Power distribution and control board

Abstract

Power distribution and control board for distributing high current between a power source and one or more subsystems and / or components, and for controlling the distribution of the high current. - a mechanical interface for the mechanical connection of an electrical component, wherein the mechanical interface ensures that the component remains electrically independent of the power distribution and control board after the mechanical connection; - a sensor for measuring the current strength of a current carried by the mechanically connected and electrically independent component, wherein the sensor is mounted directly on the power distribution and control board; wherein the interface is arranged such that it fixes the component in an area relevant to the sensor; and Power distribution and control board arrangement comprising - a power distribution and control board for distributing high current between a power source and one or more subsystems and / or components and for controlling the distribution of the high current; - a component mechanically connected to the power distribution and control board, which is electrically independent of the power distribution and control board; - a sensor for measuring the current strength of a current carried by the mechanically connected and electrically independent component.

Description

AREA OF INVENTION

[0001] The present invention relates to a power distribution and control board as well as a power distribution and control board arrangement.

[0002] DE 10 2024 206 233 A1 discloses a busbar sensor arrangement comprising a busbar, a printed circuit board with a sensor which is configured to acquire sensor data relating to the busbar, an overmolding of the busbar and a fastening means, as well as a method for manufacturing a busbar sensor arrangement. SUMMARY OF THE INVENTION

[0003] Accordingly, the following is planned: - A power distribution and control board for distributing high current between a power source and one or more subsystems and / or components and for controlling the distribution of the high current, comprising a mechanical interface for mechanically connecting an electrical component, wherein the mechanical interface ensures that the component remains electrically independent of the power distribution and control board after the mechanical connection; a sensor for measuring the current strength of a current carried by the mechanically connected and electrically independent component, wherein the sensor is mounted directly on the power distribution and control board; wherein the interface is arranged such that it fixes the component in an area relevant to the sensor; and - a power distribution and control board assembly comprising a power distribution and control board for distributing high current between a power source and one or more subsystems and / or components and for controlling the distribution of the high current; a component mechanically connected to the power distribution and control board which is electrically independent of the power distribution and control board; a sensor for measuring the intensity of current carried by the mechanically connected and electrically independent component.

[0004] A sensor, also known as a detector, transducer, or sensor, is a technical component that can qualitatively or quantitatively detect certain physical or chemical properties or conditions, such as temperature, humidity, pressure, speed, brightness, acceleration, pH value, ionic strength, electrochemical potential, and / or the material composition of its environment. These quantities are detected using physical or chemical effects and converted into a processable electrical signal as sensor data.

[0005] A current control and distribution board (CCDB) is a printed circuit board designed for controlling and distributing high electrical currents within a system. Unlike a conventional printed circuit board (PCB), which primarily serves to connect and control signals and small currents, a CCDB is designed for handling and monitoring high-current applications.

[0006] A CCDB is suitable for carrying high currents, in the range of one or several hundred amperes. This is made possible by the use of wide conductor tracks, thicker copper layers (over 105 µm), and integrated busbars that distribute the current. In contrast, a printed circuit board (PCB) is generally designed for carrying signals and low to medium currents, typically below 10 amperes, and uses thinner copper layers, usually between 35 µm and 70 µm.

[0007] In addition to its current-carrying capacity, a CCDB can incorporate integrated current sensors and control circuitry that allow for monitoring and regulating the current flow within the power distribution and control board. These components detect overcurrent conditions and trigger protective mechanisms.

[0008] Due to the high currents flowing through a CCDB, it may incorporate thermal management techniques such as thermally conductive materials, heat dissipation, and possibly heat sinks.

[0009] The mechanical structure of a CCDB can be designed to withstand high physical loads, using reinforced materials and robust constructions to meet the demands of high-current applications.

[0010] While a CCDB is designed for high-current applications or power electronics, a PCB is generally used primarily for signal processing and low-current routing.

[0011] A power distribution and control board assembly comprises a power distribution and control board and another component.

[0012] Thermal forming encompasses various techniques in which material is plastically deformed through the controlled application of heat to create permanent bonds or specific structures. Hot riveting is one example of thermal forming.

[0013] Hot riveting involves deforming a protruding part of a first component, often called a dome, using heat and pressure to create a mechanical connection with a second component. The process begins by inserting the dome through a recess, such as a hole, into the second component. Heat is then applied to the dome, softening the material and making it plastically deformable. Once the dome is sufficiently heated, pressure is applied to deform it. The dome material expands, forming a mushroom-shaped cap that extends over the edge of the hole in the second component. After cooling, the material hardens again, creating a stable and permanent mechanical connection.

[0014] Hot riveting ensures a secure and firm connection without the need for additional fasteners. The cap formed by the crimping process provides high mechanical stability, particularly resistant to tensile forces, vibrations, and other mechanical stresses. Because the joining process takes place entirely within the material itself, the structure remains lightweight and a compact connection is created.

[0015] A busbar, also known as a conductor rail, is a conductive piece of metal used in electrical systems to distribute electrical power. It is designed to carry large amounts of electric current. Busbars are typically made of materials such as copper or aluminum.

[0016] The core of the invention lies in the use of a power distribution and control board that is mechanically connected to an electrically independent component in order to monitor the current flow through this component using a sensor integrated into the power distribution and control board. This arrangement enables the control and monitoring of the current in the component without requiring a direct electrical connection between the power distribution and control board and the current-carrying component.

[0017] This arrangement allows for the effective distribution and control of current flow while minimizing electrical interference or disturbances, as the mechanical connection between the power distribution and control board and the current-carrying component does not involve an electrical connection. Current monitoring is performed by a sensor that detects the current flow in the mechanically connected component, enabling precise control and monitoring of the component's current behavior.

[0018] Thus, the power distribution and control board can be used to take over functionalities, in this case current measurement, of a component whose main functionality can be independent of the power distribution and control board.

[0019] The mechanical connection between the component and the power distribution and control board ensures stable and reliable measurement results from the sensor.

[0020] The sensor is mounted directly and securely onto the power distribution and control board, enabling it to function without additional cables, connectors, or external components. The sensor is directly connected to the board's circuit traces or circuitry, creating a seamless electrical connection that requires no further mechanical or electrical connections outside the board.

[0021] Accordingly, the invention comprises both a power distribution and control board and a power distribution and control board assembly. A power distribution and control board is suitable for manufacturing a power distribution and control board assembly and comprises a mechanical interface for mechanically connecting an electrical component, wherein the mechanical interface ensures that the component remains electrically independent of the power distribution and control board after the mechanical connection, and a sensor for measuring the current of a current supplied by the mechanically connected and electrically independent component, wherein the sensor is mounted directly on the power distribution and control board, and wherein the interface is arranged such that it fixes the component in an area relevant to the sensor.

[0022] Advantageous designs and further developments result from the further sub-claims as well as from the description with reference to the figures in the drawing.

[0023] According to a preferred embodiment of the invention, the component is designed as a busbar. This allows the current monitoring of a busbar that runs close to the power distribution and control board, but is not electrically coupled to it, to be ensured by the power distribution and control board itself. This eliminates the need to provide and integrate a separate board for monitoring the busbar's current.

[0024] According to a preferred embodiment of the invention, the mechanical connection is produced by thermal deformation, in particular by hot riveting.

[0025] This ensures stable fastening of the components and makes the use of additional mechanical connecting elements obsolete.

[0026] According to a preferred embodiment of the invention, the sensor has a wireless interface to a control unit which is configured to control current supplied by the mechanically connected and electrically independent component.

[0027] This ensures flexible placement of the sensor near the power rail and simplifies installation, as no additional cable connections to the control unit are required. CONTENT OF THE DRAWINGS

[0028] The present invention will be explained in more detail below with reference to the exemplary embodiments shown in the schematic figures of the drawings. These show: Fig. 1 a perspective overview of an embodiment of the invention; Fig. 2a perspective detail view of an embodiment of the invention;

[0029] The accompanying drawings are intended to provide a further understanding of the embodiments of the invention. They illustrate embodiments and, in conjunction with the description, serve to explain the principles and concepts of the invention. Other embodiments and many of the advantages mentioned will become apparent with reference to the drawings. The elements of the drawings are not necessarily shown to scale.

[0030] In the figures of the drawings, identical, functionally equivalent and equally effective elements, features and components - unless otherwise stated - are each provided with the same reference symbols. DESCRIPTION OF EXAMPLES OF EXECUTION

[0031] Fig. 1 and Fig. Figure 2 shows a perspective view of a power distribution and control board arrangement 1 comprising a power distribution and control board 10 for distributing high current between a power source (not shown) and one or more subsystems and / or components (not shown) and for controlling the distribution of the high current, a component 2 mechanically connected to the power distribution and control board 10 by hot staking, which is designed as a busbar and is electrically independent of the power distribution and control board 10, and a sensor 3 for measuring the current strength of the current carried by the mechanically connected and electrically independent component 2.

[0032] Fig. Figure 1 shows an overview. Fig. Figure 2 shows a section 100 from Fig. 1.

[0033] The drawings illustrate the mechanical connection by hot riveting using a first and a second hot riveted domes 4, 5 of the busbar, which is passed through recesses provided for this purpose in the power distribution and control board 10. Reference sign 1 Power distribution and control board arrangement 10 Power distribution and control board 2 components 3 Sensors 4 Domes 5 Dome 100 excerpts

Claims

[1] Power distribution and control board (10) for distributing high current between a power source and one or more subsystems and / or components (2) and for controlling the distribution of the high current comprising - a mechanical interface for the mechanical connection of an electrical component (2), wherein the mechanical interface ensures that the component (2) remains electrically independent of the power distribution and control board after the mechanical connection; - a sensor (3) for measuring the current strength of a current supplied by the mechanically connected and electrically independent component, wherein the sensor (3) is mounted directly on the power distribution and control board (10); wherein the interface is arranged such that it fixes the component (2) in an area relevant to the sensor (3). [2] Power distribution and control board arrangement (1) comprising - a power distribution and control board (10) for distributing high current between a power source and one or more subsystems and / or components and for controlling the distribution of the high current; - a component (2) mechanically connected to the power distribution and control board (10), which is electrically independent of the power distribution and control board; - a sensor (3) for measuring the current strength of the current supplied by the mechanically connected and electrically independent component (2). [3] Power distribution and control board arrangement (1) according to claim 2, wherein the component (2) is designed as a busbar. [4] Power distribution and control board arrangement (1) according to one of the preceding claims 2 or 3, wherein the mechanical connection is made by thermal deformation, in particular by hot riveting. [5] Power distribution and control board arrangement (1) according to any one of the preceding claims 2 to 4, wherein the sensor (3) has a wireless interface to a control unit which is configured to control current supplied by the mechanically connected and electrically independent component (2).

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