EP4748205A1

EP4748205A1 - On-board power supply device and vehicle

Info

Publication number: EP4748205A1
Application number: EP24739586.6A
Authority: EP
Inventors: Gongyuan Qu; Yuncong ZHU; Ronghui Li
Original assignee: Valeo eAutomotive Germany GmbH
Current assignee: Valeo Electrification SAS
Priority date: 2023-07-17
Filing date: 2024-07-05
Publication date: 2026-05-27
Also published as: CN119325222A; WO2025016753A1

Abstract

The present disclosure provides an on-board power supply device (1) The on-board power supply device includes a housing and an electromagnetic interference shielding element (2), wherein the housing includes a cover (11) and a wall (12), the wall (12) separates two adjacent spaces in the housing, and the electromagnetic interference shielding element (2) is arranged between the cover (11) and the wall (12) and is in electrically conductive contact with the cover (11) and the wall (12). The present disclosure also relates to a vehicle including the on-board power supply device.

Description

DESCRIPTION

ON-BOARD POWER SUPPLY DEVICE AND VEHICLE

TECHNICAL FIELD

The present disclosure relates to the field of electrical technology, in particular to an on-board power supply device and a vehicle comprising the on-board power supply device.

BACKGROUND

During operation, an on-board power supply device of a vehicle will give rise to electromagnetic radiation, wherein the interference source couples its signals to other electrical networks through space. In system design, high-frequency signal lines, integrated circuit pins and various kinds of connectors, etc. may all become radiative interference sources with antenna characteristics, which can emit electromagnetic waves and thus affect the normal operation of other systems or other sub-systems within the system in question. To prevent electromagnetic interference, it is necessary to ensure that the on-board power supply device remains a complete conductor, which requires good contact to be maintained between any two adjacent electrically conductive wall parts in the on-board power supply device. For example, a gap is formed between a wall and a cover of the onboard power supply device, and consequently, there are unclosed cavities in the on-board power supply device, so electromagnetic compatibility is affected. For this reason, conventionally, a metallic elastic plate for preventing electromagnetic interference is used to be in electrically conductive contact with the wall and cover respectively. However, the disadvantage of this design is that the assembly of the metallic elastic plate for preventing electromagnetic interference may be difficult, which makes this method costly; in addition, in existing designs, the wall and the cover may be in direct contact (or not in contact, but the gap between the wall and the cover is very small, e.g. 0.05 mm), however, the disadvantage of this design is that fragments/powder caused by wear of the on-board power supply device is i often generated due to the vibration of vehicle operation, which is fatal for electrical products.

Thus, there is a need for an on-board power supply device that is easier to assemble, has lower manufacturing costs, and prevents fragments/powder caused by wear, while achieving electromagnetic interference prevention.

SUMMARY

In response to the above problem, the present disclosure provides an on-board power supply device and a vehicle comprising the on-board power supply device. Using the on-board power supply device provided by the present disclosure can make it easier to assemble, have lower manufacturing costs, and prevent fragments/powder problems caused by wear, while effectively preventing electromagnetic interference.

To solve the technical problem, the present disclosure provides an on-board power supply device. According to the present disclosure, the on-board power supply device comprises a housing and an electromagnetic interference shielding element, wherein the housing comprises a cover and a wall, the wall separates two adjacent space in the housing, and the electromagnetic interference shielding element is arranged between the cover and the wall and is in electrically conductive contact with the cover and the wall.

Preferably, a top surface of the wall is adjacent to the cover and the electromagnetic interference shielding element is a strip-shaped shielding element.

Further preferably, the electromagnetic interference shielding element is an electromagnetic interference shielding layer.

In this case, the electromagnetic interference shielding layer extends in a gap between the cover and the wall, thereby forming a substantially closed cavity.

Preferably, the electromagnetic interference shielding layer is made of an elastically compressible non-metallic electrically conductive material, wherein the thickness of the electromagnetic interference shielding layer in an uncompressed original state is greater than the width of the gap between the cover and the wall.

According to the present disclosure, the electromagnetic interference shielding element is made of a non-metallic electrically conductive material. On the one hand, the electromagnetic interference shielding element experiences elastic deformation when compressed, thus being clamped between at least two adjacent wall parts of the on-board power supply device, and thereby filling a slit that was originally formed at this position, establishing a reliable electrically conductive connection between the adjacent wall parts, forming a substantially closed cavity, and eliminating the resulting electromagnetic interference; On the other hand, the non-metallic material composition avoids the risk of the on-board power supply device producing fragments/powder due to vibration and wear; Furthermore, due to good elastic deformation characteristics and the selection of non-metallic materials, the drawbacks of noise being produced between components due to vibration is essentially eliminated, thus achieving a good silencing effect.

Preferably, the electromagnetic interference shielding element is made of electrically conductive foam or electrically conductive rubber. Preferably, the electrically conductive foam comprises a foamed polymer, an electrically conductive filler and an antistatic agent.

According to the present disclosure, preferably, the electromagnetic interference shielding element is bonded to the cover and/or the wall.

Alternatively or additionally, the cover and/or the wall are provided with a slot for accommodating the electromagnetic interference shielding element.

Further preferably, the electromagnetic interference shielding element is snapped into the slot of the cover and/or the wall.

Preferably, the wall is integrally formed with the housing.

Preferably, the wall is molded inside the housing by a casting or splicing process.

In this way, the electromagnetic interference shielding element is installed between the wall and the cover by a simple process.

Preferably, the on-board power supply device comprises an on-board charger or a DC converter or a power distribution unit or a motor controller.

To solve the technical problem, the present disclosure also provides a vehicle that comprises the on-board power supply device described above. The vehicle may be a plug-in hybrid electric vehicle, or a battery electric vehicle or other types of motor vehicle. Based on the above, the vehicle can realize the functions of the motor component and motor described above, and has the advantages described above.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to give a clearer explanation of the technical solutions in embodiments of the present disclosure, the drawings of the embodiments will be briefly described below, wherein it is apparent that the accompanying drawings in the following description only relate to some embodiments of the present disclosure and are not intended to be a limitation of the present disclosure.

Fig. 1 is a partial perspective drawing of an on-board power supply device according to the present disclosure, with no electromagnetic interference shielding element installed;

Fig. 2 is an exploded drawing of the on-board power supply device according to the present disclosure;

Fig. 3 is a partial perspective drawing of the on-board power supply device shown in Fig. 2;

Fig. 4 is a partial perspective drawing of the on-board power supply device shown in Fig. 3; and

Fig. 5 is a partial three-dimensional drawing of the on-board power supply device shown in Fig. 2.

List of reference numbers

1 On-board power supply device

11 Cover

12 Wall

2 Electromagnetic interference shielding element

20 Bent part

221 First space

222 Second space

DETAILED DESCRIPTION The technical solution in embodiments of the present disclosure will be described clearly and completely below with reference to the drawings in the embodiments of the present disclosure. Obviously, the described embodiments are only a part of the embodiments of the present disclosure, not the entire embodiments.

The expression “an embodiment” or “embodiment” as used herein means a specific feature, structure or characteristic that may be comprised in at least one implementation of the present disclosure. In the description of the present disclosure, it should be understood that orientational or positional relationships indicated by the terms “up”, “down”, “left”, “right”, “top”, “bottom”, etc. are based on the orientational or positional relationships shown in the drawings, and are merely intended to facilitate and simplify the description of the present disclosure, rather than indicating or implying that the apparatus or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the present disclosure.

Fig. 1 shows schematically a partial perspective drawing of an on-board power supply device 1 according to an embodiment of the present disclosure. The on-board power supply device may comprise an on-board charger or a direct current (DC) converter or a power distribution unit or a motor controller, etc. It should be noted that the on-board power supply device in the present disclosure is not limited by the specific type of the on-board power supply device.

The on-board power supply device 1 comprises a housing. The housing comprises a cover 11 and a wall 12. A circuit board together with various electrical components on the circuit board are installed in the housing. The circuit board is, for example, an alternating current (AC) filter board or a DC filter board, and the electrical components comprise, for example, a signal connector, a filter assembly and a functional assembly. The signal connector is used to connect with other onboard power supply devices, receive control or feedback signals from other onboard power supply devices, and be able to output corresponding feedback or control signals to other on-board power supply devices. The signals received or outputted via the signal connector may for example be voltage signals or current signals, which are not limited by the specific type of the on-board power supply device to which the signal connector is connected and the content of the signals inputted/ outputted by the signal connector.

The filter assembly is mainly used to prevent noise generated by components inside the on-board power supply device from radiating out from a connector opening or being conducted to the outside along a cable to which the connector is butt-jointed. In addition, it may also filter AC from an external power grid to filter out AC noise therein. It may comprise, for example, one or more inductors and one or more capacitors.

For example, an input filter assembly may be disposed at an input connector port on the circuit board, and an output filter assembly may be disposed at an output connector port on the circuit board. For example, the input filter assembly is a two- stage filter assembly that comprises a first common-mode inductor, a second common-mode inductor, a first input capacitor, and a second input capacitor. The output filter assembly is a single-stage filter assembly that comprises a third common-mode inductor and an output capacitor module. Since the specific compositional forms and setting positions of the input filter assembly and the output filter assembly do not have a significant impact on the disclosed ideas of the present disclosure, they are not shown in detail in the drawings. It should also be noted that, based on different actual needs, the filter assembly may have different compositional forms and setting positions.

The functional assembly is used to realize corresponding functions of the onboard power supply device. The functional assembly of the on-board power supply device may comprise, for example, a resonant inductor, a transformer, an inductor and multiple transistor zones, and is used to process AC inputted at an input end and convert it to a required voltage, e.g. a 400 V DC voltage, or a 450 V DC voltage. There are no restrictions with regard to the specific composition of the functional assembly of the on-board power supply device or the specific function that it performs.

For conciseness, only two adjacent components in the on-board power supply device 1 are shown in Fig. 1: parts of the cover 11, which extends substantially in a horizontal direction, and the wall 12, which extends substantially in a vertical direction. The wall 12, as an electromagnetic compatibility shielding wall, is designed as a plate-like structure, and is intended to block outward electromagnetic radiation produced by an internal functional module of the on-board power supply device, for example, prevent noise generated by an internal device from radiating to the outside through a connector opening or being conducted to the outside along a cable to which the connector is butt-jointed, so as to reduce electromagnetic interference to external devices therefrom, and improve the electromagnetic combatibility (EMC) of the on-board power supply device. The wall 12 is of electrically conductive material, for example may be made of a metallic material, and for example may be formed as a thin metal plate.

However, it should be understood that other electrically conductive materials may be chosen to make the wall 12, as long as they can perform the function of reducing electromagnetic interference as mentioned herein. Embodiments of the present disclosure are not restricted with regard to the specific material of which the wall is composed.

In some embodiments, the wall 12 is multiple walls, which may for example form multiple shielding cavities in the housing of the on-board power supply device 1 that are used to shield a component associated therewith from the influence of electromagnetic radiation generated by the on-board power supply device 1.

However, embodiments of the present disclosure are not limited thereto, and may also comprise a single wall; for example, a single wall is provided to protect the input filter assembly in the on-board power supply device from the influence of electromagnetic radiation generated by the on-board power supply device. It should be understood that embodiments of the present disclosure are not restricted with regard to the number of the walls and their connection relationship.

As shown in Fig. 1, there is a gap between the cover 11 and the wall 12; unfavourably, this gap will result in undesired electromagnetic interference.

Fig. 2 shows schematically an exploded drawing of an on-board power supply device 1 according to an embodiment of the present disclosure. As stated above, the on-board power supply device 1 comprises a housing, the housing comprises a cover 11 and a wall 12. The wall 12 may for example be formed integrally with the housing, whereas the cover 11 is constructed independently of the wall 12. Embodiments of the present disclosure are not restricted with regard to the specific way in which the housing and the wall are integrally formed.

Based on the above, as a result of having the wall 12 and the housing integrally formed, during the manufacture of the on-board power supply device, separate steps of assembly and fixation by welding no longer need to be performed between the wall 12 and the housing, which simplifies the manufacturing procedure and streamlines the manufacturing process, while reducing manufacturing costs.

In some embodiments, the wall is formed inside the housing by a casting or splicing process.

Specifically, the wall 12 may for example be cast together with the housing and thus integrally formed therewith by means of a preset mould. Alternatively, the wall 12 may also be manufactured independently of the housing and then fitted thereto; for example, multiple channels are formed in the housing in advance, and the wall 12 can then be inserted into the channels that are formed in the housing in advance, so as to fit the wall and the housing together.

However, it should be understood that the wall and the housing may also be manufactured in other ways. Embodiments of the present disclosure are not restricted with regard to the specific way in which the wall and the housing are manufactured. The circuit board together with the electrical components, e.g. the signal connector, filter assembly and functional assembly, are arranged in a space defined by the housing, wherein the wall 12 separates two adjacent space in the housing. As stated above, a gap which will result in electromagnetic interference is present between the cover 11 and the wall 12. To eliminate electromagnetic interference, an electromagnetic interference shielding element 2 is provided between the cover 11 and wall 12 of the on-board power supply device 1.

In an alternative embodiment which is not shown, the electromagnetic interference shielding element according to the present disclosure may be used between any at least two wall parts in the on-board power supply device that might give rise to electromagnetic interference due to a gap, and not only between the cover 11 and the wall 12.

Here, the electromagnetic interference shielding element 2 is an elastically deformable electromagnetic interference shielding layer, wherein the electromagnetic interference shielding element 2 is preferably made of electrically conductive foam, which is elastically compressible. It should be noted that the electromagnetic interference shielding element 2 may be made of electrically conductive foam, electrically conductive rubber or other macromolecular materials, and the present disclosure imposes no restrictions in this regard. The initial thickness of the electromagnetic interference shielding element 2 in an uncompressed original state is greater than the width of the gap between the cover 11 and the wall 12, so that when the installation of the on-board power supply device 1 is completed, the electromagnetic interference shielding element 2 sandwiched between the cover 11 and the wall 12 is compressed between the cover

11 and the wall 12, and is thus in tight contact with the cover 11 and the wall 12, forming a reliable electrically conductive connection between the cover 11 and the wall 12, thus isolating different space on two sides of the wall 12 from each other in a closed manner, forming multiple electromagnetically isolated space, such as the first space 221 located at the left side of the wall 12 and the second space 222 located at the right side of the wall 12 as shown in Fig. 3.

The use of the electromagnetic interference shielding element described above avoids the risk of the on-board power supply device producing fragments/powder due to vibration and wear; due to good elastic deformation characteristics and the selection of non-metallic materials, the drawbacks of noise being produced between components due to vibration is essentially eliminated, thus achieving a good silencing effect; and the electromagnetic interference shielding element is easy to assemble, and has low manufacturing costs.

Fig. 4 shows schematically an enlarged drawing of the circled part in Fig. 3. As shown in Fig. 4, the cover 11 is constructed substantially in the form of a plate, and an annular flange protruding from a bottom face towards the interior of the housing space is constructed at an edge of the cover 11. A top surface of the wall

12 is adjacent to a plate-like part of the cover 11, forming a substantially T-shaped contact region.

The electromagnetic interference shielding element 2 is a strip-shaped shielding element, and extends longitudinally on a lower surface of the cover 11 in a middle part thereof, wherein bent parts 20 adapted in shape to the cover 11 are comprised at two ends of the electromagnetic interference shielding element 2 respectively, so as to fit corresponding wall parts as much as possible.

In a compressed state, the electromagnetic interference shielding element 2 contacts the lower surface of the cover 11 with its top face, and contacts the top surface (facing the cover 11) of the wall 12 with its bottom face, thereby establishing an electrically conductive connection between the cover 11 and the wall 12. In the embodiment shown in Fig. 5, the electromagnetic interference shielding element 2 is bonded to the lower surface of the cover 11 by its top face, and is correspondingly clamped between the cover 11 and the wall 12.

As an alternative, the electromagnetic interference shielding element 2 may also be bonded to an upper edge of the wall 12 by its bottom face, or the electromagnetic interference shielding element 2 may be bonded to both the lower surface of the cover 11 and the upper surface of the wall 12 by its top face and bottom face respectively.

An electrically conductive connection is thus established between the electromagnetic shielding element 2 and the cover 11 and/or wall 12. This manner of connection has the advantages of a simple process and low costs, as well as flexibility of arrangement of the electromagnetic shielding element.

However, in an embodiment which is not shown, a slot for accommodating the electromagnetic interference shielding element 2 may also be provided on the cover 11 or wall 12, such that the electromagnetic shielding element 2 is accommodated in the slot in a shape-fitted manner. A sidewall height of the slot should be less than the original thickness of the electromagnetic interference shielding element 2 in its uncompressed state; that is to say, in the uncompressed state of the electromagnetic shielding element 2, a free end of the electromagnetic shielding element 2 should protrude from an upper edge of the slot, rather than being sunk in the slot, such that the electromagnetic interference shielding element 2 can tightly abut the cover 11 and the wall 12 with its top and bottom faces respectively when in a compressed state, so as to establish a reliable electrically conductive connection between the cover and the wall.

A separable connection is thus established between the electromagnetic shielding element 2 and the cover 11 and/or wall 12. In addition, the above-described ways of connecting the electromagnetic shielding element 2 may be combined, i.e., a slot for accommodating the electromagnetic shielding element 2 may be provided on the cover 11 and/or wall 12, such that the electromagnetic shielding element 2 can be inserted in the slot in a shape-fitted manner, and an adhesive may be applied to the top face and/or bottom face of the electromagnetic shielding element 2, to enable it to form a bond with the cover 11 and/or wall 12.

At least one embodiment of the present disclosure further provides a vehicle comprising the on-board power supply device provided by at least one embodiment of the present disclosure. The vehicle may be an electrified vehicle, such as a battery electric vehicle (BEV), a hybrid electric vehicle (HEV), a plug-in hybrid electric vehicle (PHEV), a range extended EV and a fuel cell electric vehicle (FCEV). The vehicle may also be a hydrogen-powered vehicle.

As a result of comprising the above-described on-board power supply device in the vehicle, electromagnetic interference is effectively prevented when the onboard power supply device performs its corresponding functions, and in addition, assembly is easier and the manufacturing cost is lower, and the problem of fragments/powder caused by wear can be prevented.

Certain features, structures or characteristics in one or more embodiments of the present application may be combined appropriately.

Unless otherwise defined, all of the terms (comprising technical and scientific terms) used herein have the same meanings as those commonly understood by those skilled in the art. It should also be understood that terms such as those defined in a common dictionary should be interpreted as having the same meanings as they have in the context of the related art, rather than being interpreted in an idealized or extremely formalized sense, unless expressly so defined herein.

The above is a description of the present disclosure, and should not be regarded as limiting it. Although some exemplary embodiments of the present disclosure have been described, those skilled in the art will readily understand that many modifications could be made to the exemplary embodiments without departing from the original teaching and advantages of the present disclosure. Therefore, all such modifications are intended to be included in the scope of the present disclosure as defined by the claims. It should be understood that the above is a description of the present disclosure, and the present disclosure should not be regarded as being limited to the specific embodiments disclosed; moreover, modifications to the disclosed embodiments and other embodiments are intended to be included in the scope of the present disclosure.

Claims

1. An on-board power supply device (1), characterized in that the on-board power supply device comprises a housing and an electromagnetic interference shielding element (2), wherein the housing comprises a cover (11) and a wall (12), the wall (12) separates two adjacent space in the housing, and the electromagnetic interference shielding element (2) is arranged between the cover (11) and the wall (12) and is in conductive contact with the cover (11) and the wall (12).

2. The on-board power supply device according to claim 1, characterized in that a top surface of the wall (12) is adjacent to the cover (11) and the electromagnetic interference shielding element (2) is a strip-shaped shielding element.

3. The on-board power supply device according to claim 2, characterized in that the electromagnetic interference shielding element (2) is an electromagnetic interference shielding layer.

4. The on-board power supply device according to claim 3, characterized in that the electromagnetic interference shielding layer is made of an elastically compressible non-metallic conductive material, and a thickness of the electromagnetic interference shielding layer in an uncompressed original state is greater than a width of a gap between the cover (11) and the wall (12).

5. The on-board power supply device according to claim 1, characterized in that the material of the electromagnetic interference shielding element (2) comprises conductive foam or conductive rubber.

6. The on-board power supply device according to claim 1, characterized in that the electromagnetic interference shielding element (2) is bonded to the cover (11) and/or the wall (12).

7. The on-board power supply device according to claim 1, characterized in that the cover (11) and/or the wall (12) are provided with a slot for accommodating the electromagnetic interference shielding element (2).

8. The on-board power supply device according to claim 7, characterized in that the electromagnetic interference shielding element (2) is snapped into the slot of the cover (11) and/or the wall (12).

9. The on-board power supply device according to claim 1, characterized in that the wall (12) is integrally formed with the housing.

10. The on-board power supply device according to claim 1, characterized in that the wall (12) is molded inside the housing by a casting process or a splicing processes.

11. The on-board power supply device according to claim 1 , characterized in that the on-board power supply device comprises an on-board charger or a DC converter or a power distribution unit or a motor controller.

12. A vehicle, characterized in that the vehicle comprises the on-board power supply device according to any one of claims 1 to 11.