WO2024254495A1 - Power distribution unit having contactors and shunt connected to printed circuit board - Google Patents

Power distribution unit having contactors and shunt connected to printed circuit board Download PDF

Info

Publication number
WO2024254495A1
WO2024254495A1 PCT/US2024/033070 US2024033070W WO2024254495A1 WO 2024254495 A1 WO2024254495 A1 WO 2024254495A1 US 2024033070 W US2024033070 W US 2024033070W WO 2024254495 A1 WO2024254495 A1 WO 2024254495A1
Authority
WO
WIPO (PCT)
Prior art keywords
circuit board
electrical components
unit
contactors
pin
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2024/033070
Other languages
French (fr)
Inventor
Richard Hampo
Shane GREENWOOD
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Our Next Energy Inc
Original Assignee
Our Next Energy Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Our Next Energy Inc filed Critical Our Next Energy Inc
Priority claimed from US18/737,045 external-priority patent/US20240413557A1/en
Publication of WO2024254495A1 publication Critical patent/WO2024254495A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/30—Assembling printed circuits with electric components, e.g. with resistors
    • H05K3/32—Assembling printed circuits with electric components, e.g. with resistors electrically connecting electric components or wires to printed circuits
    • H05K3/325—Assembling printed circuits with electric components, e.g. with resistors electrically connecting electric components or wires to printed circuits by abutting or pinching; Mechanical auxiliary parts therefor
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
    • H01R12/50—Fixed connections
    • H01R12/51—Fixed connections for rigid printed circuits or like structures
    • H01R12/55—Fixed connections for rigid printed circuits or like structures characterised by the terminals
    • H01R12/58—Fixed connections for rigid printed circuits or like structures characterised by the terminals terminals for insertion into holes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
    • H01R12/70—Coupling devices
    • H01R12/7088—Arrangements for power supply
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/09—Shape and layout
    • H05K2201/09009—Substrate related
    • H05K2201/09063—Holes or slots in insulating substrate not used for electrical connections
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
    • H05K2201/10227—Other objects, e.g. metallic pieces
    • H05K2201/10272—Busbars, i.e. thick metal bars mounted on the printed circuit board [PCB] as high-current conductors
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
    • H05K2201/10227—Other objects, e.g. metallic pieces
    • H05K2201/1031—Surface mounted metallic connector elements
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
    • H05K2201/10613—Details of electrical connections of non-printed components, e.g. special leads
    • H05K2201/10954—Other details of electrical connections
    • H05K2201/10962—Component not directly connected to the PCB

Definitions

  • This disclosure relates to power distribution units for safely distributing high voltage DC power using contactors controlled by a low voltage source, and more particularly to such units that have been configured to reduce mass and cost, while simplifying assembly.
  • contactors and shunts are electrically connected with wire harnesses that have mass, volume and costs that would be desirable to reduce. Additionally, it would be desirable to simplify the structure and assembly process, and to reduce the potential for failure by using fewer and more reliable components and connections.
  • the disclosed power distribution units utilize direct connection of contactors and/or shunt to a printed circuit board to eliminate wire harnesses and thereby reducing space, mass and cost, while also simplifying assembly and providing more robust and reliable interfacing between contactors and control circuitry and/or between a shunt and the control circuitry.
  • the power distribution units include a circuit board (e.g., a printed circuit board, PCB) that can have conductive traces electrically connecting electrical or electronic components to distribute power from one or more DC power sources to one or more DC loads, and one or more electrical (or electronic) components having connector pins.
  • the circuit board includes pin receptacles for receiving and electrically connecting with a corresponding pin of an electrical (or electronic) component.
  • the power distribution unit includes one or more contactors that electrically interface with the circuit board via pins projecting from the contactors.
  • the power distribution unit includes a shunt that electrically interfaces with the circuit board via pins projecting from the shunt.
  • the power distribution unit includes one or more contactors that are electrically interfaced with the circuit board via preferably pins and a shunt that electrically interfaces with the circuit board via projecting pins.
  • the pin receptacles can be solder connected to the circuitry of the circuit board.
  • the circuit board and the one or more electrical (or electronic) components can be fixed to and enclosed within a housing.
  • Figure 1 is a schematic block diagram showing the electrical architecture of a power distribution unit.
  • Figure 2 is an exploded perspective view of a power distribution unit in accordance with this disclosure.
  • Figure 3 is an enlarged bottom view of a pin receptacle used in the power distribution unit of Figure 2.
  • a power distribution unit 10 for distributing DC power from a plurality of DC power sources 12, 14, 16 (e.g., batteries) to high voltage connector 18 and low voltage connector 20, which interface with DC loads.
  • Unit 10 includes a positive contactor 22 and a negative contactor 24.
  • a shunt 26 which is a low resistance path for measuring current and/or voltage.
  • the contactors 22, 24 and shunt 26 do not interface directly with the circuit board, but instead interface via a wire harness.
  • Unit 10 includes a circuit board 28 configured to provide electrical connections among components that together control power distribution, contactors 22, 24, a shunt 26 integrated directly into busbar 32, various other busbars 34, 36, 38, 40 and 42 for electrical connections among various components, and pyro fuses 44, 46.
  • the various components along with fasteners and retainers are affixed to and enclosed within a housing having a base 48 and a cover 49.
  • electrical components such as contactors, shall be interpreted to include electronic components, such as diodes.
  • contactors 22, 24 and shunt 26 Rather than using wire harnesses to electrically connect contactors 22, 24 and shunt 26 with circuit board 28, contactors 22, 24 have projecting pins 50 that engage pin receptacles 52 soldered to circuit board 28, and shunt 26 has projecting pins 54 that engage pin receptacles 56 soldered to circuit board 28.
  • the pins 50 and 54 may be selectively deployable (extendable) and retractable.
  • FIG. 3 Shown in Figure 3 is an enlarged bottom view of a pin receptacle 52 (or 56).
  • the pin receptacles include outwardly projecting tabs 58 to facilitate attachment and electrical connection to circuit board 28, a cylindrical pin receiving section 60, and inwardly projecting resilient spring tabs 62 to achieve reliable electric contact with pins 50 (or 54) of contactors 22, 24 (or shunt 26), without requiring a solder connection between the pins and the PCB or the receptacles.
  • the pin receiving section 60 of the receptacles extend at least partially through the thickness of the PCB, such that pins 50 and/or 54 extend into the depth (thickness) of the PCB.

Landscapes

  • Engineering & Computer Science (AREA)
  • Metallurgy (AREA)
  • Manufacturing & Machinery (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Coupling Device And Connection With Printed Circuit (AREA)

Abstract

Power distribution units, such as for electric vehicles, having a power distribution circuit board (28) having pin receptacles (52, 56) for receiving and electrically connecting with corresponding pins (50, 54), and electrical components (22, 24, 26) having pins (50, 54) such that the electrical components (22, 24, 26) are located in fixed proximity to the circuit board (28) to facilitate an electrical connection between a connector pin (50, 54) and a corresponding pin receptacle (52, 56) on the circuit board (28).

Description

POWER DISTRIBUTION UNIT HAVING CONTACTORS AND SHUNT CONNECTED TO PRINTED CIRCUIT BOARD
FIELD OF THE DISCLOSURE
[0001] This disclosure relates to power distribution units for safely distributing high voltage DC power using contactors controlled by a low voltage source, and more particularly to such units that have been configured to reduce mass and cost, while simplifying assembly.
BACKGROUND OF THE DISCLOSURE
[0002] In conventional power distribution units, contactors and shunts are electrically connected with wire harnesses that have mass, volume and costs that would be desirable to reduce. Additionally, it would be desirable to simplify the structure and assembly process, and to reduce the potential for failure by using fewer and more reliable components and connections.
SUMMARY OF THE DISCLOSURE
[0003] The disclosed power distribution units utilize direct connection of contactors and/or shunt to a printed circuit board to eliminate wire harnesses and thereby reducing space, mass and cost, while also simplifying assembly and providing more robust and reliable interfacing between contactors and control circuitry and/or between a shunt and the control circuitry. The power distribution units include a circuit board (e.g., a printed circuit board, PCB) that can have conductive traces electrically connecting electrical or electronic components to distribute power from one or more DC power sources to one or more DC loads, and one or more electrical (or electronic) components having connector pins. The circuit board includes pin receptacles for receiving and electrically connecting with a corresponding pin of an electrical (or electronic) component. The electrical component or electronic component is located in fixed proximity to the circuit board so that an electrical connection between a pin receptacle and corresponding pin is reliably made. [0004] In certain embodiments, the power distribution unit includes one or more contactors that electrically interface with the circuit board via pins projecting from the contactors.
[0005] In certain other embodiments, the power distribution unit includes a shunt that electrically interfaces with the circuit board via pins projecting from the shunt.
[0006] In additional embodiments, the power distribution unit includes one or more contactors that are electrically interfaced with the circuit board via preferably pins and a shunt that electrically interfaces with the circuit board via projecting pins.
[0007] In any of the foregoing embodiments, the pin receptacles can be solder connected to the circuitry of the circuit board.
[0008] In any of the foregoing embodiments, the circuit board and the one or more electrical (or electronic) components can be fixed to and enclosed within a housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Figure 1 is a schematic block diagram showing the electrical architecture of a power distribution unit.
[0010] Figure 2 is an exploded perspective view of a power distribution unit in accordance with this disclosure.
[0011] Figure 3 is an enlarged bottom view of a pin receptacle used in the power distribution unit of Figure 2.
DETAILED DESCRIPTION
[0012] Shown schematically in Figure 1 is a power distribution unit 10 for distributing DC power from a plurality of DC power sources 12, 14, 16 (e.g., batteries) to high voltage connector 18 and low voltage connector 20, which interface with DC loads. Unit 10 includes a positive contactor 22 and a negative contactor 24. Also included is a shunt 26, which is a low resistance path for measuring current and/or voltage. In a conventional power distribution unit, the contactors 22, 24 and shunt 26 do not interface directly with the circuit board, but instead interface via a wire harness.
[0013] An exploded perspective of a power distribution unit 10 in accordance with the principals of this disclosure is shown in Figure 2. Unit 10 includes a circuit board 28 configured to provide electrical connections among components that together control power distribution, contactors 22, 24, a shunt 26 integrated directly into busbar 32, various other busbars 34, 36, 38, 40 and 42 for electrical connections among various components, and pyro fuses 44, 46. The various components along with fasteners and retainers are affixed to and enclosed within a housing having a base 48 and a cover 49. As used herein, “electrical components,” such as contactors, shall be interpreted to include electronic components, such as diodes.
[0014] Rather than using wire harnesses to electrically connect contactors 22, 24 and shunt 26 with circuit board 28, contactors 22, 24 have projecting pins 50 that engage pin receptacles 52 soldered to circuit board 28, and shunt 26 has projecting pins 54 that engage pin receptacles 56 soldered to circuit board 28.
[0015] In certain embodiments, the pins 50 and 54 may be selectively deployable (extendable) and retractable.
[0016] Shown in Figure 3 is an enlarged bottom view of a pin receptacle 52 (or 56). The pin receptacles include outwardly projecting tabs 58 to facilitate attachment and electrical connection to circuit board 28, a cylindrical pin receiving section 60, and inwardly projecting resilient spring tabs 62 to achieve reliable electric contact with pins 50 (or 54) of contactors 22, 24 (or shunt 26), without requiring a solder connection between the pins and the PCB or the receptacles. The pin receiving section 60 of the receptacles extend at least partially through the thickness of the PCB, such that pins 50 and/or 54 extend into the depth (thickness) of the PCB.
[0017] While the present invention is described herein with reference to illustrated embodiments, it should be understood that the invention is not limited hereto. Those having ordinary skill in the art and access to the teachings herein will recognize additional modifications and embodiments within the scope thereof. Therefore, the present invention is limited only by the claims attached herein.

Claims

IN THE CLAIMS:
1 . A power distribution unit, comprising: a circuit board configured to distribute power from one or more DC power sources to one or more DC loads, the circuit board including pin receptacles for receiving and electrically connecting with a corresponding pin; and one or more electrical components, each having conductive connector pins that project from the component, each electrical component being located in fixed proximity to the circuit board to facilitate an electrical connection between a connector pin and a corresponding pin receptacle soldered on the circuit board.
2. The unit of claim 1, wherein at least one of the one or more electrical components is a contactor.
3. The unit of claim 1, wherein at least two of the one or more electrical components are contactors.
4. The unit of claim 1, wherein at least one of the one or more electrical components is a shunt.
5. The unit of claim 1, wherein at least one of the one or more electrical components is a contactor, and at least one of the one or more electrical components is a shunt.
6. The unit of claim 1, wherein at least two of the one or more electrical components are contactors, and at least one of the one or more electrical components is a shunt.
7. The unit of claim 1 , wherein the circuit board and the one or more electrical components are fixed to and enclosed by a housing.
8. The unit of claim 1 , wherein the pins of at least one electrical component are selectively deployable and retractable.
9. The unit of claim 1. wherein each pin receptacle has a pin receiving section that extends at least partially through a thickness of the circuit board and a corresponding pin received in the pin receiving section extends into the depth of the circuit board.
PCT/US2024/033070 2023-06-07 2024-06-07 Power distribution unit having contactors and shunt connected to printed circuit board Ceased WO2024254495A1 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US202363506824P 2023-06-07 2023-06-07
US63/506,824 2023-06-07
US18/737,045 2024-06-07
US18/737,045 US20240413557A1 (en) 2023-06-07 2024-06-07 Direct connection of contactors and shunt to printed circuit board

Publications (1)

Publication Number Publication Date
WO2024254495A1 true WO2024254495A1 (en) 2024-12-12

Family

ID=91853396

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2024/033070 Ceased WO2024254495A1 (en) 2023-06-07 2024-06-07 Power distribution unit having contactors and shunt connected to printed circuit board

Country Status (1)

Country Link
WO (1) WO2024254495A1 (en)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20070108963A1 (en) * 2005-11-16 2007-05-17 Hamilton Sundstrand Corporation Electrical distribution system and modular high power board contactor therefor
CN101743681A (en) * 2007-05-09 2010-06-16 松塞博兹自动化公司 Dashboard indicator module formed by a motor and electrical connection means
CN217435547U (en) * 2022-05-27 2022-09-16 上海西艾爱电子有限公司 Charging pile power distribution module
US20230130608A1 (en) * 2013-09-06 2023-04-27 Cps Technology Holdings Llc Bus bar link for battery cell interconnections in a battery module

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20070108963A1 (en) * 2005-11-16 2007-05-17 Hamilton Sundstrand Corporation Electrical distribution system and modular high power board contactor therefor
CN101743681A (en) * 2007-05-09 2010-06-16 松塞博兹自动化公司 Dashboard indicator module formed by a motor and electrical connection means
US20230130608A1 (en) * 2013-09-06 2023-04-27 Cps Technology Holdings Llc Bus bar link for battery cell interconnections in a battery module
CN217435547U (en) * 2022-05-27 2022-09-16 上海西艾爱电子有限公司 Charging pile power distribution module

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