Vehicle Power Supply Device with Separable Energization Module
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Solution Overview
Problem
Existing vehicle power supply devices face challenges in miniaturization and cost-effectiveness due to the need for increased wiring area or thickness on control boards to handle high currents, and require redesigns when specifications change, making them bulky and expensive.
Innovation Solution
The solution involves a protection circuit unit with a separable energization module that includes semiconductor switches and bus bars, housed in a resin mold, which can be replaced based on current requirements, eliminating the need for high-voltage current to flow through the control board and allowing for miniaturization and cost-effective manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the area of wiring pattern and/or thickness of copper foil on the control board is increased to handle higher current, then the current carrying capacity is improved, but the control board size increases and miniaturization becomes difficult
Solution Approach 1:
The patent divides the power supply system into two separate functional modules: the control board (for control circuits) and the energization module (for high-current power delivery). This segmentation allows each module to be optimized independently - the control board can be miniaturized while the energization module handles the high current requirements through dedicated bus bars and semiconductor devices.
Solution Approach 2:
The patent extracts the high-current power delivery function from the control board and places it in a separate energization module. This extraction removes the constraint of having to increase control board area for higher current, as the power delivery path is now independent and can be scaled separately using bus bars and other high-current components.
2Power
If a bus bar is mounted on the control board to handle high current, then the current carrying capacity is improved, but the control board design becomes fixed and requires redesign when specifications change
Solution Approach 1:
The patent segments the power supply system into a fixed control board and a replaceable energization module. This allows the energization module to be swapped based on different current requirements or vehicle models, while the control board remains unchanged. The segmentation provides design flexibility without compromising current carrying capacity.
Solution Approach 2:
The patent introduces dynamic configurability through the replaceable energization module. Different modules with varying current capacities can be installed depending on the vehicle model or application requirements, making the overall system adaptable without requiring redesign of the control board infrastructure.
3Device complexity
If the control board is designed to handle high current directly, then the device complexity is reduced, but the manufacturing cost increases due to larger board requirements
Solution Approach 1:
The patent segments the system into standard control boards and specialized energization modules. This allows manufacturers to produce control boards at standard sizes and specifications, reducing per-unit costs. The expensive high-current handling components are confined to the energization module, which can be optimized for manufacturing efficiency.
Solution Approach 2:
The patent creates a universal control board design that can work with multiple types of energization modules. This universality allows the control board to be manufactured once and used across different vehicle models or applications, reducing manufacturing costs through economies of scale, while the energization module adapts to specific requirements.
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The protection circuit unit (1) includes an energization module (10) disposed on an electric path (4) between a high-voltage battery (2) of a vehicle and a high-voltage load (3) receiving supply of power from the high-voltage battery (2), to open and close the electric path, and a control board (20) configured to be a member separated from the energization module (10) and electrically connected with the energization module (10), to control opening and closing of the electric path (4). The energization module (10) includes semiconductor switches (Q1, Q2) opening and closing the electric path (4), and a control terminal (13) connecting the semiconductor switches (Q1, Q2) with the control board (20). The control board (20) includes a connection unit (21) corresponding to the control terminal (13) of each of a plurality of types of the energization modules (10).