Power conversion electronic devices for electric or hybrid vehicles

Abstract

A power conversion electronic device (1) for an electric or hybrid vehicle, which can be installed inside at least one electric or hybrid vehicle and can be connected to at least one battery of the vehicle, said power conversion electronic device (1) comprising an outer container (2), an electronic circuit (3) housed in said container (2), said electronic circuit (3) being connectable to the battery and comprising a plurality of electric components (4) configured to convert an input current / voltage into a predetermined output current / voltage and transmit it to the battery, at least one cover (5) intended to close the container (2) on top, and at least one layer (6) positioned between the electric components (4) and the cover (5) and made at least in part from an elastically deformable material, said elastically deformable material being arranged in contact with each of the electric components (4) and adapted to damp vibrations transmitted to the electric components (4) by the electric vehicle.

Description

[Technical field]

[0001] The present invention relates to a power conversion electronic device for electric or hybrid vehicles, of the type of charger (so-called "on-board charger", OBC) or DC / DC converter that can be installed in an electric or hybrid vehicle and connected to the vehicle's battery. [Background technology]

[0002] As is known, electric and hybrid vehicles are equipped with power electronic devices, such as chargers (so-called "on-board chargers", OBC) or DC / DC converters, equipped with special electrical components (in particular of the electrolytic and / or film capacitor type), adapted to perform a conversion of an input voltage / current into a corresponding predetermined output voltage / current.

[0003] With reference to such electrical components, there has recently been an increasing need to reduce the stresses to which the electrical component is subjected during its operational life, in order to preserve its structural integrity and resulting functionality for as long as possible.

[0004] In this regard, it is well known that when a vehicle is in motion it generates vibrations which, in the long term, can damage electrical components and shorten their lifespan, as a result of the vibrations transmitted to the electrical components causing stresses on the electrical components.

[0005] To at least partially address this problem, a technical solution is known which involves applying a drop of adhesive (e.g., a type of silicone adhesive) between one electrical component and another electrical component.

[0006] In fact, the adhesive applied in this way damps the vibrations transmitted from the electric vehicle to the electrical components, thus making it possible, at least in part, to reduce the stresses to which the electrical components are subjected when the vehicle is in motion.

[0007] In this manner, the structural integrity of the electrical components can be maintained for a longer extended operational life.

[0008] Nevertheless, the above mentioned technical solutions are not without their drawbacks.

[0009] First, it should be noted that power conversion electronics can have a large number of electrical components therein.

[0010] This means that the amount of adhesive that needs to be applied between electrical components is likely to be equally high.

[0011] Moreover, the application of such a quantity of adhesive inevitably requires a rather long operating time, which ultimately has a negative impact on the yield of the equipment.

[0012] This fact leads, inter alia, to an increase in the selling price of the equipment. Summary of the Invention

[0013] Description of the Invention The main objective of the present invention is to devise a power conversion electronics for electric or hybrid vehicles, which allows reducing the mechanical stresses experienced by the electrical components due to vibrations while the vehicle is in motion, while at the same time shortening the production time and reducing the associated sales costs compared to the prior art.

[0014] Another object of the present invention is to devise a power conversion electronics for electric or hybrid vehicles that is simple, rational, easy and effective to use, as well as overcomes the aforementioned drawbacks of the prior art within the scope of a cost-effective solution.

[0015] The aforementioned object is achieved by this power conversion electronic device for electric or hybrid vehicles having the features of claim 1.

[0016] Other features and advantages of the present invention will become more apparent from the description of preferred, but not exclusive, embodiments of a power conversion electronic device for an electric or hybrid vehicle, illustrated by way of suggestive but non-limiting example in the accompanying drawings, in which: [Brief description of the drawings]

[0017] [Figure 1] FIG. 2 is an axonometric exploded view of an apparatus according to the present invention. [Diagram 2] FIG. 2 is an axonometric exploded view of an apparatus according to the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] With particular reference to these figures, the numeral 1 generally indicates power conversion electronics for an electric or hybrid vehicle.

[0019] According to one possible embodiment, device 1 consists of a charger or on-board charger ("OBC"), which is installed in an electric or hybrid vehicle and can be connected to the vehicle's battery.

[0020] Alternatively, according to another possible embodiment, the device 1 consists of a DC / DC converter, which can be installed in an electric or hybrid vehicle and connected to the vehicle's battery.

[0021] In all cases, a power conversion electronic device 1 for an electric or hybrid vehicle that can be installed inside at least one electric or hybrid vehicle and can be connected to at least one battery of the vehicle, the power conversion electronic device 1 comprising: at least one external container 2; at least one electronic circuit 3 housed in a container 2, the electronic circuit 3 being connectable to the battery and comprising a number of electrical components 4 (in particular of the electrolytic and / or film capacitor type) adapted to convert an input current / voltage into a given output current / voltage which it transmits to the battery; at least one cover 5 intended to close the container 2 on top;

[0022] In particular, the electronic circuit 3 comprises one or more power electronic boards on which power components (for example of the active semiconductor type) and electrical components 4 are provided.

[0023] In the present case, the electronic control board makes it possible to carry out the regulation of the various power and / or electrical components 4, for example depending on the input current / voltage to the device 1.

[0024] The power panels and control electronic boards are in particular of the type conventionally used in OBCs or DC / DC converters that can be installed in electric or hybrid vehicles.

[0025] According to the invention, the device 1 comprises at least one layer 6 positioned between the electrical components 4 and the cover 5 , which is placed in contact with each of the electrical components 4 .

[0026] In actual fact, layer 6 is placed on top of the various electrical components 4 and is precisely positioned between the top of the electrical components 4 and the underside of cover 5 (i.e. the surface facing the inside of container 2).

[0027] In particular, layer 6 is adapted to damp vibrations transmitted to electrical component 4 by the electric vehicle.

[0028] In this sense, the layer 6 is at least partially made from an elastically deformable material.

[0029] In particular, layer 6 is of the sponge type.

[0030] Importantly, the option of making the layer 6 of an elastically deformable material proves particularly advantageous in this context.

[0031] This property in fact causes the crushing of layer 6 induced by closing cover 5 to elastically deform itself and to wedged between one and the other of components 4 .

[0032] This increases the contact surface area between layer 6 and electrical component 4 , which has the obvious direct consequence of enabling vibrations transmitted to component 4 to be damped even more effectively.

[0033] In order to further reduce the stresses experienced by the electrical component 4, the layer 6 is provided with at least one adhesive surface 7, which faces the electrical component 4 and is associated therewith in an adhesive manner.

[0034] In actual fact, layer 6 is adhered to the top of electrical component 4 by means of adhesive surface 7 .

[0035] As expected, the bonding of adhesive surface 7 to electrical component 4 acts synergistically in conjunction with the elastically deformable material that constitutes layer 6 to ensure a significant reduction in the stress experienced by electrical component 4 .

[0036] In fact, the bonding pressure generated between the layer 6 and the electrical component 4 makes it possible to dissipate most of the vibrations transmitted to the electrical component 4, reducing their intensity and thus avoiding any adverse effects on the electrical component itself.

[0037] In describing these advantages we would like to add that the layer 6 is preferably made, at least in part, from an electrically insulating material.

[0038] In this regard, it should be noted that the electrical component 4 operates at high voltage and, as such, sufficient space must be left between the electrical component 4 and the cover 5 to avoid any risk of electrical conduction between the two and any resulting danger to the safety of vehicle passengers.

[0039] Although justified by this reason, this fact inconveniently leads to an increase in the overall dimensions of the equipment 1 and sometimes ends up complicating the installation of the equipment 1 in the vehicle (for example when the vehicle results in a reduction in the space in which the equipment 1 can be placed).

[0040] With all this in mind, it is easy to realize that by providing layer 6 made from an elastically deformable electrically insulating material, it is possible to both reduce the overall dimensions of device 1 (by crushing layer 6 and forcing layer 6 between the various electrical components 4 by closing cover 5) and at the same time ensure the completion of the electrical insulation of device 1.

[0041] According to a first embodiment, the layer 6 is at least partially made from at least one thermally conductive material.

[0042] Layer 6 can therefore be used to advantage not only to reduce the stress experienced by electrical component 4 due to vibration, but also to effectively dissipate heat generated by the electrical component itself when in operation.

[0043] More specifically, the layer 6 according to this first embodiment is entirely made of a thermally conductive material.

[0044] According to a second embodiment, which is an alternative to the previous one, the layer 6 comprises a number of heat dissipation openings, which are not shown for the sake of simplicity.

[0045] Specifically, each of the openings is located at a point where a respective electrical component 4 is located and is at least partially filled with at least one thermally conductive material.

[0046] In actual fact, in this second embodiment, the thermally conductive material is present inside the opening and thus only at the point where the electrical component 4 is located.

[0047] It is easy to appreciate that the method of the above-described embodiment allows for effective dissipation of heat generated by electrical component 4, using a reduced amount of thermally conductive material to do so.

[0048] In this way, the manufacturing costs of layer 6 and the resulting retail price of device 1 can be significantly reduced.

[0049] The openings can be obtained by stamping out the layer 6 or by different technological processes, which in all cases make it possible to obtain openings which can be filled, at least partially, with a thermally conductive material.

[0050] In this context, the thermally conductive material is preferably of the thermally conductive foam type, although it cannot still be excluded that it may, at least in part, be of a different type known to a person skilled in the art.

[0051] In fact, it has been determined that the invention as described achieves its intended objectives.

[0052] In particular, the fact is highlighted that the special measures of providing an elastically deformable layer arranged in contact with each of the components make it possible to effectively damp the vibrations transmitted by the vehicle in motion to the components, thereby reducing the stresses experienced by the components and thus increasing their operational lifespan.

Claims

1. A power conversion electronic device (1) for an electric vehicle or a hybrid vehicle, which can be installed inside at least one electric vehicle or a hybrid vehicle and can be connected to at least one battery of the vehicle, at least one outer container (2), at least one electronic circuit (3) housed in said container (2), said at least one electronic circuit (3) comprising a number of electrical components (4) connectable to said battery and adapted to convert an input current / voltage to transmit a given output current / voltage to said battery; - at least one cover (5) intended to close said container (2) on top, The power conversion electronic device (1), characterized by the fact that the electronic circuit (3) is positioned between the electrical components (4) and the cover (5), comprises at least one layer (6) made at least in part from an elastically deformable material, arranged in contact with each of the electrical components (4) and adapted to damp vibrations transmitted to the electrical components (4) by the electric vehicle.

2. 2. Device (1) according to claim 1, characterised by the fact that said layer (6) is made, at least in part, from an electrically insulating material.

3. 3. The device (1) according to claim 1 or 2, characterized by the fact that said layer (6) is provided with at least one adhesive surface (7), said adhesive surface (7) facing said electrical component (4) and associated with said electrical component (4) in an adhesive manner.

4. Device (1) according to any of the claims 1 to 3, characterised by the fact that said layer (6) is made, at least in part, from at least one heat conducting material.

5. The device (1) according to any of claims 1 to 3, characterized by the fact that said layer (6) comprises a plurality of heat dissipation openings, each of said openings being located at a point where a respective one of said electrical components (4) is located, and being at least partially filled with at least one heat conducting material.

6. Device (1) according to claim 4 or 5, characterized by the fact that said thermally conductive material is of the thermally conductive foam type.

7. Device (1) according to any of the preceding claims, characterized by the fact that said layer (6) is of the sponge type.

8. The device (1) according to any of the preceding claims, characterized by the fact that said device (1) consists of an OBC.

9. Device (1) according to any of the claims 1 to 7, characterised by the fact that said device (1) consists of a DC / DC converter.

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