A charging module power supply printed circuit board
By arranging the key circuits of the power printed circuit board of the charging module in a U-shape along the edge and setting the auxiliary power control circuit at the opening, the problems of space utilization and power loop area in the prior art are solved, achieving efficient heat dissipation and excellent EMI performance, meeting the IP65 protection level while supporting high power output.
Patent Information
- Application Number
- CN202522767583.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-26
- Publication Date
- 2026-11-03
- Estimated Expiration
- 2035-12-26
AI Technical Summary
Existing charging module power printed circuit boards have poor space utilization under IP65 protection level, and the power circuit area is large, resulting in poor heat dissipation and EMI performance.
The input electromagnetic compatibility circuit, power correction circuit, DC-DC conversion circuit, and output circuit are arranged in a U-shape along the edge of the board. The auxiliary power control circuit is located at the opening of the U-shape. A multi-layer board design and shielding cover are used to optimize space utilization and heat dissipation.
It achieves high space utilization and small power circuit area, excellent EMI performance and stable heat dissipation, meeting the IP65 protection level while improving the reliability and performance of the circuit.
Smart Images
Figure CN224935843U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to a charging module, and more specifically, to a power printed circuit board for a charging module. Background Technology
[0002] Charging stations are widely deployed in various outdoor environments, such as along highways, in underground parking lots, and in coastal areas. These environments often face challenges from dust, humidity, salt spray, and even rain. Therefore, stringent requirements are placed on the protection level of the charging modules. IP65 protection (complete dust and water resistance) has become a standard requirement for many outdoor charging stations. To achieve an IP65 rating, the charging module must use a fully sealed housing. However, this sealed structure presents significant challenges to the internal power printed circuit board (PCB) layout design in terms of heat dissipation and power circuit routing.
[0003] Currently, most charging modules on the market with IP65 protection rating and output power greater than 20KW use the Type 1 layout, which results in poor board space utilization and a large power circuit area. Utility Model Content
[0004] The technical problem to be solved by this utility model is to provide a power printed circuit board for a charging module, which has a high board space ratio and a small power circuit area, in view of the above-mentioned defects of the prior art.
[0005] The technical solution adopted by this utility model to solve its technical problem is as follows: a power printed circuit board for a charging module is constructed, including a board body, and an input electromagnetic compatibility circuit, a power correction circuit, a DC-DC conversion circuit, an output circuit and an auxiliary power source control circuit disposed on the board body; the input electromagnetic compatibility circuit, the power correction circuit, the DC-DC conversion circuit and the output circuit are arranged in a U-shape along the edge of the board body, and the auxiliary power source control circuit is disposed at the opening of the U-shape.
[0006] In the power printed circuit board of the charging module of this utility model, the board body is a rectangular board body; the rectangular board body includes a first region, a second region, a third region, a fourth region, and a fifth region; the input electromagnetic compatibility circuit is disposed in the first region, the power correction circuit is disposed in the second region, the DC-DC conversion circuit is disposed in the third region, the output circuit is disposed in the fourth region, and the auxiliary power control circuit is disposed in the fifth region; the first region, the second region, the third region, and the fourth region are arranged in a U-shape, and the fifth region is located at the opening of the U-shape.
[0007] In the power printed circuit board of the charging module described in this utility model, the input electromagnetic compatibility circuit, the power correction circuit, the DC-DC conversion circuit and the output circuit form a U-shaped power loop on the board.
[0008] In the power printed circuit board of the charging module described in this utility model, the auxiliary power control circuit and the power correction circuit form a first sampling signal loop, and the auxiliary power control circuit and the output circuit form a second sampling signal loop. The first sampling signal loop and the second sampling signal loop are isolated from each other.
[0009] In the power printed circuit board of the charging module described in this utility model, the input electromagnetic compatibility circuit includes a three-phase input interface, surge protection devices, and electromagnetic compatibility filtering devices; the power correction circuit includes a PFC inductor, a switching transistor, an electrolytic capacitor, a driving circuit, and a diode; the DC-DC conversion circuit includes a high-frequency transformer, a resonant inductor, a resonant capacitor, a switching transistor, and a driving circuit; the output circuit includes a rectifier diode, a rectifier capacitor, a filter capacitor, and an output interface; and the auxiliary power control circuit includes a control chip, a feedback and sampling module, and auxiliary power devices.
[0010] In the power printed circuit board of the charging module described in this utility model, the first region, the second region and the fifth region are all rectangular regions, the third region is an L-shaped region and the fourth region is a polygonal region; The first region, the fifth region, and the fourth region are arranged side by side along the first side of the plate, and the first region and the second region are arranged side by side along the second side of the plate. The first side of the plate is perpendicular to the second side of the plate. The third region is disposed along the third and fourth sides of the plate, and the first side of the third region is adjacent to the second region, and the second side of the third region is adjacent to the fourth region; The fourth region has a horizontal side edge along the fourth side edge of the plate and a vertical side edge adjacent to the fifth region. The fourth region covers the plate area located between the fifth region, the third region, and the second region.
[0011] In the power printed circuit board of the charging module described in this utility model, the three-phase input interface is located in the first region, the output interface is located in the fourth region, and the three-phase input interface and the output interface are arranged along the diagonal of the rectangular plate.
[0012] In the power printed circuit board of the charging module described in this utility model, the board body is a multi-layer board body. The input electromagnetic compatibility circuit, the power correction circuit, the DC-DC conversion circuit, the output circuit and the auxiliary power control circuit are arranged on the top layer of the board body. The board body has heat dissipation vias and busbars that penetrate the middle layer and the bottom layer of the multi-layer board body.
[0013] The top layer of the multilayer board has a patch, and the heat dissipation via and the busbar are directly opposite the patch. The bottom layer of the board has a heat dissipation pad, and the first side of the heat dissipation pad contacts the heat dissipation via and the busbar, and the second side contacts the heat sink.
[0014] The power printed circuit board of the charging module of this utility model further includes a shielding cover; the shielding cover is located at the dividing line between the first region and the fifth region; the shielding cover is located at the dividing line between the fourth region and the fifth region; the shielding cover is located at the dividing line between the fourth region and the second region; and / or the shielding cover is located between the primary and secondary sides of the auxiliary power transformer in the fifth region.
[0015] The power printed circuit board of the charging module implementing this utility model arranges the input electromagnetic compatibility circuit, power correction circuit, DC-DC conversion circuit and output circuit in a U-shape along the edge of the board, and sets the auxiliary power control circuit at the opening of the U-shape. Therefore, the space utilization of the board is good, and the power loop formed is U-shaped, so the area is small. Attached Figure Description
[0016] The present invention will be further described below with reference to the accompanying drawings and embodiments. In the accompanying drawings: Figure 1 This is a schematic diagram of the component arrangement in a preferred embodiment of the power printed circuit board for the charging module of this utility model. Figure 2 This is a schematic diagram of a preferred embodiment of the power printed circuit board for the charging module of this utility model. Figure 3 This is a schematic diagram of the heat dissipation path of the power printed circuit board of the charging module of this utility model. Figure 4 This is a schematic diagram showing the location of the shielding cover on the power printed circuit board of the charging module of this utility model. Detailed Implementation
[0017] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit the present utility model.
[0018] Figure 1 This is a schematic diagram of the component arrangement of a preferred embodiment of the power printed circuit board for the charging module of this utility model. Figure 2 This is a schematic diagram of a preferred embodiment of the power printed circuit board for the charging module of this utility model. The following will be combined with... Figures 1-2 The power printed circuit board of the charging module of this utility model is described as follows.
[0019] like Figures 1-2 As shown, the power printed circuit board of the charging module of this utility model includes a board body 10, and an input electromagnetic compatibility circuit 20, a power correction circuit 30, a DC-DC conversion circuit 40, an output circuit 50, and an auxiliary power source control circuit 60 disposed on the board body 10; the input electromagnetic compatibility circuit 20, the power correction circuit 30, the DC-DC conversion circuit 40, and the output circuit 50 are arranged in a U-shape along the edge of the board body 10, and the auxiliary power source control circuit 60 is disposed at the opening of the U-shape.
[0020] In this invention, the input electromagnetic compatibility circuit 20, power correction circuit 30, DC-DC conversion circuit 40, output circuit 50, and auxiliary power source control circuit 60 can all be constructed using circuits and modular devices known in the art. The inventive point of this invention lies in the specific circuit arrangement rather than the circuit design itself, and will not be elaborated upon here.
[0021] In a preferred embodiment of this utility model, the power correction circuit 30 can be selected from a three-phase Vienna topology, the DC-DC converter circuit 40 adopts a full-bridge LLC topology, and the secondary-side rectification of the output circuit 50 can be selected from a full-bridge rectification to reduce the number of switching transistors.
[0022] The power printed circuit board of the charging module implementing this utility model arranges the input electromagnetic compatibility circuit, power correction circuit, DC-DC conversion circuit and output circuit in a U-shape along the edge of the board, and sets the auxiliary power control circuit at the opening of the U-shape. Therefore, the space utilization of the board is good, and the power loop formed is U-shaped, so the area is small.
[0023] In a preferred embodiment of this utility model, the board body 10 is a multilayer board body 10, and the input electromagnetic compatibility circuit 20, the power correction circuit 30, the DC-DC conversion circuit 40, the output circuit 50, and the auxiliary power control circuit 60 are disposed on the top layer of the board body 10. The middle layer of the board body 10 is a wiring layer, and electronic devices can be installed on its top and bottom layers.
[0024] like Figures 1-2As shown, the plate 10 is a rectangular plate; the rectangular plate 10 includes a first region 11, a second region 12, a third region 13, a fourth region 14, and a fifth region 15; the input electromagnetic compatibility circuit 20 is disposed in the first region 11, the power correction circuit 30 is disposed in the second region 12, the DC-DC conversion circuit 40 is disposed in the third region 13, the output circuit 50 is disposed in the fourth region 14, and the auxiliary power source control circuit 60 is disposed in the fifth region 15; the first region 11, the second region 12, the third region 13, and the fourth region 14 are arranged in a U-shape, and the fifth region 15 is located at the opening of the U-shape.
[0025] Specifically, the rectangular plate 10 includes five core functional areas, wherein the first area 11, the second area 12, the third area 13, and the fourth area 14 form an open "U"-shaped structure along the first, second, third, and fourth sides of the plate: the fifth area 15 is located in the opening.
[0026] like Figures 1-2 As shown, the first region 11, the second region 12, and the fifth region 15 are all rectangular regions, the third region 13 is an L-shaped region, and the fourth region 14 is a polygonal region. The first region 11, the fifth region 15, and the fourth region 14 are arranged side by side along the first side 111 of the plate 10, and the first region 11 and the second region 12 are arranged side by side along the second side 112 of the plate 10. The first side 111 of the plate 10 is perpendicular to the second side 112 of the plate 10. That is, the fifth region 15 is located between the first region 11 and the fourth region along the first side 111 of the plate 10. The third region 13 is arranged along the third side 113 and the fourth side 114 of the plate 10, and the first side of the third region 13 is adjacent to the second region 12, and the second side of the third region 13 is adjacent to the fourth region 14. The fourth region 14 is a polygonal region, with one horizontal side arranged along the fourth side 114 of the plate 10 and one vertical side arranged adjacent to the fifth region 15. The fourth region 14 covers the plate region located between the fifth region 15, the third region 13 and the second region 12.
[0027] The input electromagnetic compatibility circuit 20 includes a three-phase input interface, surge protection devices, and electromagnetic compatibility filtering devices, located in the first region 11. As previously described, the first region 11 forms the left arm of the U-shape.
[0028] The power correction circuit may be a three-phase Vienna topology, including a PFC inductor, a switching transistor, an electrolytic capacitor, a drive circuit, and a diode, located in the second region 12. As previously described, the first region 12 forms the left bottom of the U-shape.
[0029] The DC-DC converter circuit 40 may be a full-bridge LLC, which includes a high-frequency transformer, a resonant inductor, a resonant capacitor, a switching transistor, and a drive circuit; it is located in the third region 13. As previously described, the third region 13 forms the bottom right side of the U-shape.
[0030] The output circuit 50 may include a secondary-side rectification and filtering circuit, as well as an output filtering circuit, specifically including a rectifier diode, a rectifier capacitor, a filter capacitor, and an output interface; it is located in the fourth region 14. As previously described, the fourth region 14 forms the right arm of the U-shape.
[0031] The auxiliary power control circuit 60 includes a control chip, a feedback and sampling module, and auxiliary power devices, but does not include the main power devices. It is located in the fifth region 15. As mentioned earlier, the fourth region 15 is located in the U-shaped opening region, which has no main power traces.
[0032] In this invention, the input electromagnetic compatibility circuit 20, the power correction circuit 30, the DC-DC conversion circuit 40, and the output circuit 50 form a U-shaped power loop on the board 10 (i.e., Figure 2 (As shown in areas 11-15); the auxiliary power source control circuit 60 and the power correction circuit 30 form a first sampling signal loop, and the auxiliary power source control circuit 60 and the output circuit 50 form a second sampling signal loop. The first sampling signal loop and the second sampling signal loop (i.e. Figure 2 The areas shown in section 15 are isolated from each other.
[0033] Combination Figures 1-2 As can be seen, the power loop flows into the input electromagnetic compatibility circuit 20 in the left arm of the U-shape, descends along the left arm to the power correction circuit 30 and the DC-DC conversion circuit 40 at the bottom for core DC-DC conversion, and then flows upward through the secondary rectification and filtering circuit of the output circuit 50 in the right arm before exiting from the output terminal. The entire energy path is smooth, short, and without intersections. The three most critical high-frequency, high-current loops—the power correction circuit 30, the DC-DC conversion circuit 40, and the output circuit 50—are physically isolated and each constrained within one arm of the U-shape, with the loop area independently compressed to a minimum.
[0034] Combination Figures 1-2It can be seen that the sampling signal of the power correction circuit 30 flows from the left arm of the U-shape into the primary side of the auxiliary power source control circuit 60 in the open area (fifth region), and the sampling signal of the output circuit 50 flows from the right arm of the U-shape into the secondary side of the auxiliary power source control circuit 60 in the open area (fifth region). The communication between the primary and secondary sides is relayed through a digital isolator. This layout makes the control loop clear and the sampling path is not affected by the power loop.
[0035] Figure 3 This is a schematic diagram of the heat dissipation path of the power printed circuit board of the charging module of this utility model. Combined with... Figures 1-3 It can be seen that the main heat sources, such as the PFC inductor, high-frequency transformer, switching transistor, transformer, and rectifier in the input electromagnetic compatibility circuit 20, power correction circuit 30, DC-DC conversion circuit 40, and output circuit 50, are placed on the three arms of the U-shape respectively, thus avoiding the concentrated accumulation of heat.
[0036] Due to size limitations, a heat dissipation structure cannot be installed on the top layer A of the board. Therefore, a heat dissipation through-hole 16 and a busbar 17 are formed on the board 10 at position A1 opposite to the patch of the top layer A, connecting the intermediate layer B and the bottom layer C. A heat dissipation pad is installed on the bottom layer C of the board 10. The first side of the heat dissipation pad contacts the heat dissipation through-hole 16 and the busbar 17, and the second side contacts the heat sink. This allows the heat generated by the heat source on the top layer to be efficiently conducted to the bottom layer, and then dissipated to the heat sink through the heat dissipation pad, achieving uniform vertical heat dissipation facing the bottom.
[0037] Figure 4 This is a schematic diagram showing the location of the shielding cover on the power printed circuit board of the charging module of this utility model. (See diagram for example.) Figure 4 As shown, a complete ground plane is constructed below the opening area (fifth region). If necessary, shielding covers 18 can be installed at the left and right arm edges of the U-shape to further isolate the power region from the radiation interference of the control region. Specifically, the shielding cover 18 is located at the dividing line between the first region 11 and the fifth region 15; the shielding cover 18 is located at the dividing line between the fourth region 14 and the fifth region 15; the shielding cover 18 is located at the dividing line between the fourth region 14 and the second region 12; and / or the shielding cover 18 is located between the primary and secondary side dividing line 19 of the auxiliary power transformer in the fifth region 15.
[0038] Furthermore, the three-phase input interface is located in the first region 11, and the output interface is located in the fourth region 14, with the three-phase input interface and the output interface arranged along the diagonal of the rectangular plate 10. The input and output ports are physically isolated at diagonal positions, effectively preventing near-field coupling between the input and output cables. This is crucial for suppressing conducted and radiated EMI and achieving crosstalk optimization.
[0039] The power printed circuit board for the charging module of this invention arranges the input electromagnetic compatibility circuit, power correction circuit, DC-DC conversion circuit, and output circuit in a U-shape along the edge of the board. The auxiliary power control circuit is located at the opening of the U-shape. Therefore, the space utilization of the board is good, and the formed power loop is U-shaped, resulting in a small area. Furthermore, the power printed circuit board for the charging module of this invention adopts a three-phase Vienna topology + full-bridge LLC topology, achieving excellent heat dissipation, superior EMI performance, reliable safety design, stable performance, and compact structure. Preferably, the power printed circuit board for the charging module of this invention can realize the design of an 11KW charging module with IP65 protection rating on a PCB size of 258mm*337mm.
[0040] Although this utility model has been described through specific embodiments, those skilled in the art should understand that various modifications and equivalent substitutions can be made to this utility model without departing from its scope. Furthermore, various modifications can be made to this utility model for specific situations or materials without departing from its scope. Therefore, this utility model is not limited to the specific embodiments disclosed, but should include all embodiments falling within the scope of the claims of this utility model.
[0041] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.
Claims
1. A printed circuit board for a charging module power supply, characterized in that, The device includes a board body, and an input electromagnetic compatibility circuit, a power correction circuit, a DC-DC conversion circuit, an output circuit, and an auxiliary power source control circuit disposed on the board body; the input electromagnetic compatibility circuit, the power correction circuit, the DC-DC conversion circuit, and the output circuit are arranged in a U-shape along the edge of the board body, and the auxiliary power source control circuit is disposed at the opening of the U-shape.
2. The power printed circuit board for the charging module according to claim 1, characterized in that, The plate is a rectangular plate; the rectangular plate includes a first region, a second region, a third region, a fourth region, and a fifth region; the input electromagnetic compatibility circuit is located in the first region, the power correction circuit is located in the second region, the DC-DC conversion circuit is located in the third region, the output circuit is located in the fourth region, and the auxiliary power source control circuit is located in the fifth region; the first region, the second region, the third region, and the fourth region are arranged in a U-shape, and the fifth region is located at the opening of the U-shape.
3. The power printed circuit board for the charging module according to claim 2, characterized in that, The input electromagnetic compatibility circuit, the power correction circuit, the DC-DC converter circuit, and the output circuit form a U-shaped power loop on the board.
4. The power printed circuit board for the charging module according to claim 3, characterized in that, The auxiliary power source control circuit and the power correction circuit form a first sampling signal loop, and the auxiliary power source control circuit and the output circuit form a second sampling signal loop. The first sampling signal loop and the second sampling signal loop are isolated from each other.
5. The power printed circuit board for the charging module according to claim 4, characterized in that, The input electromagnetic compatibility circuit includes a three-phase input interface, surge protection devices, and electromagnetic compatibility filtering devices; the power correction circuit includes a PFC inductor, a switching transistor, an electrolytic capacitor, a driving circuit, and diodes; the DC-DC conversion circuit includes a high-frequency transformer, a resonant inductor, a resonant capacitor, a switching transistor, and a driving circuit; the output circuit includes a rectifier diode, a rectifier capacitor, a filter capacitor, and an output interface; the auxiliary power source control circuit includes a control chip, a feedback and sampling module, and auxiliary power source devices.
6. The power printed circuit board for the charging module according to claim 5, characterized in that, The first region, the second region, and the fifth region are all rectangular regions, the third region is an L-shaped region, and the fourth region is a polygonal region; The first region, the fifth region, and the fourth region are arranged side by side along the first side of the plate, and the first region and the second region are arranged side by side along the second side of the plate. The first side of the plate is perpendicular to the second side of the plate. The third region is disposed along the third and fourth sides of the plate, and the first side of the third region is adjacent to the second region, and the second side of the third region is adjacent to the fourth region; The fourth region has a horizontal side edge along the fourth side edge of the plate and a vertical side edge adjacent to the fifth region. The fourth region covers the plate area located between the fifth region, the third region, and the second region.
7. The power printed circuit board for the charging module according to claim 6, characterized in that, The three-phase input interface is located in the first region, the output interface is located in the fourth region, and the three-phase input interface and the output interface are arranged along the diagonal of the rectangular plate.
8. The power supply printed circuit board for the charging module according to any one of claims 1 to 7, characterized in that, The board is a multi-layer board. The input electromagnetic compatibility circuit, the power correction circuit, the DC-DC conversion circuit, the output circuit, and the auxiliary power control circuit are located on the top layer of the board. The board has heat dissipation vias and busbars that penetrate the middle and bottom layers of the multi-layer board.
9. The power printed circuit board for the charging module according to claim 8, characterized in that, The top layer is provided with a patch, and the heat dissipation vias and the busbars are directly opposite the patch; The bottom layer of the plate is provided with a heat dissipation pad, the first side of the heat dissipation pad contacts the heat dissipation through hole and the busbar, and the second side contacts the heat sink.
10. The power printed circuit board for the charging module according to any one of claims 2-7, characterized in that, Further includes a shielding cover; The shielding cover is located at the dividing line between the first region and the fifth region; The shielding cover is located at the dividing line between the fourth region and the fifth region; The shielding cover is located at the dividing line between the fourth region and the second region; and / or The shielding cover is located between the primary and secondary sides of the auxiliary power transformer in the fifth region.