] Embodiment 2
[0037] Optionally, in the first printed region, the input port includes a first input port 1 and a second input port 8; the first LLC electrolytic capacitor includes a first capacitor 2, a second capacitor 3, a third capacitor 4, a fourth capacitor 9, a fifth capacitor 10 and a sixth capacitor 11; the silicon carbide MOS tube includes a first MOS tube 5, a second MOS tube 6 and a third MOS tube 7.
[0038] Optionally, in the second printed region, the LLC resonant inductor includes a first resonant inductor 13, a second resonant inductor 15 and a third resonant inductor 27; the LLC resonant capacitor includes a first resonant capacitor 12, a second resonant capacitor 14 and a third resonant capacitor 26; the LLC resonant transformer includes a first transformer 18, a second transformer 19, a third transformer 21, a fourth transformer 22, a fifth transformer 24 and a sixth transformer 25; the second Y capacitor includes a first Y capacitor 16 and a second Y capacitor 17; the current transformer includes a first transformer 20, a second transformer 23 and a third transformer 28.
[0039] Optionally, in the third printed area, the three-zone LLC electrolytic capacitors include a first zone capacitor 30, a second zone capacitor 31, a third zone capacitor 32, a fourth zone capacitor 33, a fifth zone capacitor 34, and a sixth zone capacitor 35; the three-zone Y capacitors include a first zone Y capacitor 44 and a second zone Y capacitor 45; the rectifier diode heat sinks include a first rectifier heat sink 37, a second rectifier heat sink 38, a third rectifier heat sink 39, and a fourth rectifier heat sink 40; the common-mode inductors include a first common-mode inductor 43 and a second common-mode inductor 47; and the reverse-biased diode heat sinks include a first reverse-biased heat sink 46 and a second reverse-biased heat sink 49.
[0040] Optionally, the first printing area may also be provided with a first input port 1 and a second input port 8.
[0041] The first input port 1 and the second input port 8 are respectively connected to the first capacitor 2, the second capacitor 3, the third capacitor 4, the fourth capacitor 9, the fifth capacitor 10, and the sixth capacitor 11 of the first zone.
[0042] The first input port 1 and the second input port 8 are also connected to the first MOSFET 5, the second MOSFET 6 and the third MOSFET 7, respectively.
[0043] Optionally, the individual capacitors of the three-zone LLC electrolytic capacitor are connected in parallel with the individual rectifier heat sinks of the rectifier diode heat sink.
[0044] Optionally, the LLC resonant capacitors, LLC resonant inductors, and LLC resonant transformers are sequentially connected to the silicon carbide MOS transistors in the first printed area.
[0045] Optionally, the first current transformer 20, the second current transformer 23, and the third current transformer 28 are connected to the LLC resonant transformers, the second transformer 19, the fourth transformer 22, and the sixth transformer 25.
[0046] Optionally, in the third printing area, from top to bottom, a first common-mode inductor 43, a second common-mode inductor 47, a differential-mode inductor 41, an output filter capacitor 42, a first anti-reverse heat sink 46, a second anti-reverse heat sink 49, a discharge circuit 50, and a CAN circuit 51 are arranged, with the output terminal 48 located on the far right.
[0047] In summary, Example 2 provides a more detailed description of Example 1, further clarifying the specific arrangement and connection between the various components. The technical effects are as follows.
[0048] Fine component configuration is achieved. The first printed area lists the configuration of multiple capacitors and MOS tubes, enhancing current handling capacity and high-frequency switching characteristics. By reasonably configuring these capacitors and MOS tubes, the current stability and response speed of the input end are improved. The second printed area details the configuration of multiple LLC resonant inductors, capacitors, and transformers, further improving the conversion efficiency of the power supply and avoiding energy loss. The precise cooperation of the current transformer and the DSP control module ensures accurate regulation and efficient output of the power module. The third printed area further optimizes the current rectification and filtering design, using different types of capacitors, heat sinks, and inductors to make the power output of the entire module more stable and improve the system's anti-interference ability and stability.
[0049] Enhanced heat dissipation. Through the precise parallel configuration of heat sinks, capacitors, and inductors, especially in the parallel layout of LLC capacitors and rectifier diode heat sinks in the third area, the system's heat dissipation efficiency is further improved, reducing the risk of component failure due to high temperature and improving the long-term stability of the charging module.
[0050] Optimized electrical performance. The fine configuration and connection of various electrical components, especially the layer-by-layer connection of resonant inductors, transformers, and capacitors, optimize the current transmission path and improve the electrical performance of the entire module, ensuring efficient energy conversion and stable power output.
[0051] In summary, the above embodiments improve the working efficiency and stability of the charging module through optimized printed circuit board layout and efficient electrical component configuration. By using six silicon carbide MOS tubes, low-loss and high-efficiency power conversion is achieved; the reasonable heat dissipation layout in the structural design ensures the module's heat dissipation needs when working at high power, reducing temperature rise and improving system reliability. Example 2 provides more detailed component configuration and connection methods, enabling each module to achieve optimal electrical performance and thermal management during operation, further improving the overall performance and service life of the charging module.
[0052] The above is only an optional embodiment of the present application and does not limit the present application. Any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present application shall be included in the protection scope of the present application.
Claims
1. A three-phase bridge charging module printed circuit board, suitable for a 40KW charging module, characterized in that, include: A printed circuit board, wherein a first printing area, a second printing area, and a third printing area are sequentially provided from left to right by lines; The first printed area is equipped with an input port, an LLC electrolytic capacitor, and a silicon carbide MOSFET. The second printing area is equipped with an LLC resonant inductor, an LLC resonant capacitor, an LLC resonant transformer, a second-zone Y capacitor, a current transformer, and a DSP control module (29). The third printing area is provided with a three-zone LLC electrolytic capacitor, a three-zone Y capacitor, a relay (36), a rectifier diode heat sink, a common-mode inductor, a differential-mode inductor (41), an output filter capacitor (42), an anti-reverse diode heat sink, a discharge circuit (50), a CAN circuit (51), and an output terminal (48).
2. The printed circuit board of the three-phase bridge charging module according to claim 1, characterized in that, In the first printing area, the input port includes a first input port (1) and a second input port (8); the first LLC electrolytic capacitor includes a first capacitor (2), a second capacitor (3), a third capacitor (4), a fourth capacitor (9), a fifth capacitor (10), and a sixth capacitor (11); the silicon carbide MOSFET includes a first MOSFET (5), a second MOSFET (6), and a third MOSFET (7).
3. The printed circuit board of the three-phase bridge charging module according to claim 1, characterized in that, In the second printing area, the LLC resonant inductor includes a first resonant inductor (13), a second resonant inductor (15), and a third resonant inductor (27); the LLC resonant capacitor includes a first resonant capacitor (12), a second resonant capacitor (14), and a third resonant capacitor (26); the LLC resonant transformer includes a first transformer (18), a second transformer (19), a third transformer (21), a fourth transformer (22), a fifth transformer (24), and a sixth transformer (25); the second-zone Y capacitor includes a second-zone first Y capacitor (16) and a second-zone second Y capacitor (17); the current transformer includes a first current transformer (20), a second current transformer (23), and a third current transformer (28).
4. The printed circuit board of the three-phase bridge charging module according to claim 1, characterized in that, In the third printing area, the three-zone LLC electrolytic capacitors include a third-zone first capacitor (30), a third-zone second capacitor (31), a third-zone third capacitor (32), a third-zone fourth capacitor (33), a third-zone fifth capacitor (34), and a third-zone sixth capacitor (35); the three-zone Y capacitors include a third-zone first Y capacitor (44) and a third-zone second Y capacitor (45); the rectifier diode heat sinks include a first rectifier heat sink (37), a second rectifier heat sink (38), a third rectifier heat sink (39), and a fourth rectifier heat sink (40); the common-mode inductor includes a first common-mode inductor (43) and a second common-mode inductor (47); and the anti-reverse diode heat sink includes a first anti-reverse heat sink (46) and a second anti-reverse heat sink (49).
5. The printed circuit board of the three-phase bridge charging module according to claim 2, characterized in that, The first printing area is also provided with a first input port (1) and a second input port (8); The first input port (1) and the second input port (8) are respectively connected to the first capacitor (2), the second capacitor (3), the third capacitor (4), the fourth capacitor (9), the fifth capacitor (10), and the sixth capacitor (11) of the first zone; The first input port (1) and the second input port (8) are also connected to the first MOS transistor (5), the second MOS transistor (6) and the third MOS transistor (7), respectively.
6. The printed circuit board of the three-phase bridge charging module according to claim 4, characterized in that, The three-zone LLC electrolytic capacitor comprises each capacitor connected in parallel with the rectifier heat sink comprises each rectifier heat sink.
7. The printed circuit board of the three-phase bridge charging module according to claim 3, characterized in that, The LLC resonant capacitor, the LLC resonant inductor, and the LLC resonant transformer are sequentially connected to the silicon carbide MOS transistor in the first printed area.
8. The printed circuit board of the three-phase bridge charging module according to claim 3, characterized in that, The first current transformer (20), the second current transformer (23) and the third current transformer (28) are connected to the LLC resonant transformer second transformer (19), fourth transformer (22) and sixth transformer (25).
9. The printed circuit board of the three-phase bridge charging module according to claim 4, characterized in that, In the third printing area, from top to bottom, the first common mode inductor (43), the second common mode inductor (47), the differential mode inductor (41), the output filter capacitor (42), the first anti-reverse heat sink (46), the second anti-reverse heat sink (49), the discharge circuit (50), and the CAN circuit (51) are arranged, and the output terminal (48) is located on the far right.