EP2625937A1

EP2625937A1 - Power electronic vehicle component

Info

Publication number: EP2625937A1
Application number: EP11764318.9A
Authority: EP
Inventors: Axel Krause
Original assignee: Brusa Elektronik AG
Current assignee: Brusa Elektronik AG
Priority date: 2010-10-04
Filing date: 2011-09-06
Publication date: 2013-08-14
Also published as: WO2012046152A1

Abstract

A power electronic vehicle component, such as an on-board charging device, a converter, or a voltage converter, for electric or hybrid vehicles. The power electronic vehicle component includes a housing (1 ), in which at least one power module (4) and at least one printed circuit board (2, 3) electrically communicating with the power module (4) are accommodated. The printed circuit board (2, 3) is electrically connected to the power module (4) via at least one plug connection (5) which is formed by connector parts (5a, 5b) of male and female type that can be pressed into one another, wherein one of the connector parts (5a) sits directly on the printed circuit board (2, 3) and the other connector part (5b) sits directly on the power module (4).

Description

Power electronic vehicle component

[0001 ] This application claims benefit of priority to prior U.S. provisional application no. 61/389,566 filed on October 4, 2010, and as a non-provisional thereof; this application also claims benefit of priority to prior European application no.

EP10186458 filed on October 4, 2010; the entirety of European application no. EP10186458 and of U.S. application no. 61/389,566 are expressly incorporated herein by reference in their entirety, for all intents and purposes, as if identically set forth herein.

[0002] The invention relates to a power electronic vehicle component, such as an on-board charging device, a converter or a voltage converter for electric or hybrid vehicles, having a housing accommodating at least one power module and at least one printed circuit board electrically communicating with the power module. The invention relates to an electric or hybrid vehicle which comprises such a vehicle component.

[0003] In modern power electronics the designer is faced repeatedly with similar tasks. In particular for mobile applications, power modules, chokes, transformers and capacitors must be electrically and mechanically connected together in such a manner that the requirements for reliable contacting, vibration-proof construction, simple and space-saving assembly, lowest possible weight and good cooling are satisfied.

[0004] There is a range of standard solutions for the electrical connection of power modules to capacitors. In most applications the connection is effected via a circuit board, wherein the capacitors are soldered or screwed onto the circuit board and the power modules are also soldered or pressed in. The entire unit is screwed onto a heat-sink, so that the heat produced by the power modules is optimally dissipated.

[0005] Larger inductive components (chokes, transformers) are excluded from this assembly technique however, since they are usually so heavy (e.g. over 1 kg) that they cannot be directly soldered onto the circuit board. In contrast to the markedly lighter capacitors, inductive components also produce considerable waste heat, which, in the best case, is fed directly into the heat-sink on which the power modules are already located. In this context, it has proved useful, for example, to cast the inductive component directly into a recess in the heat-sink with a thermally conductive casting compound. This satisfies the requirement for vibration-proof construction with optimal heat dissipation, but it still does not produce an electrical connection to the circuit board described above.

[0006] A further complication is the fact that the windings of the transformer and chokes are formed with HF stranded wires. The insulation of the stranded wires, constructed from many single wires, can be removed by tin plating, so that a good contact site is produced. In the assembly process the wound components are cast in the housing first, then the circuit boards are mounted. The direct soldering of the tin- plated winding contacts in the device would certainly be possible, but in the context of quality requirements for cars in particular, it is not considered a reliable process.

[0007] As another possibility for providing the contacting, the stranded wire may be soldered to plug-in contacts, which are then fixed onto the housing (electrically insulated). The mating counterpart is already soldered in the circuit board at the correct place, so that when the circuit board is placed on top, a reliable contact is made. This method has been proven in practice, but requires additional plug-in contacts.

[0008] Another important aspect in the automotive field relates to the connection between circuit boards and power modules. Here also, an optimal approach must be found with regard to weight minimisation (fewest possible components), space optimisation (smallest possible components, space-saving arrangement), temperature optimisation (lowest possible waste heat, efficient cooling) and large lot sizes. The latter aspect requires as high a degree of automation as possible in production.

[0009] Approaches to solutions proposed in the prior art are presented below:

[0010] Prior document US 20090154101 A discloses a converter arrangement with a housing and a substrate arranged therein, on which converter switches are fixed, and a printed circuit board. The converter is cooled with liquid and is intended for use in an electric car.

[001 1] The electrical connection between the printed circuit board and the substrate is made via a plurality of spring pins. This connection serves to transmit control signals for the switches of the substrate. In the assembled condition the spring pins are pressed between the printed devices to be connected and thus form the electrical contact.

[0012] The converter arrangement comprises a jet array, in order to direct the cooling liquid over the converter switches and the substrate. The electrical connection between the printed circuit board and the substrate is effected through this jet array. Guide channels are provided for this purpose. This means that the spring pins penetrate the jet array filled with cooling liquid. [0013] An arrangement of this type has a complicated and space-consuming construction, wherein furthermore the contacting by means of spring pins through an intermediate layer filled with cooling liquid requires enormous precision during production and assembly. The electrical connection by means of spring pins is itself susceptible to vibrations due to its construction, and therefore not trouble-free.

Particular disadvantages with regard to the weight are caused by the jet array inside the housing and the device for collecting the cooling liquid.

[0014] EP 1428419B1 discloses an actively externally-cooled housing with a power- loss heat generating electronics module. The electronics module is placed on a side wall of the housing, by means of which the heat can be dissipated. A ventilator unit is provided outside the housing for this purpose. On an outer side of the housing a plug and socket combination can be seen for the electronic connection of the ventilator unit. This arrangement does not involve a vehicle component, and neither does this document contain any teaching about the connections between electrical modules inside the housing.

[0015] US 2009/0021971 A1 discloses a converter arrangement for a vehicle, having a housing and three converters. This document is mainly concerned with the arrangement of a cooling loop in a U-shape, on the outer side of which power modules are placed. How these power modules are connected together and to other components remains open. It is a fact however that the cooling loop has a negative effect on the weight and space requirements, which leads to increased production and operating costs, in particular when it is used in vehicles. [0016] WO 95/01088 A1 discloses a converter module with a metal housing, the front and top faces of which are each designed as a cooling channel plate, on which the circuit components are mounted. This document provides no teaching about the arrangement and connection of electronic components inside the housing.

[0017] EP 1363026 A2 discloses a motor for a vehicle with an integrated converter. Transistor modules, from which contact arms project upwards, are placed directly on the engine housing. Above these transistor modules sits a board with supply leads embedded in resin. Above this sits a printed circuit board. The connection to the MOS transistor modules lying underneath is effected via an intermediate board and via contact pins projecting from this board. After the printed circuit board is placed on top, these are soldered to it.

[0018] In this document a type of sandwich structure with increased packing density is disclosed. The soldering of connections however involves increased cost and an additional, error-prone process step. At the same time the increased packing density causes a sharply increased concentration of heat, which can only be inadequately dissipated with the present cooling system. [0019] Below, prior art which deals with a connection between printed circuit boards is discussed.

[0020] The internet site

"www.phoenixcontact.de/leiterplattenanschluss/226_51579.htm" (bottom of page) discloses a plug connector component which connects two circuit boards together. Such a connection requires an additional component, namely the plug connector between the printed circuit boards, which has an adverse effect on weight, space requirements, assembly effort and costs. [0021 ] FR 2 693 340 A1 discloses a rectangular arrangement of printed circuit boards, which can be connected together via a rectangular intermediate piece - i.e. without cables. As in the previous document this arrangement contains an intermediate part, besides which there would be no space for a rectangular arrangement of this type in a compact designed and commercially competitive vehicle component. [0022] EP 1 978 600 B1 discloses a circuit board arrangement in which two or more circuit boards are connected together via fixed plug connectors. The plug

connectors themselves have a planar construction and overlap with neighbouring circuit boards. For example, one circuit board can be a circuit board for power electronics and the other circuit board can be a signal electronics circuit board. An application in a power distributor box or BCU (Body Controller Unit) in powered vehicles is mentioned. [0023] Instead of a simple plug connector, a fuse holder can also be plugged in between two circuit boards and there provide both a mechanical and an electrical connection between the circuit boards, wherein it accommodates one or more electrical fuses at the same time. [0024] In this arrangement also an additional plug connector is necessary, so that here also the same disadvantages occur as in the case of the previous documents.

[0025] DE 10 2005 061 166 A1 discloses circuit board plug and socket connections and is concerned in particular with a precise guiding of contacts by the use of pressure springs. Other than a spatial arrangement of the circuit boards to be connected, nothing can be found in this document in regard to space, weight or cost savings.

[0026] US 20050152100 A1 discloses electrical power systems particularly to power converters; however, it does not relate to the field of electrical vehicles. In a power module housing a base plate with semiconductor devices such as IGBTs, MOSFETs is accommodated. The base plate is electrically and mechanically connected with a gate drive board indirectly or directly by means of connector sockets.

[0027] DE 10 031 678 A1 discloses a power module with a housing. Contact pins are fixed in the base of the housing. A substrate with semiconductor elements forming a control circuit is pressed to the contact pins. The other ends of the contact pins are connected via leads with semiconductor chips on a metal plate. DE 10 031 678 A1 does not relate to electric vehicles. The heat produced in the semiconductor chips is not comparable to the heat produced by an inductive power element. Thus, the assembly disclosed therein would not help to solve the problems arising in a vehicle power component. [0028] DE 10 2006 025 453 A1 does not relate to electronic vehicles and discloses a press-fit module and a semiconductor press-fit module. The assemblies comprising semiconductor circuits are connected by means of PCB structures.

[0029] DE 10 039 1 10 A1 discloses in connection with a vehicle an arrangement of a printed circuit board with power elements and a support. The connection between board and support is done by contact pins received by corresponding contact openings. The support has an integrated planar transformer with windings.

[0030] US 20100072865 A discloses a vehicle device including a motor generator, a power control unit and a case. The publication does not give any teaching of how to efficiently and space-saving connecting a power module and a printed circuit board electrically.

[0031] US 6320776 B1 relates to a power drive apparatus comprising a main circuit board which is connected with a filter substrate. The filter substrate is accommodated in a housing having openings for receiving switching terminals of the circuit board. All of the above described assemblies are not efficiently space-saving and are not suitable for use in electronic vehicles. [0032] The object of the invention consists of eliminating the above described disadvantages and providing a power electronics vehicle component, which is characterized by a more reliable electrical contacting between the individual components, lower space requirements, higher weight savings and simpler assembly. The cooling of heat generating components is to be effected in a particularly efficient and direct manner. In regard to this optimisation the production and operating costs of the power electronics vehicle component, and therefore of the vehicle overall, should also turn out to be lower than with known solutions.

[0033] This object is achieved with a power electronic vehicle component of the type given at the beginning by the fact that the printed circuit board is connected to the power module by means of at least one plug and socket connection, which is formed by connector parts of male and female type that can be pressed into one another, wherein one of the connector parts sits directly on the printed circuit board and the other connector part sits directly on the power module.

[0034] Instead of the term "power electronic vehicle component" also the equivalent term "vehicle component comprising power electronics" may be used.

[0035] The term, that the connector parts of male and female type can be pressed into one another, is to be understood as indicating that the connector parts may be pressed into one another with low pressure or with high pressure and/or forming a press-fit connection.

[0036] Printed circuit board and power module are here directly plugged into one another, which means that connection cables are no longer necessary and thus space and weight can be saved. The gap between printed circuit board and power module is minimal, so that a high packing density is obtained. The direct insertion by pressing also results in a high mechanical stability of the arrangement. [0037] These coordinated measures produce an optimised arrangement in which the printed circuit board can be simply and reliably electrically connected to the power module, wherein an efficient dissipation of heat can be achieved by means of an arrangement of the power module directly on the housing wall. In this case the heat of the power module is conducted directly into the housing wall. Furthermore, by means of the connection according to the invention, a compact space-saving construction is produced. During assembly, the printed circuit board only needs to be pressed down from above, that is, perpendicular to the printed circuit board, into the connector parts, e.g. in the form of connector strips, arranged or fixed underneath it. Such a press-fit connection requires only a single, short and straightforward process step. Press-fit insertion to produce contact connections is considerably better than soldering and is also preferred as such by the automotive industry. A detachable connection exists, and one which involves a simpler process step, wherein the vibration resistance and mechanical stability increase in equal measure. The latter properties are very important criteria in the vehicle industry in particular for use in batch production. [0038] The term "power electronic vehicle component" is to be understood as a component that contains power electronics, but which moreover can also comprise control electronics (e.g. driver circuits) for controlling the power electronics and therefore serves to provide the appropriate electrical power (voltage, current). This can take the form of e.g. a charging device for charging up a vehicle battery, a converter for generating an AC voltage for the drive unit of a motor or a voltage converter for supplying other devices, such as radio, GPS, air conditioning unit, heating, lights, etc.

[0039] The term "power module" is understood to mean a unit containing power electronics, in particular electronic switches such as IGBTs (Insulated gate bipolar transistors), MOSFETs, diodes, but also capacitors etc., and which in some cases is driven by a set of control electronics. The power module itself can be accommodated in a separate housing or be placed on a separate circuit board. In general, and especially in the automotive field, the power module generates large amounts of waste heat.

[0040] The term "power electronics component" is to be understood to mean a component separate from the power module that also processes electrical power, in particular an inductive component, such as a coil, choke or transformer. The power electronics component is also characterized by increased amounts of waste heat.

[0041] Reference in this specification to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. The appearances of the phrase "in an/one embodiment" in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not other embodiments.

[0042] In one embodiment the male plug part is substantially perpendicular to the plane of the printed circuit board, so that the printed circuit board and power module at least partially overlap. This not only produces a higher packing density, but also allows a simpler installation into the housing from above.

[0043] In one embodiment the power module is fixed onto the housing, preferably abutting it in a planar manner. This causes a direct conduction of the waste heat into the housing.

[0044] In one embodiment the housing is liquid cooled (e.g. with water, oil, etc.). This guarantees a particularly efficient cooling of the power module and all other parts fixed to the housing, such as, for example, connector parts and where appropriate, other power electronics components.

[0045] In one embodiment the power module comprises electronic switches, such as IGBT's, MOSFET's and/or diodes. The power module here consists of multiple components, is used for switching the power current, e.g. to set it high or low, conversion, etc., and is sometimes also referred to as a switching module.

[0046] In one embodiment at least two printed circuit boards are provided, which electrically communicate with the power module and border one another to the side and each of which partially overlaps with the power module, the printed circuit boards preferably lying in the same plane. Both printed circuit boards are connected to the power module in the same manner, that is, pressed directly into the latter via the plug connection. Consequently, two printed circuit boards with different functionality can be connected to the same power module. The arrangement of the printed circuit boards in the same plane guarantees a compact space-saving design. A great advantage of this embodiment lies in the fact that no separate connection element, which otherwise has no additional function, is required for the connection between the two printed circuit boards, but rather a component (power module) is exploited, which already has an inherent important function in itself. This results in a considerable reduction in components.

[0047] In one embodiment the contours of the printed circuit boards lying above the power module and its immediate edge region each have a profile that deviates from a straight line, preferably a profile with at least one bend or one curve, preferably of essentially 90°, wherein the surfaces of the printed circuit boards lying above the power module and its immediate edge region are essentially complementary to each other. By means of this and the two special embodiments discussed below, the two printed circuit boards can cover the plug pin assignment on the power module, so that the contact points of each of the two printed circuit boards, distributed, for example, around the periphery, can be reached/contacted in accordance with the wiring requirements.

[0048] In preferred embodiments, one of the printed circuit boards has an L-shape or a modified U-shape, in which one of the arms is shorter than the other.

[0049] In one embodiment one of the printed circuit boards serves to control the power module and the other printed circuit board serves to electrically connect the power module to another power electronics component, in particular an inductive component, integrated in the vehicle component. By means of this measure the functions of the individual components can also be spatially assigned, with additional connection elements (e.g. plug-in devices) being unnecessary.

[0050] In one embodiment electrical connection leads are fixed, preferably by soldering, to the other printed circuit board, which lead to the additional power electronics component, and electronic components are preferably mounted on this printed circuit board, preferably by means of SMD technology. Thus, other inductive components in particular (transformers, chokes), which are too large to be integrated in a module or on a printed circuit board, can be easily connected up. At the same time the printed circuit board used for the connection can perform other electronic functions.

[0051] The terminals of a transformer or a choke often only need to be connected to the power module, this in turn to a large capacitor and the drive circuit. To do this, the tin-plated HF stranded wires of the inductive component are soldered into a small printed circuit board. This printed circuit board contains plated-through bores (identical to female connector parts) for receiving press-in contacts. In the power module these press-in contacts are arranged as male connector parts into two groups: the first group is, for example, connected to a "large" printed circuit board, which contains the link capacitors and driver connections. This printed circuit board is - as mentioned previously - recessed in the region of the remaining module connections. The small printed circuit board connected to the power electronics component (transformer or choke contacts) fits into this recess and can - after the assembly of the power module and the "large" printed circuit board in the housing - be pressed into the remaining connector parts on the power module. A detachable connection that is secure to process is thus obtained between the inductive component and the power module without the use of additional plug contacts.

[0052] In one embodiment the printed circuit board is electrically connected to a power electronics component via at least one plug connection, which is formed by connector parts of male and female type that can be pressed into one another, wherein one of the connector parts sits directly on the printed circuit board and the other connector part is fixed onto the housing and connected via a connection cable to the power electronics component. [0053] Here the terminals of the power electronics component, e.g. of the transformer or the choke, are connected to a plug part. The plug part is directly mounted on the housing wall or on the base of the housing. The waste heat from the plug-in devices and the printed circuit board is dissipated onto the housing by means of the direct contact of the plug part with the housing. The additional inductance of a supply lead cable barely has any effect.

[0054] Here also a simplified mounting of the printed circuit board is also obtained: it is well known that it is not easy to work under the printed circuit board, since the printed circuit board and power module are accommodated in a housing that is preferably water-cooled. Instead of a complicated soldering process, according to the invention only the printed circuit board connector parts need to be inserted or pressed into the connector parts arranged underneath on the housing. Facing the connector strip, diametrically opposed pins are soldered onto the printed circuit board that communicate with the connector strip.

[0055] In one embodiment the other connector part is fixed to the inside of the housing and sits on the same wall of the housing as the power module. [0056] In one embodiment the power electronics component sits in a cut-out with side walls that project into the interior of the housing and is preferably glued into it, which means the thermal coupling to the housing is improved. [0057] In one embodiment the connector part seated directly on the printed circuit board is of female type.

[0058] In one embodiment the plug connection is made in the form of connector strips which comprise multiple contacts. This results in a simpler assembly and a more stable mechanical connection.

[0059] Further aspects of the invention are indicated in the Figures and in the dependent claims. [0060] The list of reference marks forms part of the disclosure.

[0061] With reference to the Figures of drawings, versions of the invention will now be explained in more detail by means of symbols and examples. [0062] The Figures will be described in combination and taken as a whole.

Equivalent reference marks indicate identical components, and reference marks with different indices indicate functionally equivalent or similar components.

[0063] In the drawings:

[0064] Fig.1 shows a power electronic vehicle component in a schematic view,

[0065] Fig.2 shows a detail of a vehicle component with the housing open from above,

[0066] Fig.3 shows the vehicle component of Fig. 2 along section A-A,

[0067] Fig.4 shows a variant of the invention, [0068] Fig.5 shows a further variant with a combination of contact mechanisms according to the invention.

[0069] Figure 1 shows a power electronic vehicle component in a schematic view. In a housing 1 of the vehicle component a power module 4, a printed circuit board 2, a further printed circuit board 3 and a separately arranged power electronics component 8, for example an inductive component, such as a coil, transformer or similar, are accommodated. The printed circuit board 2 is populated with control electronics, driver circuits and capacitors and serves to control the power module 4, to which it is connected via a plug connection 5. The plug connection 5 includes a connector part 5a assigned to the printed circuit board 2 and a connector part 5b assigned to the power module 4. One of the connector parts, here 5a, sits directly on the printed circuit board 2, the other connector part 5b directly on the power module 4. The connector parts 5a, 5b, one being of male, the other of female type, are pressed into one another and form a press-fit connection. The male connector part is essentially perpendicular to the plane of the printed circuit board. The plug direction therefore is also perpendicular to the printed circuit board. During the assembly the printed circuit board 2 is pressed onto the power module 4 from above, which produces an electrical, and at the same time also a mechanical, connection between the power module 4 and the printed circuit board 2. The pressing of the two connector parts 5a, 5b into each other guarantees a reliable, vibration-proof and trouble-free electrical connection.

[0070] It is irrelevant to the essence of the invention on which component the male connector part or female connector part respectively is arranged, however it has proved advantageous when the male connector part sits on the power module 4 and the female connector part on the printed circuit board 2.

[0071] In the embodiment of Fig.1 a second printed circuit board 3 is also connected to the power module 4 via a plug connection 5 of the same type. It serves to electrically connect the power module 4 to a further power electronics component 8. For this purpose connection leads 7, leading to the power electronics component 8, are fixed, preferably soldered, onto the printed circuit board 3. To connect the power electronics component 8 during assembly, all that is necessary is for the printed circuit board 3 to be plugged or pressed into the power module 4 from above. Apart from the connections to the connection leads 7, other components, e.g. capacitors, can be soldered onto the circuit board 3.

[0072] The housing 1 is preferably liquid cooled, as is indicated by the round liquid channels in the base of the housing 1. The heat that is produced mainly in the power module 4 and also in the other power electronics component 8 can be thereby efficiently dissipated. The power module 4 is consequently also directly mounted on the housing 1. Due to its planar construction it is in contact with the housing over its whole surface, which means the heat is dissipated essentially downwards. To the side of the power electronics component 8, side walls 12 projecting from the housing wall into the interior of the housing form a cut-out, in which the power electronics component 8 is embedded, preferably with an adhesive of high thermal conductivity. An enclosure and embedding of this type is in particular suitable for inductive components, since these are inherently non-planar.

[0073] Figure 2 shows a detailed view of the arrangement according to the invention in a vehicle component from above. The two printed circuit boards 2, 3 each overlap with the power module 4 (shown as transparent in dashed lines), border each other laterally in the region above the power module 4 and form between them a small gap 9. A gap 9 between the printed circuit boards 2, 3 facilitates the mounting on the power module 4. The printed circuit boards 2, 3 lie essentially in the same plane and are shaped in the manner of matching puzzle parts. [0074] The contours of the printed circuit boards 2, 3 that lie above the power module 4 and its immediate edge region each have a profile that deviates from a straight line. In the example illustrated the contours of the printed circuit boards 2, 3 or more comprise bends with a bending angle of essentially 90°, wherein the surfaces of the printed circuit boards 2, 3 that lie above the power module 4 and its immediate edge region are complementary to each other. The printed circuit board 3 has, broadly speaking, an L-shape, which when considered in more detail is seen to be a modified U-shape, in which one of the arms is shorter than the other. By means of this geometrical design the connector parts 5b distributed over the top in the edge region of the power module 4 are contacted by the printed circuit board 3 and also by the printed circuit board 2 in equal measure. The special geometrical design of the printed circuit boards 2, 3 overlapping with the power module 4 depends on the plug pin assignment, however the embodiment illustrated is also proven in relation to the mechanical stability of the connection. Instead of bends in the side contours, curves can also be provided.

[0075] Figure 3 shows the arrangement of Fig. 2 according to the invention along section A-A. The plug connections 5 form between the printed circuit boards 2, 3 and the power module 4 a compact and reliable, space and weight saving connection. The printed circuit boards 2, 3 are in this arrangement immediately adjacent to the power module 4 from above. The printed circuit board 2 can also be populated with electronic components 6, which generate a non-negligible amount of heat and have some space requirements. These electronic components 6 are fixed to the underside of the printed circuit board 2 and are therefore located at the level of the power module 4. The fixing of the components 6 is preferably implemented by solder connections 10. The soldering of the components 6 into the printed circuit board 2 guarantees a reliable electrical and mechanical coupling. At the same time, these heat-generating electronic components 6 are directed downwards, that is, directly facing towards the cooled housing wall. [0076] The printed circuit board 3 can also be populated with small and light electronic components, preferably in SMD (surface mounted device) technology.

[0077] A preferable embodiment of the invention with two printed circuit boards 2, 3 is characterised by the fact that one of the printed circuit boards 2 carries electrical components while the other printed circuit board 3 serves to electrically connect the power module 4 to another power electronics component 8 integrated in the vehicle component, in particular an inductive component. The components of the printed circuit board 2 are preferably components used for controlling the power module 4. Alternatively or additionally, other components, e.g. link capacitors or filter elements, may be provided on that printed circuit board 2. The power electronics component 8 is in that embodiment a coil, a choke or a transformer.

[0078] Figure 4 shows a further contacting option, namely between the printed circuit board 2 and a power electronics component 8, in which one of the connector parts 5b is internally fixed to the housing 1 , for example by means of adhesive or screws. The connector part 5b is connected with a connection cable 1 1 to an inductive power electronics component 8, e.g. a coil, choke or transformer. As in the previous example, during assembly the printed circuit board 2 is pressed with its connector parts 5a into the connector parts 5b perpendicularly from above. In addition to providing the simple and space-saving assembly, such an embodiment also facilitates the thermal decoupling of power electronics component 8 and printed circuit board 2, since the connector parts 5b in contact with the housing 1 are themselves cooled, because the heat transferred onto it can be emitted directly onto the housing 1 . Exactly as in the embodiment of Fig. 1 to 3, the plug connection 5 between printed circuit board 2 and power electronics component 8 facilitates a simple assembly and space-saving design.

[0079] The features described in connection with Fig. 1 to 3 relating to the arrangement, fixing and embedding of the power electronics component 8, the arrangement and function of the printed circuit board 2, the housing 1 and its cooling, and the special construction of the plug connection can naturally also be transferred to the embodiment of Fig. 4.

[0080] The embodiment is not limited to the embodiment illustrated. It is quite conceivable and possible to accommodate in one housing multiple power modules and power electronics components, which are connected to printed circuit boards in the manner according to the invention. Also, more than two printed circuit boards can be assigned to a power module. These can bound one another with their contours in the region above the power module in the manner of a puzzle, which means an optimal plug assignment can be obtained. It is also conceivable to combine the described connector mechanisms as desired, wherein multiple printed circuit boards, power modules and/or power electronics components can also be electrically connected in different ways. The arrangement of the individual parts can thereby be adapted to the design of the housing or of the vehicle component. Such a possibility is discussed below:

[0081] Fig. 5 shows a further embodiment, in which the connector mechanisms of both Fig. 1 to 3 and that of Fig. 4 are combined with one another. The printed circuit board 2 is electrically connected to the power module 4 by means of a direct plug connection, as described in relation to Figs. 1 to 3. With the inductive power electronics component 8, the printed circuit board 2 is connected via a further plug connection, wherein the one set of connector parts sit directly on the printed circuit board 2 and the other connector parts are internally fixed to the housing 1 and pass into a connection cable 1 1 leading to the power electronics component 8. Such a combination solution can be realised in an elegant and space-saving manner in particular when the housing comprises a recess, so that the difference in level between the power module 4 and the connector part seated on the housing is small. An alternative solution results when the power module 4 and the connector part seated on the housing are not fixed to the same housing wall.

[0082] List of reference marks

1 - Housing

2- Printed circuit board

3- Printed circuit board

4- Power module

5- Plug connection

5a- - Connector part

5b- - Connector part

6- Electronic component

7- Connection cable

8- Power electronics component

9- Gap

10- Plug connection

11 - Connection cable

12 - Side walls

Claims

Patent Claims

1 . A power electronic vehicle component, such as an on-board charging device, a converter or a voltage converter, for electric or hybrid vehicles, having a housing (1 ), in which at least one power module (4) and at least one printed circuit board (2, 3) electrically communicating with the power module (4) are accommodated, characterized in that

the printed circuit board (2, 3) is electrically connected to the power module (4) via at least one plug connection (5), which is formed by connector parts (5a, 5b) of male and female type that can be pressed into one another, wherein one of the connector parts (5a) sits directly on the printed circuit board (2, 3) and the other connector part (5b) sits directly on the power module (4).

2. The power electronic vehicle component according to Claim 1 , characterized in that

the male connector part (5a) is essentially perpendicular to the plane of the printed circuit board, so that printed circuit board (2, 3) and power module (4) at least partially overlap. 3. The power electronic vehicle component according to one of the preceding claims,

characterized in that the connector part (5a) seated directly on the printed circuit board (2,

3) is of female type.

4. The power electronic vehicle component according to one of the preceding claims,

characterized in that

the plug connection (5) is made in the form of connector strips which comprise multiple contacts.

5. The power electronic vehicle component according to one of the preceding claims,

characterized in that

the power module (4) is fixed to the housing (1 ), preferably abutting thereto in a planar manner.

6. The power electronic vehicle component according to one of the preceding claims,

characterized in that

the power module (4) comprises electronic switches, such as IGBT's, MOSFET's and/or diodes.

7. The power electronic vehicle component according to one of the preceding claims,

characterized in that

at least two printed circuit boards (2, 3), electrically communicating with the power module (4) are provided, which laterally border one another and each of which partially overlaps with the power module (4), wherein the printed circuit boards (2, 3) preferably lie in the same plane.

8. The power electronic vehicle component according to claim 7,

characterized in that

the contours of the printed circuit boards (2, 3) lying above the power module (4) and its immediate edge region each have a profile that deviates from a straight line, preferably a profile with at least one bend, preferably of essentially 90°, or one curve, wherein the surfaces of the printed circuit boards (2, 3) lying above the power module (4) and its immediate edge region are essentially complementary to each other.

9. The power electronic vehicle component according to one of the claims 7 to 8, characterized in that

one of the printed circuit boards (3) is L-shaped.

10. The power electronic vehicle component according to one of the claims 7 to 9, characterized in that

one of the printed circuit boards (3) has a modified U-shape, in which one of the arms is shorter than the other.

1 1 . The power electronic vehicle component according to one of the claims 7 to 10, characterized in that one of the printed circuit boards (2) carries components used for controlling the power module (4) and/or other components, e.g. a link capacitor or a filter element, and that the other printed circuit board (3) serves to electrically connect the power module (4) to another power electronics component (8) integrated in the vehicle component, in particular an inductive component.

12. The power electronic vehicle component according to claim 1 1 ,

characterized in that

electrical connection leads (7) are fixed, preferably soldered, to the other printed circuit board (3), which lead to the other power electronics component (8), and that electronic components are preferably fixed to this printed circuit board (3), preferably by means of SMD technology.

13. The power electronic vehicle component according to one of the preceding claims,

characterized in that

the printed circuit board (2) is electrically connected to a power electronics component (8) via at least one plug connection (5), which is formed by connector parts (5a, 5b) of male and female type that can be pressed into one another, wherein one of the connector parts (5a) sits directly on the printed circuit board (2, 3) and the other connector part (5b) is fixed to the housing (1 ) and is connected to the via a connection cable (1 1 ) to the power electronics component (8).

14. The power electronic vehicle component according to Claim 13, characterized in that

the housing (1 ) is liquid cooled.

15. The power electronic vehicle component according to one of the preceding claims,

characterized in that

the connector parts (5a, 5b), one being of male, the other of female type, are pressed into one another and form a press-fit connection.

16. The power electronic vehicle component according to one of the Claims 1 1 to 15, characterized in that

the power electronics component (8) is a coil, a choke or a transformer.

17. The power electronic vehicle component according to one of the Claims 1 1 to 16,

characterized in that

both printed circuit boards (2, 3) are connected to the power module (4) in being pressed directly into the latter via a plug connection (5).

18. The power electronic vehicle component according to one of the Claims 7 to 17, characterized in that

the two printed circuit boards (2, 3) form between them a small gap (9).

19. Electric or hybrid vehicle,

characterized in that

said vehicle comprises a power electronic vehicle component according to one of the preceding claims.

20. A power electronic vehicle component comprising:

a housing;

at least one power module in said housing;

a first printed circuit board in said housing; and,

at least one plug connection electrically connecting said printed circuit board to said at least one power module, said plug connection having a first male connector part, said plug connection having a first female connector part being connectable to said first male connector part by press-insertion of said first male connection part into said first female connector part;

one of said first male and female connector parts being seated on said printed circuit board, and the other of said first male and female connector parts being seated directly on said at least one power module.

21 . The power electronic vehicle component as claimed in claim 20 wherein:

said male connector part is perpendicular to a plane of said printed circuit board so that when assembled in connection said printed circuit board and said at least one power module at least partially overlap.

22. The power electronic vehicle component as claimed in claim 20 wherein:

said one of said first male and female connector parts being seated on said printed circuit board is said first female connector part.

23. The power electronic vehicle component as claimed in claim 20 wherein:

said one of said first male and female connector parts being seated on said printed circuit board is said first male connector part.

24. A power electronic vehicle component as claimed in claim 20 further comprising:

said at least one plug connection includes connector strips, said connector strips having multiple electrical contacts.

25. The power electronic vehicle component as claimed in claim 20 wherein:

said at least one power module is fixed to said housing and abuts thereon planar contact.

26. A power electronic vehicle component as claimed in claim 20 further comprising:

electronic switches in said power module, said electronic switches selected from the group of switches consisting of IGBT's, MOSFET's, and diodes.

27. A power electronic vehicle component as claimed in claim 20 further comprising:

a second printed circuit board in said housing, said second printed circuit board being in electrical communication with said at least one power module, said second printed circuit board situated coplanar with and laterally bordering said first printed circuit board;

wherein in the connected assembly of said first and second printed circuit boards and said at least one power module, said first and second printed circuit boards at least partially overlap said at least one power module.

28. The power electronic vehicle component as claimed in claim 27 wherein: said second printed circuit board is assembled directly onto said at least one power module by plug connection

29. A power electronic vehicle component as claimed in claim 27 further comprising:

said first printed circuit board has a first edge region having a respective contour;

said second printed circuit board has a second edge region having a respective contour, said second edge region being complementary to and bordering with said first edge region;

said first and second edge region contours having at least one bend.

30. The power electronic vehicle component as claimed in claim 29 wherein:

said at least one bend includes a curve.

31 . The power electronic vehicle component as claimed in claim 29 wherein:

at least one of said first and second printed circuit boards is L-shaped.

32. The power electronic vehicle component as claimed in claim 29 wherein:

at least one of said first and second printed circuit boards has a modified U- shape.

33. The power electronic vehicle component as claimed in claim 32 wherein:

said modified U-shape is one in which one of the arms of said U-shape is shorter than another of the arms of said U-shape.

34. A power electronic vehicle component as claimed in claim 29 further comprising:

a gap between said bordering first and second edge regions.

35. A power electronic vehicle component as claimed in claim 29 further comprising:

one of said first and second printed circuit boards carries electronic components configured to control said at least one power module; and, the other one of said first and second printed circuit boards electrically connects said at least one power module with a power electronics component in said housing.

36. The power electronic vehicle component as claimed in claim 35 wherein:

said power electronics component is an inductive component selected from the group of inductive components consisting of a coil, a choke, and a transformer.

37. A power electronic vehicle component as claimed in claim 29 further

comprising:

one of said first and second printed circuit boards carries electronic components configured to control said at least one power module; and,

the other one of said first and second printed circuit boards electrically connects said at least one power module with a power electronics component in said housing, this other one of said first and second printed circuit boards having electrical connection leads fixed thereon to connect it to said power electronics component; and said electrical connection leads are SMD-fixed to said respective printed circuit board.

38. A power electronic vehicle component as claimed in claim 20 further

comprising:

a power electronics component in said housing, said power electronics component being electrically connected to said first printed circuit board via a second plug connection;

said second plug connection having a second male connector part, said second plug connection having a second female connector part being connectable to said second male connector part by press-insertion of said second male connection part into said second female connector part, one of said second plug connection's respective male and female parts being seated on said first printed circuit board and the other of said second plug connection's respective male and female parts being fixed to said housing and electrically communicating with said power electronics component via a connecting cable.

39. The power electronic vehicle component as claimed in claim 38 wherein:

said housing is liquid-cooled.