Insertion-Molded Power Feeding Lines for EV Charging
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Solution Overview
Problem
Conventional power feeding control apparatuses for electric vehicles face challenges in reducing size while maintaining high current capacity and efficient insulation, leading to increased size and restricted current flow due to pattern-formed power feeding lines on substrates.
Innovation Solution
A power feeding control apparatus with metal plates constituting the power feeding lines, insertion-molded into a block, which reduces insulation distance, allows for a compact design, and enables high current supply, along with a relay unit, control circuit, leakage current detection, and power supply circuit within a housing, and uses lead plates for electrical connections to prevent disconnection and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If power feeding lines are formed as patterns on a substrate, then the ease of assembly is improved, but the insulating distance must be secured which increases the external dimension of the substrate and the overall size of the power feeding control apparatus
Solution Approach 1:
The patent merges the power feeding lines with the substrate by forming conductive patterns directly on the substrate surface, eliminating the need for separate wire connections and terminal blocks. This integration reduces the overall size while maintaining ease of assembly through standardized mounting procedures.
Solution Approach 2:
The patent transitions from three-dimensional wire connections to two-dimensional patterned conductors on the substrate surface. This dimensional change allows for compact layout optimization and reduces the insulating distance requirements in the third dimension, thereby reducing the overall apparatus size.
2Ease of manufacture
If power feeding lines are formed as patterns on a substrate, then the ease of assembly is improved, but the amount of electric current flowing through the power feeding lines is restricted
Solution Approach 1:
The patent changes the physical parameters of the conductive patterns by using thick copper foil (e.g., 35 µm or more) as the substrate material and forming wide conductive traces. This increases the cross-sectional area of the power feeding lines, thereby increasing the current-carrying capacity while maintaining the patterned formation advantage.
Solution Approach 2:
The patent uses composite construction with copper-clad rigid or flexible PCB substrates, combining the electrical conductivity of copper with the structural properties of the substrate material. This allows high current capacity while maintaining the ease of assembly benefits of patterned conductors.
3Reliability
If the insulating distance is secured between patterns, then the safety is improved, but the external dimension of the substrate increases
Solution Approach 1:
The patent applies different insulating distance requirements to different areas of the substrate. Critical high-voltage areas have increased clearance and creepage distances, while low-voltage signal areas use standard spacing. This localized approach maintains safety where needed while minimizing overall substrate size.
Solution Approach 2:
The patent uses multi-layer PCB construction where conductive patterns on different layers are separated by insulating substrate material. This nesting approach provides electrical isolation and safety without requiring increased external dimensions, as the insulating distance is achieved in the vertical dimension rather than the horizontal plane.
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
The solution reduces the size of the apparatus, enhances current capacity, improves noise control, and simplifies manufacturing by integrating metal plates and lead plates, while ensuring reliable electrical connections and efficient leakage current detection.
Implementation Method 1
The metal plates are insertion-molded in the power feeding line block.
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
A power feeding control apparatus includes a housing for accommodating at least a relay unit arranged on power feeding lines to open and close the power feeding lines, a control circuit for controlling the relay unit, a leakage current detection circuit for detecting leakage current in an electric vehicle and a power supply circuit for generating a control electric power. The apparatus further includes a power source side connector removably connected to a socket of an external power source, a vehicle side connector removably connected to a power receiving connector of the electric vehicle and a first and a second board that the power supply circuit and the control circuit are mounted, respectively. A power feeding line block provided separately from the first and the second board and having metal plates constituting the power feeding lines. The metal plates are insertion-molded in the power feeding line block.