Hub PCB Electrical Interconnection System for EV Modules
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Solution Overview
Problem
Existing electrical interconnection systems for electric and hybrid electric vehicle modules face challenges with bulky components, thick wiring, layout restrictions, and manual assembly, leading to quality risks, electromagnetic compatibility issues, and increased costs due to the need for robust connections and guide frames.
Innovation Solution
An electrical interconnection system utilizing a hub printed circuit board (PCB) with conductive tracks and terminals that connect external electrical components, allowing for simplified and automated assembly, reduced height, and improved electromagnetic compatibility without the need for screws or guide frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate connecting wires with heavier gauges are used to handle high currents, then the electrical connection reliability is improved, but the wire thickness increases causing physical interference with other internal elements and module cover closure
Solution Approach 1:
The patent combines multiple separate connecting wires into a single integrated PCB trace system. The PCB integrates multiple conductive paths that were previously requiring separate thick wires, thereby reducing the overall volume and eliminating physical interference while maintaining electrical connection reliability through controlled impedance and standardized trace designs.
Solution Approach 2:
The patent replaces the mechanical wire connection system with an integrated PCB electrical connection system. Instead of using separate physical wires with connectors and terminals, the electrical connections are achieved through PCB traces and solder joints, eliminating the need for manual wire routing and reducing physical space requirements.
2Ease of manufacture
If cables or wires are routed to cross over each other due to layout restrictions, then the connection between components is achieved, but electromagnetic compatibility is degraded and quality risks increase
Solution Approach 1:
The patent replaces the mechanical cable routing system with an integrated PCB trace system that eliminates the need for physical cable crossings. The PCB layout allows for optimized trace routing that avoids electromagnetic interference issues inherent in crossed cables, while maintaining all necessary electrical connections through controlled impedance traces.
Solution Approach 2:
The patent utilizes the third dimension by routing PCB traces on multiple layers rather than forcing all connections to occur on a single plane. This allows connections to be achieved without physical crossings by utilizing vertical separation between PCB layers, thereby eliminating electromagnetic compatibility issues associated with crossed cables.
3Object-affected harmful factors
If fixed routing elements are integrated with wiring to ensure stable routing, then electromagnetic compatibility is improved, but device complexity and manufacturing cost increase due to guide frames and routing structures
Solution Approach 1:
The patent merges the routing function directly into the PCB structure itself. The PCB substrate and trace layout provide the necessary routing guidance and electromagnetic shielding without requiring separate guide frames or additional routing structures. The PCB serves both as the electrical connection medium and the routing constraint structure.
Solution Approach 2:
The PCB performs multiple functions simultaneously: it provides electrical connections, defines wireless routing paths, provides electromagnetic shielding, and serves as the mechanical support structure. This multi-functionality eliminates the need for separate routing elements and reduces overall device complexity.
4Adaptability or versatility
If manual assembly steps are used for wiring connections, then flexibility in connection configuration is maintained, but assembly time increases and opportunities for errors increase
Solution Approach 1:
The patent replaces manual wire connection operations with automated PCB assembly processes. The PCB is pre-configured with traces and terminals that define all necessary connections, allowing for automated placement and soldering operations that eliminate manual wiring while maintaining design flexibility through PCB layout variations.
Solution Approach 2:
The patent performs the connection configuration work during the PCB design and manufacturing phase rather than during assembly. All routing paths, trace widths, and terminal locations are predetermined in the PCB layout, allowing for rapid automated assembly without compromising connection configuration flexibility.
Data Source
AI summary
An electrical interconnection system for electrical components of a module includes a hub printed circuit board (PCB) having a first electrically conductive track and a second electrically conductive track. Each of the first and second electrically conductive tracks is configured to electrically connect at least two of the electrical components of the module, wherein the at least two of the electrical components of the module are external to the hub PCB. The system also includes multiple electrical terminals, wherein each of the electrical terminals is configured to electrically connect one of the first and second electrically conductive tracks of the hub PCB to one of the at least two electrical components of the module.