A power conversion module and an on-board charger

Abstract

The utility model relates to the technical field of automobile charging and power transformation, specifically relates to a power conversion module and vehicle charger, including the casing, the casing top fixed mounting has the cover, the bottom fixed mounting of casing inside has the locating rack, the positive surface fixed mounting of locating rack has the fixed plate, the inside left and right two ends of locating rack all swing mounting have the transformer, the inside of locating rack and located between two groups of transformer fixedly connected have the partition, two groups the top of transformer is equipped with the insulating locating plate, the inside of insulating locating plate is embedded with the PCB board, the utility model discloses the layered mechanical bearing structure is used to design, and the weight of transformer is directly borne through the locating rack and is passed to the casing, makes the PCB board only bear the electrical connection function, improves the installation convenience, solves the problem that the traditional PCB board installation mode leads to the inconvenience of installation and the risk of knocking inductance.

Description

Technical Field

[0001] This utility model relates to the field of automotive charging and power conversion technology, specifically to a power conversion module and an on-board charger. Background Technology

[0002] As a crucial component of electric vehicle charging systems (including electric vehicle charging piles, on-board chargers (OBC), voltage converters (DCDC), and related integrated products), power conversion modules will see enormous market demand in the future. With rising labor costs, automated production of power conversion modules such as OBC charging modules is an inevitable trend in this field to ensure stable product quality and consistent manufacturing.

[0003] Currently, the conventional installation procedure for the transformer of the power conversion module is to first solder the transformer onto the PCB board, and then install and fix the transformer and PCB board as a whole onto the housing. However, for chargers with high power, especially PCB boards with many magnetic components, the PCB board bears a lot of weight after the transformer is installed on it. This makes the installation inconvenient and poses a risk of damaging the inductor.

[0004] Therefore, it is of great importance to design a power conversion module and on-board charger to solve the above-mentioned defects. Utility Model Content

[0005] To address the shortcomings of existing technologies, this utility model designs a power conversion module and an on-board charger. The power conversion module and on-board charger aim to solve the technical problems of inconvenient installation and the risk of inductor damage during transformer installation in existing power conversion modules.

[0006] To achieve the above objectives, this utility model provides the following technical solution:

[0007] A power conversion module includes a housing, a cover fixedly installed on the top of the housing, a positioning frame fixedly installed at the bottom inside the housing, a fixing plate fixedly installed on the front of the positioning frame, transformers movably installed at both ends inside the positioning frame, a partition fixedly connected inside the positioning frame and between two sets of transformers, an insulating positioning plate installed on the top of the two sets of transformers, a PCB board embedded in the inner side of the insulating positioning plate, a fixing rod fixedly connected to the top of the partition, and a first locking cap threaded to the top end of the fixing rod.

[0008] As a preferred embodiment of this utility model, a protective interlayer is provided on the inner side wall of the shell, and a reinforcing plate is fixedly connected inside the protective interlayer. Multiple sets of heat dissipation holes are opened on both the front and rear sides of the shell, and dustproof nets are installed on the outer sides of the multiple sets of heat dissipation holes.

[0009] As a preferred embodiment of this utility model, the four corners of the top of the cover are fixedly connected to the housing by fixing screws, and a through groove is provided on the front of the cover.

[0010] As a preferred embodiment of this utility model, both ends of the positioning frame are fixedly connected to the housing by assembly screws. Fixed posts are provided on both ends of the front side of the positioning frame. The front ends of the two sets of fixed posts are threaded with second locking caps. A first rubber protective plate is fixedly connected to the inner side of the fixing plate and to the front side of the two sets of transformers. A second rubber protective plate is fixedly connected to both sides of the partition.

[0011] As a preferred embodiment of this utility model, an assembly groove is provided at the top of the insulating positioning plate corresponding to the position of the PCB board, multiple sets of contacts are fixedly connected to the top of the transformer, and positioning holes are provided inside the PCB board at the positions corresponding to the multiple sets of contacts.

[0012] As a preferred embodiment of this utility model, an insulating sleeve is fixedly connected to the top of the fixing rod, the insulating sleeve penetrates the PCB board, and the first locking cap is threadedly connected to the insulating sleeve.

[0013] This utility model also provides an on-board charger, including a power conversion module as described in any one of the above.

[0014] Compared with the prior art, the beneficial effects of this utility model are:

[0015] In this invention, through the coordinated design of the housing, cover, positioning frame, fixing plate, transformer, partition, insulating positioning plate, PCB board, and fixing rod, the positioning frame is first fixed to the bottom of the housing. Two sets of transformers are installed separately by the partition, forming electromagnetic shielding and physical isolation. Then, an insulating positioning plate with an assembly groove is installed on the top of the transformer. Electrical connection and mechanical positioning are completed simultaneously by using the contacts and positioning holes of the PCB board. The insulating sleeve at the top of the fixing rod penetrates the PCB board and is locked by the first locking cap, which not only achieves electrical isolation but also disperses mechanical stress. The protective interlayer and reinforcing plate of the housing form an impact-resistant structure. The heat dissipation holes covered by the dustproof mesh balance the heat dissipation and protection requirements. The cover is pressed into the overall structure by fixing screws. The cable tray optimizes cable management. By adopting a layered mechanical load-bearing structure, the positioning frame directly bears the weight of the transformer and transfers it to the housing, so that the PCB board only undertakes the electrical connection function. At the same time, the installation convenience is improved, and the problems of inconvenience and risk of impact and inductance caused by traditional PCB board installation methods are completely solved. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0017] Figure 2This is a schematic diagram of the internal structure of the housing of this utility model;

[0018] Figure 3 This is a diagram showing the transformer and PCB board after installation of this utility model.

[0019] Figure 4 This is a schematic diagram of the insulating positioning plate structure of this utility model;

[0020] Figure 5 This is a schematic diagram of the internal structure of the positioning frame of this utility model.

[0021] In the diagram: 1. Shell; 101. Protective interlayer; 102. Reinforcing plate; 103. Heat dissipation hole; 104. Dustproof mesh; 2. Cover; 201. Fixing screw; 202. Cable channel; 3. Positioning frame; 301. Assembly screw; 302. Fixing post; 303. Second locking cap; 304. First rubber protective plate; 4. Fixing plate; 5. Transformer; 6. Partition; 601. Second rubber protective plate; 7. Insulating positioning plate; 701. Assembly groove; 702. Contact point; 703. Positioning hole; 8. PCB board; 9. Fixing rod; 901. Insulating sleeve; 10. First locking cap. Detailed Implementation

[0022] The technical solutions of the present utility model will be clearly and completely described below with reference to the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the protection scope of the present utility model.

[0023] Example: Please refer to Figures 1-5 This utility model provides a technical solution:

[0024] A power conversion module includes a housing 1, a cover 2 fixedly installed on the top of the housing 1, a positioning frame 3 fixedly installed at the bottom inside the housing 1, a fixing plate 4 fixedly installed on the front of the positioning frame 3, transformers 5 movably installed at both ends inside the positioning frame 3, a partition 6 fixedly connected inside the positioning frame 3 and between the two sets of transformers 5, an insulating positioning plate 7 installed on the top of the two sets of transformers 5, a PCB board 8 embedded in the inner side of the insulating positioning plate 7, a fixing rod 9 fixedly connected to the top of the partition 6, and a first locking cap 10 threadedly connected to the top of the fixing rod 9.

[0025] First, a protective interlayer 101 is provided on the inner wall of the housing 1. A reinforcing plate 102 is fixedly connected inside the protective interlayer 101. Multiple sets of heat dissipation holes 103 are opened on the front and rear sides of the housing 1, and dustproof nets 104 are installed on the outer side of the multiple sets of heat dissipation holes 103. First, the positioning frame 3 is fixed to the bottom inside the housing 1. Two sets of transformers 5 are movably installed inside the positioning frame 3 and isolated by the partition 6 to form physical separation and electromagnetic shielding. Then, an insulating positioning plate 7 is installed on the top of the transformers 5. Then, a PCB board 8 is embedded in the top of the insulating positioning plate 7. The fixing rod 9 is quickly fixed by threaded connection with the first locking cap 10, so that the PCB board 8 only undertakes the electrical connection function. The mechanical load is directly transmitted to the housing 1 by the positioning frame 3. The protective interlayer 101 and the reinforcing plate 102 of the housing 1 form a composite impact-resistant structure, thereby improving the protective effect of the housing 1. With the heat dissipation holes 103 with dustproof nets 104 on the front and rear sides, both heat dissipation effect is guaranteed and dust is prevented from entering.

[0026] Furthermore, the four corners of the top of the cover 2 are fixedly connected to the housing 1 by fixing screws 201. The front of the cover 2 is provided with a wire channel 202. After the PCB board 8 and the transformer 5 are installed, the cover 2 is installed on the top of the housing 1 by fixing screws 201. The wire harness is led out through the wire channel 202 on the front of the cover 2 for easy wiring.

[0027] Then, the left and right ends of the positioning frame 3 are fixedly connected to the housing 1 by mounting screws 301. The left and right ends of the front of the positioning frame 3 are provided with fixing posts 302. The front ends of the two sets of fixing posts 302 are threaded with second locking caps 303. The inner side of the fixing plate 4 and the front of the two sets of transformers 5 are fixedly connected with first rubber protective plates 304. The left and right sides of the partition 6 are fixedly connected with second rubber protective plates 601. The positioning frame 3 is rigidly connected to the bottom of the housing 1 by the mounting screws 301 at the left and right ends to achieve initial positioning and ensure the overall structural stability. The fixing posts 302 are provided at the two ends of the front of the positioning frame 3. The second locking caps 303 are tightened by thread to form a secondary lock to prevent the transformers 5 from shifting under vibration conditions. The first rubber protective plate 304 is installed on the inner side of the fixing plate 4 to cover the front of the transformers 5. At the same time, the second rubber protective plates 601 are embedded on both sides of the partition 6, thereby effectively suppressing vibration displacement and improving the overall working stability.

[0028] Secondly, an assembly slot 701 is provided at the top of the insulating positioning plate 7 corresponding to the position of the PCB board 8. Multiple sets of contacts 702 are fixedly connected to the top of the transformer 5. Positioning holes 703 are provided inside the PCB board 8 at the positions corresponding to the multiple sets of contacts 702. The assembly slot 701 on the top of the insulating positioning plate 7 is precisely aligned with the PCB board 8. At the same time, the multiple sets of contacts 702 on the top of the transformer 5 are embedded in the positioning holes 703 of the PCB board 8, so that electrical connection and mechanical fixation are completed simultaneously. The assembly slot 701 ensures the stable positioning of the PCB board 8 and avoids installation offset. The cooperation between the contacts 702 and the positioning holes 703 not only provides a reliable electrical conduction path, but also enhances the connection strength through multi-point contact.

[0029] Finally, an insulating sleeve 901 is fixedly connected to the top of the fixing rod 9. The insulating sleeve 901 penetrates the PCB board 8, and the first locking cap 10 is threadedly connected to the insulating sleeve 901. By the insulating sleeve 901 at the top of the fixing rod 9 penetrating the PCB board 8 and being threadedly connected to the first locking cap 10, the dual functions of electrical isolation and mechanical fixation are achieved. The insulating sleeve 901 effectively prevents the risk of short circuit and absorbs installation stress to protect the PCB board 8.

[0030] This utility model also provides an on-board charger, including a power conversion module.

[0031] In this embodiment, the specific implementation scenario is as follows: First, the positioning frame 3 is fixed to the bottom of the housing 1. Two sets of transformers 5 are installed separately by the partition 6 to form electromagnetic shielding and physical isolation. Then, an insulating positioning plate 7 with an assembly groove 701 is installed on the top of the transformer 5. Electrical connection and mechanical positioning are achieved simultaneously by using the contact 702 and the positioning hole 703 of the PCB board 8. The insulating sleeve 901 at the top of the fixing rod 9 passes through the PCB board 8 and is locked by the first locking cap 10, which achieves both electrical isolation and dispersion of mechanical stress. The protective interlayer 101 of the housing 1 and the reinforcing plate 1 02 forms an impact-resistant structure, which, together with the dustproof mesh 104 covering the heat dissipation holes 103, balances the heat dissipation and protection requirements. The cover 2 is tightened into the overall structure by fixing screws 201, and the cable channel 202 optimizes cable management. The entire operation process is simple and convenient. This utility model adopts a layered mechanical load-bearing structure, in which the positioning frame 3 directly bears the weight of the transformer 5 and transfers it to the housing 1, so that the PCB board 8 only undertakes the electrical connection function. At the same time, it improves the ease of installation and completely solves the problems of inconvenient installation and the risk of impact and inductance caused by the traditional PCB board 8 installation method.

[0032] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A power conversion module, comprising a housing (1), characterized in that: A cover (2) is fixedly installed on the top of the housing (1). A positioning frame (3) is fixedly installed at the bottom inside the housing (1). A fixing plate (4) is fixedly installed on the front of the positioning frame (3). Transformers (5) are movably installed on both the left and right ends inside the positioning frame (3). A partition (6) is fixedly connected inside the positioning frame (3) and between the two sets of transformers (5). An insulating positioning plate (7) is installed on the top of the two sets of transformers (5). A PCB board (8) is embedded on the inner side of the insulating positioning plate (7). A fixing rod (9) is fixedly connected to the top of the partition (6). A first locking cap (10) is threaded to the top of the fixing rod (9).

2. The power conversion module according to claim 1, characterized in that: The inner wall of the housing (1) is provided with a protective interlayer (101), and a reinforcing plate (102) is fixedly connected inside the protective interlayer (101). Multiple sets of heat dissipation holes (103) are opened on the front and rear sides of the housing (1), and dustproof nets (104) are installed on the outer side of the multiple sets of heat dissipation holes (103).

3. The power conversion module according to claim 1, characterized in that: The four corners of the top of the cover (2) are fixedly connected to the housing (1) by fixing screws (201), and a through groove (202) is provided on the front of the cover (2).

4. A power conversion module according to claim 1, characterized in that: The left and right ends of the positioning frame (3) are fixedly connected to the housing (1) by mounting screws (301). The left and right ends of the front of the positioning frame (3) are provided with fixing posts (302). The front ends of the two sets of fixing posts (302) are threaded with second locking caps (303). The inner side of the fixing plate (4) and the front of the two sets of transformers (5) are fixedly connected with first rubber protective plates (304). The left and right sides of the partition (6) are fixedly connected with second rubber protective plates (601).

5. A power conversion module according to claim 1, characterized in that: The top of the insulating positioning plate (7) is provided with an assembly groove (701) at a position corresponding to the PCB board (8). The top of the transformer (5) is fixedly connected with multiple sets of contacts (702). The PCB board (8) is provided with positioning holes (703) at positions corresponding to the multiple sets of contacts (702).

6. A power conversion module according to claim 1, characterized in that: An insulating sleeve (901) is fixedly connected to the top of the fixing rod (9). The insulating sleeve (901) penetrates the PCB board (8), and the first locking cap (10) is threadedly connected to the insulating sleeve (901).

7. An on-board charger, characterized in that: Includes a power conversion module as described in any one of claims 1-6.

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