TWI745904B - Power supply unit - Google Patents

Abstract

An object of the present disclosure is to provide a power supply unit with improved waterproofness. A power supply unit (100) according to an embodiment is designed to output, through a relay (170) to a power cable, electric power to charge a storage battery used as a power source for a moving vehicle. The power supply unit (100) includes: an inner box (110) housing a board (150) on which the relay (170) is implemented; and an outer box (130) nesting the inner box (110) therein. The inner box (110) includes: a first body (111) having a first opening; and a first lid (112) closing the first opening and having a smaller depth than the first body (111). The outer box (130) includes: a second body (131) having a second opening (133); and a second lid (132) closing the second opening (133) and having a smaller depth than the second body (131). The inner box (110) is arranged with respect to the second body (131) such that the first body (111) of the inner box (110) is located closer to the second opening (133) than the first lid (112) thereof is.

Description

Power supply unit

The present disclosure relates to a power supply unit for charging a storage battery.

For example, electric motor vehicles such as electric vehicles (EV) and plug-in hybrid vehicles (PHV) include batteries as their power source. The accumulator is charged by a charging stand installed in the user's home or commercial facility.

Such a charging base includes a box body containing a relay and a control circuit for the control relay. The relay is used to open and close the power feeding path, and the power is supplied to the storage battery through the cable through the power feeding path.

The charging stand is usually installed outdoors, and therefore the box body has a waterproof structure. Because if water enters the box when it is raining, its internal circuits and other components may be short-circuited, so this waterproof structure is required.

Not only is such a box provided for the charging stand, but the box with a known waterproof structure also includes: an outer shell with a double frame (consisting of an inner frame and an outer frame); an inner cover made of elastic material; and an outer cover. Specifically, in the box body having such a waterproof structure, the electronic circuit board is housed inside the inner frame of the housing. The inner cover is installed in the outer periphery of the inner frame to cover the open end surface of the inner frame with the inner cover. Then the outer cover is installed to cover the open end surface of the outer frame and the inner cover (see, for example, JP 2014-53405A).

However, in the waterproof box of JP 2014-53405A, the first joint surface between the outer cover and the double-frame housing is close to the second joint surface between the inner cover and the double-frame housing, so that rainwater that penetrates through the first joint surface It often enters the box through the second joint surface. Especially when there is a storm due to the approach of a typhoon, the effectiveness limit of the waterproof structure of the box body may be too low to prevent rainwater from penetrating into the box body.

Therefore, the purpose of the present disclosure is to provide a power supply unit with a waterproof structure, and its reliability is improved by reducing the chance of rainwater and other moisture entering the inner box containing the circuit board.

The power supply unit according to the aspect of the present disclosure is designed to output power to the power cable to charge the storage battery used as the power source of the mobile vehicle. The power supply unit includes: an inner box accommodating a board on which electronic components are implemented; and an outer box in which the inner box is nested. The inner box includes: a first body having a first opening; and a first cover that closes the first opening and has a smaller depth than the first body. The outer box includes: a second body having a second opening; and a second cover that closes the second opening and has a smaller depth than the second body. The inner box is arranged relative to the second body, so that the first body of the inner box is positioned closer to the second opening than the first cover of the inner box.

100: power supply unit

101: Charger body

102: mounting surface

103: plug

104: Power cable

105: retainer

106: Mobile Vehicle

107: Battery

108: Power grid

109: Pillar

110: inner box

111: The first body

112: first cover

113: The first opening

114: first floor

115: The first left side panel

116: first right side panel

117: The first upper side panel

118: The first lower side panel

119: First flange

120: Peripheral wall

121: first screw hole

122: second bottom plate

123: second left side panel

124: second right side panel

125: second upper side panel

126: second lower side panel

127: second flange

129: Resection

130: Outer box

131: The second body

132: second cover

133: second opening

134: Third Floor

135: Third left side panel

136: third right side panel

137: The third upper side panel

138: Third lower side panel

139: Space

140: Power cable terminal block

141: Fourth Floor

142: Fourth left side panel

143: Fourth right side panel

144: The fourth upper side panel

145: Fourth lower side panel

150: first board

151: second board

156: Input terminal

157: output terminal

158: Power Line

159: control unit

161: Communication Cable

170: Relay

180: Heat conduction member

200: cable

Fig. 1 is an overall perspective view of a power supply unit according to an exemplary embodiment; Fig. 2 is an exploded perspective view of a charger body, which forms a part of a power supply unit according to an exemplary embodiment; The front view of the appearance of the power supply unit when the second cover of the outer box of the unit is opened; 4 is a cross-sectional view taken along the plane A-A of FIG. 3 and showing the configuration of the power supply unit according to the exemplary embodiment; and FIG. 5 is a circuit diagram of the power supply unit according to the exemplary embodiment.

An exemplary embodiment of the power supply unit according to the present disclosure will be described with reference to FIGS. 1-5. Note that the embodiments disclosed in the following description are only examples, and should not be construed as limiting the scope of the power supply unit according to the present disclosure.

In addition, in the following description of the embodiments, unnecessary detailed descriptions may be omitted. For example, detailed descriptions of things that are already well-known and redundant descriptions of substantially the same configuration may be omitted. This is to avoid making the following descriptions excessively redundant, and to help those with ordinary knowledge in the field to more easily understand the present disclosure.

The power supply unit 100 (see FIG. 1) according to the exemplary embodiment outputs power to the power cable 104 (see FIG. 1) to charge the storage battery 107 (see FIG. 5) used as the power source of the mobile vehicle 106 (see FIG. 5) . The power supply unit 100 includes: an inner box 110 (see FIG. 2) accommodating a board (the first board 150, see FIG. 2), a relay 170 (see FIG. 5) and other electronic components are implemented on the board; and the inner box 110 sets of the outer box 130 (see Figure 1). The inner box 110 includes: a first body 111 (see FIG. 2) having a first opening 113 (see FIG. 4); and a first cover 112 (see figure 2). The outer box 130 includes: a second body 131 (see FIG. 2) having a second opening 133 (see FIG. 2); and a second cover 132 (see FIG. 2) having a smaller depth than the second body 131. The second cover 132 closes the second opening 133. The inner box 110 is arranged relative to the second body 131 so that the first body 111 of the inner box 110 is positioned closer to the second opening 133 than the first cover 112 thereof.

This connects the joint surface between the first cover 112 and the first body 111 (that is, the interface of the inner box 110) and the joint surface between the second cover 132 and the second body 131 (that is, the interface of the outer box 130). ) Are separated and leave at least a certain distance between the two joint surfaces. Therefore, the distance left between the individual interface surfaces of the outer box 130 and the inner box 110 reduces the chance that the static rainwater that has entered the outer box 130 is deep enough to enter the inner box 110, thereby improving the reliability of waterproofing.

(First embodiment)

As shown in FIG. 1, the power supply unit 100 according to the first embodiment is installed on a predetermined installation surface 102 of a pillar 109 which is specifically set up for this power supply unit 100. The pillar 109 is set up on the ground so that the longitudinal axis of the pillar 109 is substantially upright. The power supply unit 100 includes a charger body 101, a plug 103, a power cable 104, and a holder 105. The power cable 104 connects the charger body 101 to the plug 103. In this embodiment, the power supply unit 100 is installed on the dedicated pillar 109 and on its back. However, this is only an example and should not be construed as restrictive. Alternatively, the power supply unit 100 can also be installed on a different installation surface, such as a wall or a pillar of a building.

The charger body 101 outputs power to charge the battery 107, and the battery 107 is used as a power source for the mobile carrier 106. The charger body 101 has its input terminal connected to the power grid 108 (see FIG. 5) through a cable 200 (see FIG. 5). As the power output from the charger main body 101 to the storage battery of the mobile vehicle 106, AC power supplied from the power grid 108 can be used.

The plug 103 can be connected to the charging port of the battery 107 in the mobile carrier 106. The charger body 101 uses the plug 103 connected to the charging port of the mobile carrier 106 to output charging power, thereby supplying power to the storage battery 107 via the plug 103 and charging the storage battery 107 with the power. When the plug 103 is not in use, the holder 105 holds the plug 103.

The mobile vehicle 106 includes a storage battery 107 and uses the electric energy stored in the storage battery 107 to travel. Examples of mobile vehicles 106 include electric vehicles (EV), plug-in hybrid electric vehicles (PHEV), and fuel cell vehicles (FCV) designed to use a combination of internal combustion engine output and electric motor output. , Electric pallets, electric two-wheelers, electric tricycles, and four-wheel off-road vehicles. Examples of electric motorcycles include motorcycles, electric motorcycles, and electric assisted motorcycles. Examples of electric tricycles include electric motorcycles and electric assisted tricycles. Examples of the mobile vehicle 106 further include flying objects, such as drones and aircraft. That is, the mobile vehicle 106 may not necessarily be a vehicle with wheels.

As shown in FIG. 2, the charger body 101 includes an inner box 110 (outer shell) and an outer box 130. The charger body 101 has a nested structure composed of an inner box 110 and an outer box 130, and may be made of resin, for example. In addition, the inner box 110 is preferably but not necessarily made of a highly heat-resistant resin such as polyethylene, polypropylene, polycarbonate, polyphenylene sulfide, or polyvinylidene chloride to accommodate the heat-generating relay 170 and Other components will be explained later. The inner box 110 includes a first body 111 and a first cover 112. The outer box 130 includes a second body 131 and a second cover 132, and the inner box 110 is nested therein.

The first body 111 is formed into a box shape, and one end surface of the box body is open to form a first opening 113. The first body 111 includes a substantially rectangular first bottom plate 114 and four side plates extending from the periphery of the first bottom plate 114 substantially perpendicular to the first bottom plate 114. As shown in FIG. 3, the four side panels are composed of a first left side panel 115, a first right side panel 116, a first upper side panel 117, and a first lower side panel 118.

In the following description of this embodiment, unless otherwise stated, when the charger body 101 is installed on the pillar 109, the rear surface of the power supply unit 100 should face rearward, and the front surface of the power supply unit 100 should face forward. And, when used here, the "upward/downward direction" should be the direction perpendicular to the ground, and the "rightward/leftward direction" should be the direction pointing to the right and to the left in the front view of the power supply unit 100 direction.

In the space inside the first body 111 (that is, the internal space), the first board 150 and the second board 151 can be accommodated.

Each of the first board 150 and the second board 151 is a rigid board, and its base material is made of glass epoxy resin. Implemented on the first board 150 are electronic components such as a power supply circuit (see FIG. 5), at least two relays 170, and a heat conducting member 180. Each of the thermally conductive members 180 abuts against the feet of the related ones of the relay 170 to dissipate the heat generated by the relay 170. The first board 150 is mounted on the first bottom plate 114 of the first body 111 so that the surface of the board on which the electronic components, the relay 170 and the heat conducting member 180 are assembled faces the first opening 113. That is, the board (the first board 150) is installed on the bottom of the first body 111 (that is, the first bottom board 114). This helps to leave a sufficient distance between the first opening 113 of the first body 111 and the board (ie, the first board 150).

As shown in FIG. 4, the first plate 150 is configured to be positioned along the depth of the first body 111 closer to the bottom than at least the middle portion of the depth (ie, the middle portion of the depth of the first body 111). With such a structure, the first plate 150 is further away from the first opening 113, thereby reducing the chance of static rainwater or any other moisture that has entered the inner box 110 reaching the first plate 150. This also further improves the waterproofness of the charger body 101.

As shown in FIG. 5, the cable 200 connected to the power grid 108 is connected to a pair of input terminals 156 of the power cable terminal block 140 (see FIG. 3), and the power cable 104 is connected to a pair of output terminals of the power cable terminal block 140. Terminal. The input terminal 156 and the output terminal 157 of the power cable terminal block 140 are connected together via a pair of power lines 158, and the two relays 170 are inserted into the pair of power lines 158, respectively.

AC power is supplied from the power grid 108 to the output terminal 157 of the power cable terminal block 140 through the input terminal 156 and the relay 170 of the power cable terminal block 140. Then, the AC power from the electric power The cable terminal block 140 transmits through the power cable 104 and the plug 103 to the storage battery 107 of the mobile carrier 106. The plug 103 is connected to the power cable 104.

In addition, the power supply unit 100 further includes a control unit 159 for opening and closing the relay 170. The control unit 159 is connected to the mobile carrier 106 via a communication cable 161. According to the charge/discharge command from the mobile vehicle 106, the control unit 159 opens and closes the relay 170.

Any type of relay can be used as the relay 170 as long as the relay 170 is controllable by the control unit 159. In this embodiment, the relay 170 is implemented as a mechanical relay with mechanical contacts. However, this is only an example and should not be construed as restrictive. Alternatively, the relay 170 may also be a semiconductor relay without mechanical contacts.

The first body 111 further includes a first flange 119 (see FIG. 2). The first flange 119 extends from the first left side plate 115, the first right side plate 116, the first upper side plate 117, and the first opening 113. The individual edges of the lower side plate 118 extend outward (that is, extend toward the outer circumference of the first body 111).

On the outside of the first flange 119, a part extending outward (that is, upward) from the first upper side plate 117 and another part extending outward (that is, downward) from the first lower side plate 118 are each provided with a first The screw hole 121 (see FIG. 2) is used to fasten the first cover 112 with screws. In this embodiment, a single first screw hole 121 is provided for each of the two parts of the first flange 119. However, this is only an example and should not be construed as restrictive. Alternatively, two or more first screw holes 121 may be provided to each of the two parts of the first flange 119. Alternatively or additionally, the part of the first flange 119 that extends from any side plate other than the first upper side plate 117 and the first lower side plate 118 (that is, the first left side plate 115 or the first right side plate 116) The first screw hole 121 is provided.

The first cover 112 is formed in the shape of a box with an opening, as shown in FIG. 2. The first cover 112 includes a substantially rectangular second bottom plate 122, and a peripheral edge of the second bottom plate 122 is substantially perpendicular to the second bottom plate 122 And the extension of the four side panels. The four side panels are composed of a second left side panel 123, a second right side panel 124, a second upper side panel 125, and a second lower side panel 126.

The first cover 112 further includes a second flange 127 that faces the respective edges of the second left side plate 123, the second right side plate 124, the second upper side plate 125, and the second lower side plate 126 that form the opening. Extend outward (that is, extend toward the outer circumference of the first cover 112). The second flange 127 may have substantially the same size and almost the same shape as the first flange 119. Alternatively, the second flange 127 may have a slightly smaller size than the first flange 119.

On the outside of the second flange 127, a portion extending outward (ie upward) from the second upper side plate 125 and another portion extending outward (ie downward) from the second lower side plate 126 each have a cutout 129 , For fastening the first cover 112 to the first flange 119 of the first body 111 with screws. Adopting such a structure allows the first cover 112 to be removably attached to the first opening 113, and also makes the inner space of the first body 111 hermetically sealed. In addition, when the first body 111 is hermetically sealed, a gasket member (not shown) for improving waterproofness is appropriately inserted between the first body 111 and the first cover 112.

The dimensions of the first left side plate 115 and the first right side plate 116 measured in the forward/backward direction (that is, along the depth of the first body 111) are designed to be larger than the second left side plate 123 and the second right side plate 124 The size measured in the frontward/rearward direction (that is, along the depth of the first cover 112). Therefore, the first cover 112 is formed into a box shape having a smaller depth than the first body 111. In addition, the peripheral wall 120 (see FIG. 4) stands upright from the outer circumference of the first flange 119 and has substantially the same size as the first cover 112 measured in the forward/rearward direction. This allows the first cover 112 to be contained in the space surrounded by the first flange 119 and the peripheral wall 120. That is, the first cover 112 is inserted into the first body 111. Therefore, the boundary between the first body 111 and the first cover 112 (that is, the joint surface between the first flange 119 and the second flange 127) is located inside the first body 111, thereby improving the waterproofness.

The second body 131 of the outer box 130 is formed in a box shape, and one end surface of the box body is opened as a second opening 133. The second body 131 includes a substantially rectangular third bottom plate 134 (see FIG. 4) and four side plates extending from the periphery of the third bottom plate 134 substantially perpendicular to the third bottom plate 134. As shown in FIG. 3, the four side panels are composed of a third left side panel 135, a third right side panel 136, a third upper side panel 137, and a third lower side panel 138. The outer surface of the third bottom plate 134 corresponds to the rear surface of the power supply unit 100, and it is in a close state with the above-mentioned mounting surface 102.

The third lower plate 138 has a substantially circular insertion port through which the power cable 104 and the cable 200 are inserted into the second body 131, as will be described later. In this embodiment, the insertion port has a substantially circular shape. However, this is only an example and should not be construed as restrictive. Alternatively, the insertion port may also have a rectangular shape. Optionally, in order to improve water resistance, the insertion port may be provided with a rubber gasket member, or for example, after the power cable 104 and the cable 200 have passed through the insertion port, the surroundings of the power cable 104 and the cable 200 may be filled with putty. Close the plug-in port.

As shown in FIG. 2, the second cover 132 is formed in the shape of a box having an opening. The second cover 132 includes a substantially rectangular fourth bottom plate 141 and four side plates extending from the periphery of the fourth bottom plate 141 substantially perpendicular to the fourth bottom plate 141. The four side panels are composed of a fourth left side panel 142, a fourth right side panel 143, a fourth upper side panel 144, and a fourth lower side panel 145 (see FIG. 4).

The dimensions of the third left side plate 135 and the third right side plate 136 measured in the forward/backward direction (that is, along the depth of the second body 131) are designed to be larger than the fourth left side plate 142 and the fourth right side plate 143 The size measured in the frontward/rearward direction (that is, along the depth of the second cover 132). Therefore, the second cover 132 is formed in a box shape having a smaller depth than the second body 131.

The inner box 110 is nested in the second body 131 and installed on the third bottom plate 134 of the outer box 130, so that when the first opening 113 is covered by the first cover 112, the first body 111 is positioned closer Second opening 133. That is, the inner box 110 is nested in the second body 131 of the outer box 130 such that the first body is closer to the second opening 133 than the first cover 112. Then, the second cover 132 is fastened and fixed on the second body 131 with screws to close the second opening 133. This allows the inner box 110 to be contained in an airtight sealed space surrounded by the second body 131 and the second cover 132, that is, in the inner space of the outer box 130. When the boxes 110 and 130 are hermetically sealed, a gasket member (not shown) for improving waterproofness is appropriately inserted between the second body 131 and the second cover 132.

This configuration allows the joint surface between the first cover 112 and the first body 111 (that is, the interface of the inner box 110) to be positioned closer to the rear surface of the power supply unit 100 (that is, closer to the third bottom plate of the second body 131) 134). On the other hand, this also allows the joint surface between the second cover 132 and the second body 131 (that is, the interface of the outer box 130) to be positioned closer to the front surface of the power supply unit 100 (that is, closer to the second body 131). The second opening 133). This allows the individual interface surfaces of the inner box 110 and the outer box 130 to be separated from each other. In other words, this leaves at least a certain distance between the two interfaces. Therefore, even if rainwater penetrates into the outer box 130, the distance left between the individual interface of the outer box 130 and the inner box 110 still reduces the chance of rainwater entering the inner box 110, thereby improving the reliability of its waterproofness.

In addition, as shown in FIG. 3, the size of the inner box 110 measured in the upward/downward direction is approximately two-thirds of the size of the outer box 130 measured in the upward/downward direction. Therefore, the inner box 110 is disposed in the inner space of the outer box 130 such that the top of the inner box 110 is positioned close to the top of the outer box 130. In other words, the space 139 that does not have the inner box 110 is generated in the lower part of the inner space of the outer box 130. This space 139 will be used to accommodate the power cable terminal block 140 and for the power cables 104 and cables 200 to be connected to the power cable terminal block 140 to pass. That is, in the inner space of the outer box 130, a space for the power cable 104 to pass through is left under the inner box 110. This allows the power cable 104 to extend downward relative to the inner box 110. So even if the rainwater runs along the electricity The cable 104 travels into the outer box 130, which still reduces the chance of rainwater traveling along the power cable 104 reaching the inner box 110.

The power cable terminal block 140 is arranged adjacent to the first lower side plate 118 on the outer periphery of the inner box 110. That is, the terminal block (ie, the power cable terminal block 140) to which the power cable 104 is connected is provided on the outer circumference of the first body 111. This reduces the chance of interference between the power cable 104 connected to the terminal block (ie, the power cable terminal block 140) and the first body 111. The size of the inner box 110 measured in the upward/downward direction does not have to be two-thirds of the size measured in the upward/downward direction of the outer box 130, but can be the outer box 130 in the upward/downward direction. Approximately one-half, one-quarter, or any other fraction of the size measured upwards.

110: inner box

111: The first body

112: first cover

114: first floor

116: first right side panel

117: The first upper side panel

119: First flange

120: Peripheral wall

121: first screw hole

122: second bottom plate

123: second left side panel

124: second right side panel

125: second upper side panel

126: second lower side panel

127: second flange

129: Resection

130: Outer box

131: The second body

132: second cover

133: second opening

135: Third left side panel

136: third right side panel

137: The third upper side panel

140: Power cable terminal block

141: Fourth Floor

142: Fourth left side panel

143: Fourth right side panel

144: The fourth upper side panel

150: first board

151: second board

170: Relay

180: Heat conduction member

Claims (5)

A power supply unit for outputting power to a power cable to charge a storage battery used as a power source for a mobile vehicle. The power supply unit includes: An inner box containing a board on which electronic components are implemented; and An outer box with the inner box nested in it, The inner box contains: A first body having a first opening; and A first cover that closes the first opening and has a smaller depth than the first body, The box contains: A second body having a second opening; and A second cover that closes the second opening and has a smaller depth than the second body, The inner box is arranged relative to the second body, so that the first body of the inner box is positioned closer to the second opening than the first cover of the inner box. Such as the power supply unit of claim 1, wherein the board is installed on a bottom of the first body. Such as the power supply unit of claim 1 or 2, wherein a terminal block to which the power cable is connected is arranged on an outer circumference of the first body. Such as the power supply unit of claim 1 or 2, wherein in an internal space of the outer box, a space for the power cable to pass through is left under the inner box. For example, the power supply unit of claim 1 or 2, wherein the first cover is inserted into the first body.

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