Power Module of a Charging Station, Method for Equipping a Power Module and Charging Station with a Power Module

Abstract

Embodiments of a power module of a charging station are disclosed herein. The power module includes a printed circuit board, an electrical input for connection to an electrical supply network, an electrical output for connection to a charging control circuit, and a switching actuator electrically connected between the input and the output. The switching actuator is encapsulated in a housing and connected to the printed circuit board by connection contacts led out of the housing. According to the present disclosure, a base of a protective trough is arranged between the housing and the printed circuit board.

Claims

1. A power module of a charging station, comprising: a printed circuit board, an electrical input for connection to an electrical supply network, an electrical output for connection to a charging control circuit, a switching actuator electrically switched between the input and the output, the switching actuator being encapsulated in a housing and being connected to the printed circuit board by means of terminal contacts guided out of the housing, and a base of a protective trough arranged between the housing and the printed circuit board.

2. The power module according to claim 1, wherein the protective trough has through-openings in its base and wherein the connecting contacts are guided through the through-openings.

3. The power module according to claim 2, wherein the connection contacts are guided in press fit through the through-holes.

4. The power module according to claim 1, the connection contacts are formed as solder tabs.

5. The power module according to claim 1, wherein the number of through holes exceeds the number of connecting contacts of a switching actuator, in particular it is twice as large as the number of connecting contacts of the switching actuator.

6. The power module according to claim 1, wherein an inwardly pointing projection dividing the base into two regions is provided in the base, a switching actuator being arrangeable in each region.

7. The power module according to claim 1, wherein the protective trough is formed from the floor and side walls enclosing the floor.

8. The power module according to claim 1, wherein the protective trough is open on the side opposite the floor.

9. The power module according to claim 1, wherein the protective tub is made of a flame-retardant material, in particular a plastic, in particular a material of class V0, in accordance with UL94 Tests for Flammability of Plastic Materials for Parts in Devices and Appliances, IEC/DIN EN 60695-11-10 and -20 and/or Canadian CAN/CSA C 22.2.

10. The power module according to claim 1, wherein the base and/or the side walls have a wall thickness of less than 2 mm and more than 0.5 mm.

11. A method for equipping a power module of a charging station comprising, providing a printed circuit board, providing of a switching actuator with a housing and connection contacts led out of the housing, providing of a protective trough, wherein the protective trough is arranged between the housing and the printed circuit board, wherein the connection contacts are guided through through-holes in the bottom of the protective trough, and wherein the connecting contacts are electrically contacted with the printed circuit board, in particular are soldered.

12. A charging station comprising a power module according to claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In the following, the object is explained in more detail by means of a drawing showing examples of its design. In the drawings:

[0028] FIG. 1 a view of a protective trough;

[0029] FIG. 2 shows a top view of an unassembled printed circuit board; and

[0030] FIG. 3 a cross-section through an assembled printed circuit board.

DETAILED DESCRIPTION

[0031] FIG. 1 shows a protective trough 2 with a base 2a and four side walls 2b enclosing the base. The bottom 2a of the protective trough 2 has several passage openings 4-10. A conductor path is connected in a switching actuator between two through-holes 4a, 4b, 6a, 6b; 8a, 8b and 10a, 10b each. The switching actuator with its connection contacts is inserted through the respective openings 4-6 and 8-10. The protective trough 2 can be equipped with two switching actuators and has a central web 12 which is arranged on the floor and points in the direction of the side walls. One switching actuator can be arranged on each side of the projection 12.

[0032] The protective trough 2 is fitted on a printed circuit board 14, as indicated in FIG. 2. The PCB 14 has an electrical input 14b and an electrical output 14a. The electrical input 14b can be formed by contact areas or terminal lugs and is used to connect a single-phase or three-phase electrical supply network. The electrical output 14a can also be formed by contact areas or terminal lugs and can also be prepared for a single-phase or three-phase connection of a charge controller.

[0033] Between input 14b and output 14a, protective circuits are provided at least for each phase and the neutral, including in particular a switching actuator. The switching actuator is used to switch one conductor path per phase or neutral between input 14b and output 14a.

[0034] For assembly, the circuit board 14 has a connection area on which the protective trough 2 can be placed. Contact areas, in particular solder points, are provided in the connection area for soldering the connection contacts of a switching actuator. When mounted, the holes of the connecting contacts on the printed circuit board 14 or the contact areas align with the through-holes 4-10 of the protective trough 2.

[0035] As shown in FIG. 3, the protective trough 2 is placed on the printed circuit board 14 for assembly. A switching actuator 16 with a housing 16a and connection contacts 16b is inserted into the protective tub 2 and inserted with the connection contacts 16b through two or four through-holes 4-6, 8-10. A conductor path can be switched through the switching actuator 16 between two connection contacts 16b. The switching actuator 16 is connected to the circuit board 14 with the aid of the connection contacts 16b. In particular, a solder connection 18 is formed between the connection contacts 16b and the contact areas of the printed circuit board 14 on the side of the printed circuit board 14 opposite the protective trough 2.

[0036] The protective trough 2 protects the printed circuit board 14 or the components installed on it from splinter parts which can occur if the switching actuator 16 switches at overload and is explosively destroyed. This is particularly the case if the switching actuator 16 is only designed for normal operating modes and is destroyed in the event of overload. The resulting arcs lead to an explosive destruction. The flying parts are stopped by the protective trough 2 so that they cannot come into contact with the rest of the circuit board 14.

[0037] All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

[0038] The use of the terms a and an and the and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms comprising, having, including, and containing are to be construed as open-ended terms (i.e., meaning including, but not limited to,) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., such as) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0039] Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.