On-Board Charging Module Layout for Compact Transformer Mounting
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Solution Overview
Problem
The existing on-board power supply systems in vehicles require separate mounting of large DC transformers and PFC inductors, leading to complex assembly procedures, excessive components, high costs, and reduced space utilization due to the need for additional fixation structures.
Innovation Solution
A charging module integrates a substrate with a first transformer, PFC inductor, and second transformer, fixedly connected to reduce area occupation, simplify assembly, and improve thermal management, using adhesive fixation and limiting grooves without additional structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate mounting structures are used for DC transformers and PFC inductor, then each component can be independently fixed, but the assembly procedure becomes complicated and additional fixation structures are needed
Solution Approach 1:
The patent integrates multiple independent components (first DC transformer, second DC transformer, and PFC inductor) onto a single common substrate. This merging approach eliminates the need for separate fixation structures for each component, simplifying the assembly procedure while maintaining reliable fixation of all components through their unified mounting platform.
2Reliability
If additional fixation structures are added to fix DC transformers and PFC inductor, then component fixation is ensured, but the number of components increases and costs rise
Solution Approach 1:
The common substrate serves as a universal fixation platform that simultaneously mounts the first DC transformer, second DC transformer, and PFC inductor. This multi-functional substrate replaces multiple individual fixation structures, reducing the total number of components needed while ensuring reliable fixation of all power supply components.
3Reliability
If separate fixation structures are used for each transformer and inductor, then each component can be securely mounted, but the overall area occupied increases
Solution Approach 1:
By consolidating multiple components onto a single common substrate, the patent reduces the total area occupied compared to separate mounting arrangements. The integrated configuration allows for optimized spatial utilization while maintaining secure mounting of all components through their shared attachment platform.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates miniaturization, enhances space utilization, simplifies assembly, reduces costs, and improves thermal management by integrating transformers and inductors on a single substrate with adhesive fixation and grooves.
Implementation Method 1
The first transformer, the PFC inductor, and the second transformer are fixed to the substrate by dispensing an adhesive
Data Source
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AI summary
The present disclosure discloses a charging module, an on-board power supply, and a vehicle. The charging module includes a substrate, a first transformer, a power factor correction (PFC) inductor, and a second transformer. The first transformer, the PFC inductor, and the second transformer are fixed to the substrate. The first transformer, the PFC inductor, and the second transformer are fixedly connected with the substrate. Therefore, the first transformer, the PFC inductor, and the second transformer independent of each other are configured to integrate into a device, which can reduce an area occupied by the first transformer, the PFC inductor, and the second transformer, thereby facilitating miniaturization of the on-board power supply, and then increasing a space utilization rate of the vehicle. In addition, the first transformer, the PFC inductor, and the second transformer are configured to integrate into a device through the substrate without needing an additional fixation structure. Therefore, an assembly is relatively simple, development costs can be reduced, and a heat generated by the first transformer, the PFC inductor, and the second transformer can be collected and then processed, thereby improving a thermal management capability.