A flip-chip charging gun printed circuit board assembly

Abstract

This utility model discloses a flip-chip charging gun printed circuit board assembly, disposed within the charging gun body, comprising: a main layer circuit board; a secondary layer circuit board, disposed parallel below the main layer circuit board, with the area of ​​the secondary layer circuit board being smaller than that of the main layer circuit board, forming a receiving space between the main layer circuit board and the secondary layer circuit board for accommodating electronic components; and at least two intermediate circuit boards facing different directions, vertically disposed between the main layer circuit board and the secondary layer circuit board, with the upper and lower sides of the intermediate circuit boards respectively plugging into the main layer circuit board and the secondary layer circuit board. This utility model features a stable, non-deformable, and compactly arranged three-dimensional structure that allows for efficient use of the upper space of the charging gun body and enables the lower space of the charging gun body to contract.

Description

Technical Field

[0001] This utility model relates to the field of charging gun technology, and in particular to an inverted charging gun printed circuit board assembly. Background Technology

[0002] The charging gun is a crucial interface device connecting charging stations and electric vehicles, and its electrical performance and structural design directly affect charging safety and user experience. With continuous technological advancements, the functions of charging guns are becoming increasingly complex, and traditional internal printed circuit board assemblies (PCBAs) using a single-planar layout or simple double-layer stacking are gradually becoming insufficient to meet the demands.

[0003] On the one hand, charging guns need to integrate multiple functional modules, including but not limited to power conversion circuits, communication control units, power metering chips, and various protection circuits. This significantly increases the number and types of components required, leading to PCBAs occupying more installation space. On the other hand, traditional PCBA layouts have low space utilization, with functional modules often scattered, resulting in a loose overall structure. This further exacerbates the PCBA's space occupation problem, forcing the gun body to expand and hindering the smooth contraction of the grip area at the bottom of the gun, affecting user convenience and comfort. Due to limited installation space, some circuit boards are also forced to be thinner, resulting in poor overall structural stability and susceptibility to deformation.

[0004] In the integrated charging and discharging gun type, the PCBA has to undertake the task of fast charging and also has the ability to reverse discharge. It requires more integrated functional modules, and the above problems are more obvious. Utility Model Content

[0005] The purpose of this invention is to provide an inverted charging gun printed circuit board assembly that, while ensuring structural stability, allows for the retraction of the lower part of the gun body.

[0006] To achieve the above objectives, the technical solution adopted by this utility model is as follows: A flip-chip charging gun printed circuit board assembly is disposed within the charging gun body, comprising: a main layer circuit board; a secondary layer circuit board disposed parallel to and below the main layer circuit board, wherein the area of ​​the secondary layer circuit board is smaller than that of the main layer circuit board, and a receiving space for accommodating electronic components is formed between the main layer circuit board and the secondary layer circuit board; and at least two intermediate circuit boards facing different directions, vertically disposed between the main layer circuit board and the secondary layer circuit board, wherein the upper and lower sides of the intermediate circuit boards are respectively inserted and engaged with the main layer circuit board and the secondary layer circuit board.

[0007] Furthermore, the main circuit board is divided into a head, a tapered section, a middle section and a tail section in sequence along the longitudinal direction. The head can be inserted and matched with the gun body. The lateral width of the tapered section gradually decreases from the middle section to the head. The tail section has a main layer slot along the longitudinal direction.

[0008] Furthermore, a 2-3mm margin is reserved on both sides of the middle part of the main circuit board to match the sliding groove structure inside the gun body, and the edges of the middle part and the tapered part are smoothly connected.

[0009] Furthermore, a plurality of protrusions are formed on the secondary circuit board extending longitudinally, and a secondary slot is formed between two adjacent protrusions, the secondary slot facing the same direction as the primary slot.

[0010] Furthermore, the main layer circuit board is electrically connected to the secondary layer circuit board via a vertical pin header, which is vertically positioned between the main layer circuit board and the secondary layer circuit board, and is located at the boss.

[0011] Furthermore, the intermediate circuit board includes a transverse circuit board arranged in a horizontal direction and a longitudinal circuit board arranged in a vertical direction. The lower side of the longitudinal circuit board is provided with a chamfered portion, which is arranged on the same side as the head.

[0012] Furthermore, a header is electrically connected to the upper side of the main circuit board, which is used to connect to a micro switch.

[0013] Furthermore, two indicator lights are electrically connected to the upper side of the main circuit board. The indicator lights emit light synchronously and use the same light guide strip for light guiding.

[0014] Furthermore, the main circuit board has surge protection lines, EMC protection lines, output short circuit protection lines, CC-CP charge / discharge identification and switching lines, CP main circuit and a portion of current-leakage detection lines; the secondary circuit board has Bluetooth communication lines, cover opening control lines and another portion of current-leakage detection lines.

[0015] Furthermore, it also includes an AC-DC power supply line, wherein the electronic components corresponding to the charging path and discharging path of the AC-DC power supply line are disposed on different intermediate circuit boards.

[0016] This utility model has the following beneficial effects: This invention vertically inserts an intermediate circuit board between the main circuit board and the secondary circuit board to construct a stable and non-deformable three-dimensional structure. At the same time, the main circuit board and the secondary circuit board adopt a differentiated area design, forming a space between the boards to accommodate electronic components. Most electronic components can be electrically connected to the underside of the main circuit board or the intermediate circuit board, and are compactly arranged in the space. Then, the charging gun body is placed in an inverted manner, so that the upper space of the gun body is fully utilized and the lower space has the ability to shrink. Attached Figure Description

[0017] Figure 1 This is one of the three-dimensional structural schematic diagrams of this utility model.

[0018] Figure 2 This is a top view of the structure of this utility model.

[0019] Figure 3 This is a schematic diagram of the structure of this utility model from a bottom view.

[0020] Figure 4 This is a side view of the structure of this utility model.

[0021] Figure 5 This is one of the three-dimensional structural schematic diagrams of this utility model.

[0022] Figure 6 for Figure 5 A schematic diagram of the explosion structure.

[0023] Figure 7 This is one of the schematic diagrams showing the connection structure between the main circuit board and the intermediate circuit board of this utility model.

[0024] Figure 8 This is one of the schematic diagrams showing the connection structure between the main circuit board and the intermediate circuit board of this utility model.

[0025] Figure 9 This is a diagram showing the state of the present invention installed inside the gun body.

[0026] Key component symbols: 100, Main layer circuit board; 110, Head; 120, Tapered section; 130, Middle section; 140, Tail section; 141, Main layer slot; 200, Secondary layer circuit board; 210, Boss; 220, Secondary layer slot; 300, Reception space; 400, Middle circuit board; 410, Horizontal circuit board; 420, Vertical circuit board; 421, Chamfer; H, Edge distance; LED, Indicator light; J1-J2, Vertical pin header; J3, Female header; RV1-RV2, Thermistor; QD, Gas discharge tube; FU, Fuse; CX, Capacitor; K1-K4, Relay; U1-U6, Chip; HT, Current transformer. Detailed Implementation

[0027] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0028] like Figure 1-8 As shown, this utility model provides a flip-chip charging gun printed circuit board assembly (PCBA) disposed in the body of the charging gun, including: a main layer circuit board 100; a secondary layer circuit board 200 disposed parallel to the main layer circuit board 100 below it, and the area of ​​the secondary layer circuit board 200 is smaller than that of the main layer circuit board 100, forming a receiving space 300 for accommodating electronic components between the main layer circuit board 100 and the secondary layer circuit board 200; and at least two intermediate circuit boards 400 with different facing surfaces disposed vertically between the main layer circuit board 100 and the secondary layer circuit board 200, with the upper and lower sides of the intermediate circuit boards 400 respectively plugged into the main layer circuit board 100 and the secondary layer circuit board 200.

[0029] The main layer circuit board 100 and the secondary layer circuit board 200 adopt a differentiated area design, and are vertically intersected with intermediate circuit boards 400 facing different directions. With the multi-directional support of the intermediate circuit boards 400, a stable and deformation-resistant three-dimensional architecture can be constructed. In this architecture, most electronic components integrating multiple functional modules can be electrically connected to the underside of the main layer circuit board 100 or to the intermediate circuit boards 400, compactly arranged within the housing space 300, such as... Figure 9 As shown, after the PCBA is installed into the charging gun body, these electronic components can be installed inverted into the gun body in a way that is different from the traditional upright installation, making full use of the upper space of the gun body, and with the cooperation of the secondary circuit board 200, leaving more retractable space in the lower part of the gun body (such as the grip area).

[0030] The aforementioned main circuit board 100 is longitudinally divided into a head 110, a tapering section 120, a middle section 130, and a tail 140. The head 110 can be inserted into the gun body. The lateral width of the tapering section 120 gradually decreases from the middle section 130 to the head 110. The tail 140 has a main layer slot 141 longitudinally formed on it. The head 110 of the main circuit board 100 faces the hand-held side of the gun body, and the tail 140 faces the gun head (not shown). Its longitudinal direction aligns with the gun head, and its lateral direction is perpendicular to the longitudinal direction. The tapering section 120 and the middle section 130 are the main areas for arranging electronic components. The gradually decreasing lateral dimension of the tapering section 120 can adapt to the contraction of the gun body near the hand-held area, making full use of the internal space of the gun body.

[0031] The intermediate circuit board 400 includes a transverse circuit board 410 arranged laterally and a longitudinal circuit board 420 arranged longitudinally, with their surfaces perpendicular to each other for more stable support. The portion of the longitudinal circuit board 420 exposed below the secondary circuit board 200 has a chamfered portion 421. Similar to the tapered portion 120, the chamfered portion 421 is located on the same side as the head 110, similarly providing conditions for the gun body to retract closer to the gripping area.

[0032] The main layer circuit board 100 has a 2-3mm margin H reserved on both sides of the middle 130 to match the sliding groove structure inside the gun body, and the edges of the middle 130 and the tapered part 120 are smoothly connected. When the PCBA is installed into the gun body, the head 110 of the main layer circuit board 100 is inserted into the slot inside the gun body, and the reserved margin H of the middle 130 and part of the edge of the tapered part 120 slide into the sliding groove structure inside the gun body, which can realize the rapid positioning and fixation of the PCBA. The main layer slot 141 at the tail 140 can cooperate with the protruding part inside the gun head to further limit the lateral and longitudinal displacement of the PCBA, especially the main layer circuit board 100.

[0033] Similarly, a number of protrusions 210 are formed along the longitudinal direction on the secondary circuit board 200, and a secondary slot 220 is formed between two adjacent protrusions 210. The secondary slot 220 and the main slot 141 face the same direction, and their positions are staggered in the lateral direction. By utilizing the cooperation between the secondary slot 220 and the protruding structure inside the gun head, the offset of the PCBA, especially the secondary circuit board 200, can be further restricted.

[0034] The main layer circuit board 100 and the secondary layer circuit board 200 are electrically connected via vertical pin headers J1 and J2. These vertical pin headers J1 and J2 are vertically positioned between the main layer circuit board 100 and the secondary layer circuit board 200, establishing an electrical interconnection channel and providing auxiliary support to enhance the stability of the overall structure. Preferably, the vertical pin headers J1 and J2 are located at the boss 210 to reduce the impact of the slot on the mechanical strength of the secondary layer circuit board 200.

[0035] Besides the electronic components arranged in the housing space 300, only a small number of smaller electronic components are retained on the upper side of the main circuit board 100. In this embodiment, a vertical staggered connector J3 and two LED indicator lights are electrically connected to the upper side of the main circuit board 100. This connector J3 replaces the traditional wire harness terminal flying wire connection method for connecting microswitches, allowing direct embedding with the microswitches during assembly and reducing secondary assembly processes. The two LED indicator lights emit light synchronously and use the same light guide strip for light guidance, requiring no additional wiring, and providing a focused and eye-catching visual effect.

[0036] This PCBA is mainly used in integrated charging and discharging guns and integrates the following functional modules.

[0037] The main circuit board 100 includes: a surge protection circuit formed by varistor RV1, varistor RV2, and gas discharge tube QD; an EMC protection circuit formed by fuse FU and capacitor CX; a main relay K1; an output short-circuit protection circuit formed by relay K2 and its bypass; a CC-CP charge-discharge identification and switching circuit formed by relays K3 and K4 and their bypass; a CP main circuit formed by DC-DC power chip U1 and operational amplifier chip U2; and a current-leakage detection circuit formed by current transformer HT, current detection chip U3, and detection circuitry.

[0038] The secondary circuit board 200 has: a Bluetooth communication line controlled by the Bluetooth chip U4; an opening control line controlled by the opening chip U5; and a leakage current detection chip U6 and leakage current detection line forming another part of the current-leakage current detection line.

[0039] The intermediate circuit board 400 has an AC-DC power supply line. Preferably, the electronic components corresponding to the charging path and discharging path of the AC-DC power supply line are disposed on different intermediate circuit boards 400. In this embodiment, the electronic components corresponding to the charging path are disposed on the vertical circuit board 420, and the electronic components corresponding to the discharging path are disposed on the horizontal circuit board 410. The two are dedicated to different modes, and function switching can be achieved without adding additional connectors, which greatly reduces the hardware redundancy required for mode switching.

[0040] In summary, the inverted charging gun printed circuit board assembly (PCBA) provided by this utility model integrates multiple functional modules and has the advantages of stable architecture and compact layout. It can make full use of the upper space of the gun body and provide a foundation for the lower space to shrink, which is conducive to improving the ease of use and grip comfort of the charging gun body.

[0041] Although the present invention has been specifically shown and described in conjunction with preferred embodiments, those skilled in the art should understand that various changes in form and detail to the present invention without departing from the spirit and scope of the present invention as defined in the appended claims are within the scope of protection of the present invention.

Claims

1. A flip-chip charging gun printed circuit board assembly, disposed within the charging gun body, characterized in that, include: Main layer circuit board; The secondary circuit board is arranged parallel to the main circuit board below it, and the area of ​​the secondary circuit board is smaller than that of the main circuit board. The main circuit board and the secondary circuit board form a storage space that can accommodate electronic components. At least two intermediate circuit boards facing different directions are vertically disposed between the main circuit board and the secondary circuit board, and the upper and lower sides of the intermediate circuit boards are respectively inserted and engaged with the main circuit board and the secondary circuit board.

2. The inverted charging gun printed circuit board assembly as described in claim 1, characterized in that: The main circuit board is divided into a head, a tapering section, a middle section and a tail section in sequence along the longitudinal direction. The head can be inserted and matched with the gun body. The lateral width of the tapering section gradually decreases from the middle section to the head. The tail section has a main layer slot along the longitudinal direction.

3. The inverted charging gun printed circuit board assembly as described in claim 2, characterized in that: The main circuit board has a 2-3mm margin reserved on both sides of the middle section to match the sliding groove structure inside the gun body, and the edges of the middle section and the tapered section are smoothly connected.

4. The inverted charging gun printed circuit board assembly as described in claim 2, characterized in that: Several protrusions are formed along the longitudinal direction on the secondary circuit board, and a secondary slot is formed between two adjacent protrusions. The secondary slots are oriented in the same direction as the primary slots.

5. The inverted charging gun printed circuit board assembly as described in claim 4, characterized in that: The main layer circuit board is electrically connected to the secondary layer circuit board via a vertical pin header. The vertical pin header is vertically arranged between the main layer circuit board and the secondary layer circuit board, and the vertical pin header is located at the boss.

6. The inverted charging gun printed circuit board assembly as described in claim 2, characterized in that: The intermediate circuit board includes a transverse circuit board arranged in the horizontal direction and a longitudinal circuit board arranged in the vertical direction. The lower side of the longitudinal circuit board is provided with a chamfered portion, which is arranged on the same side as the head.

7. The inverted charging gun printed circuit board assembly as described in claim 1, characterized in that: The upper side of the main circuit board is electrically connected to a busbar, which is used to connect to a micro switch.

8. The inverted charging gun printed circuit board assembly as described in claim 1, characterized in that: Two indicator lights are electrically connected to the upper side of the main circuit board. The indicator lights emit light synchronously and use the same light guide strip for light guiding.

9. The inverted charging gun printed circuit board assembly as described in claim 1, characterized in that: The main circuit board has surge protection circuitry, EMC protection circuitry, output short circuit protection circuitry, CC-CP charge / discharge identification and switching circuitry, CP main circuitry, and a portion of current-leakage detection circuitry. The secondary circuit board has Bluetooth communication lines, cover opening control lines, and another part of current-leakage detection lines.

10. The inverted charging gun printed circuit board assembly as described in claim 1, characterized in that: It also includes an AC-DC power supply line, wherein the electronic components corresponding to the charging path and the discharging path of the AC-DC power supply line are disposed on different intermediate circuit boards.

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