Electric power conversion systems – Current conversion – With conductive support mounting
Reexamination Certificate
2000-09-06
2001-10-02
Berhane, Adolf Deneke (Department: 2838)
Electric power conversion systems
Current conversion
With conductive support mounting
Reexamination Certificate
active
06297981
ABSTRACT:
FIELD AND BACKGROUND OF THE INVENTION
The invention relates to a compact electrical device, especially a switched-mode power supply, comprising at least one inductance and one contacting device which can be connected to the reference voltage, the inductance being connected to the contacting device via a first electrically conductive connection.
Matching voltages between different electrical networks in a motor vehicle requires an electrical transformer which can be manufactured inexpensively and has the smallest possible constructional volume.
Known devices consist of a number of individual components. The electronic circuit board, power semiconductor with heat sink, transformer and cabling are typical standard components occurring in such devices. These numerous individual components increase the assembly costs which has a cost-increasing effect especially when large numbers of such devices are produced. In addition to the winding of the transformer, the many individual connections between the assemblies, in particular, represent a considerable time factor.
SUMMARY OF THE INVENTION
The invention is thus based on the object of specifying an electrical device which makes it possible to reduce the assembly expenditure and, nevertheless, operates reliably.
According to the invention, the object is achieved in that the inductance and/or the first electrically conductive connection and/or the contacting device are arranged at least partially in a carrier body made of insulating material and are insulated from one another by the material of the carrier body, an electrical circuit being connected to the first electrically conductive connection of the carrier body via a second electrically conductive connection.
The advantage of the invention consists in that different electrical components are combined to form a mechanically connected unit which results in mechanical stability of the device. This greatly reduces the production expenditure and the manufacturing costs of the electrical device. Such an electronic block contains all necessary electrical conductor tracks which are kept insulated from one another either by temporary spacers or genuine insulating layers and are subsequently sprayed with plastic. Apart from the reduction in process steps, this results in an improvement in the electrical characteristics with respect to the insulation. In addition, these compact electronics are shock resistant and have vibration-reducing properties which is of advantage, in particular when used in motor vehicles.
Advantageously, two inductances arranged on the carrier body are constructed as transformer for matching different electrical voltages between the electrical circuit and the contacting device, the first electrical connections connecting the primary windings of the transformer to the contacting device and the secondary winding of the transformer to the electrical circuit, the primary and the secondary windings enclosing at least a part of a transformer core.
As an alternative, the object of the invention is achieved in that the transformer core and/or the first electrically conductive connections and/or the contacting device are arranged in a carrier body consisting of insulating material, the first electrical connections being insulated from one another by the material of the carrier body and the primary and secondary windings of the transformer being arranged on a planar carrier element carrying the electrical circuit, in such a manner that the transformer core is enclosed by the windings and a second electrically conductive connection is connected, to the first electrical connection of the carrier body.
In this arrangement, too, the individual components of plug, power supply/distribution and the transformer windings and, respectively, the transformer core are arranged together in one compact constructional unit and have the advantages already explained.
In one embodiment, at least one contact pin is arranged on the carrier element for connecting the electrical circuit to at least one conductor track of the carrier body, which protrudes into an opening electrically connected to the at least one conductor track, for forming the second electrically conductive connection.
This arrangement of the rigid pin implements the electrical connection between. the electrical circuit and the electrically conductive parts of the carrier body simply by plugging the carrier body onto the contact pin as a result of which, at the same time, mechanical locking is achieved.
This electrical connection can be produced in a particularly simple manner if the contact pin for producing the electrical connection is pressed into the opening of the carrier body. This makes it possible to generate not only an electrical connection but also a permanent mechanical connection which is insensitive to vibrations.
In another embodiment, the ends of the first electrical connection constructed as conductor track are brought out of the opening of the carrier body, protruding beyond the latter, and are soldered jointly with the contact pin brought through the opening. If, at the same time, separate electrical components such as electrolytic capacitors or choke coils are arranged on the carrier body, they can be attached to the carrier body in one soldering process together with the soldering of the contact pin. This also applies to additional circuit boards with wired components which can also be mounted in the same soldering process.
The conductor tracks can he produced in a particularly simple manner if they are constructed as shaped sheet-metal parts. The carrier body can be produced in a simple manner as an injection-molded part with the aid of such punched bent sheet-metal parts which are stacked on top of one another and form the electrical conductor tracks in the carrier body.
The ends of the shaped sheet-metal parts, which are preferably angled away, are advantageously brought out of the carrier body for forming the electrical connections of the plug device. The body of the contacting device is formed by the carrier body in this arrangement.
In a further development of the invention, the carrier body is constructed for the later accommodation of further electrical and/or electronic components. In particular, it exhibits a receptacle provided with latching devices for a further component.
Thus, cased or uncased electronic components can be advantageously arranged on the outside of the carrier body.
The compact electrical block can be fashioned in the same plastic injection process in such a manner that the carrier body is a component of a housing which covers the electrical circuit of the supporting carrier element.
In this arrangement, the carrier body exhibits a peripheral angled-away collar which rests on the carrier element, a seal, which is also peripheral, being integrally molded to the collar.
In another embodiment, the carrier body is constructed as center part of the housing with an integrally molded-on seal on one side for resting on the carrier element, the center part of the housing being closed with a planar cover which also has an integrally molded seal which rests on the center part of the housing.
To remove the lost heat, the carrier element is manufactured out of metal, preferably aluminum and is used at the same time to dissipate heat from the power components.
To improve the thermal characteristics, it is provided in a further development of the invention that the carrier element carries a substrate which consists of copper applied to thermally conductive ceramics (direct copper bonding). The very good thermal conductivity of this material enables the power transistors to have high powers.
A simplified assembly of the switched-mode power supply is possible if the transformer core is constructed of two parts, a first E-like core element resting on the carrier element, its three webs, pointing perpendicularly away from the carrier element, reaching through corresponding transformer openings in the carrier body and a second planar or E-like core element covering the webs and magnetically connecting
Berberich Reinhold
Schultz Dietmar
Berhane Adolf Deneke
Farber Martin A.
Mannesmann VDO AG
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