Description:FIELD OF THE INVENTION

The present disclosure relates to electric vehicles. More particularly, the present disclosure relates to a connecting member for a motor controller of an electric vehicle.

BACKGROUND

In recent years, electric vehicles (EVs) have gained widespread popularity due to heightened environmental concerns and increased cost competitiveness with conventional gas vehicles. Typically, an electric vehicle includes a chargeable battery, an electric motor, and a motor controller connected to the electric motor. The motor controller is adapted to control operations, such as drive and control, of the electric motor. The existing motor controller includes a drive circuit board and a control circuit board in communication with the drive circuit board. The drive circuit board which consists of a power converter circuit, adapted to perform a drive function of the electric motor, and the control circuit board which consists of a control circuitry for controlling the drive circuit, adapted to perform a control function of the electric motor.

In the existing motor controller, the drive circuit board and the control circuit board are installed in the motor controller by using several mechanical fasteners, which require significant time, effort, and number of steps associated with the assembly. Moreover, this increases the overall cost associated with the assembly of the drive circuit board and the control circuit board.

Another drawback of the existing motor controller is that the mechanical fasteners provide a mechanical connection without providing an electrical connection between one or more electrical components. This means additional connecting elements are again utilized to facilitate the electrical connection between the drive circuit board and the control circuit board. This increases the number of components of the motor controller, thereby increasing space and overall installation cost of the motor controller.

Therefore, a motor controller that overcomes one or more of the above-mentioned problems associated with the existing motor controller, is desirable.

SUMMARY

This summary is provided to introduce a selection of concepts, in a simplified format, that is further described in the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.

The present disclosure provides a connecting member for securing and electrically connecting a first circuit board to a second circuit board. The connecting member may include a body having a first end and a second end opposite to the first end, and a threaded portion extending from the first end of the body. The second end is adapted to accommodate a fastening member for securing an electrical input member. The threaded portion is adapted to be engaged with a spacer positioned between the first circuit board and the second circuit board. The threaded portion secures the first circuit board to the second circuit board, such that the first end of the body is adapted to be electrically coupled with the second circuit board.

Further, the present disclosure discloses a motor controller. The motor controller may include a first circuit board, a second circuit board, and at least one connecting member. The first circuit board includes at least one spacer, and the second circuit board defines at least one opening adapted to be aligned with a cavity of the at least one spacer. The at least one connecting member is adapted to secure and electrically connect the first circuit board to the second circuit board. The at least one connecting member may include a body having a first end and a second end opposite to the first end and a threaded portion extending from the first end of the body. The second end is adapted to accommodate a fastening member for securing an electrical input member. The threaded portion is adapted to be fastened in the cavity of the at least one spacer positioned between the first circuit board and the second circuit board. The threaded portion secures the first circuit board to the second circuit board, such that the first end of the body is adapted to be electrically coupled with the second circuit board.

Moreover, a method for securing and electrically connecting a first circuit board to a second circuit board is disclosed herein. The method may include installing the first circuit board having at least one spacer and aligning at least one opening of the second circuit board with a cavity of the at least one spacer. Further, the method may include inserting at least one connecting member in the aligned at least one opening of the second circuit board and the cavity of the at least one spacer. At the next step, the inserted at least one connecting member may be fastened in the cavity of the at least one spacer. The connecting member may include a body having a first end and a second end opposite to the first end, and a threaded portion extending from the first end of the body. The second end is adapted to accommodate a fastening member for securing an electrical input member. The threaded portion is adapted to be engaged with a spacer positioned between the first circuit board and the second circuit board. The threaded portion secures the first circuit board to the second circuit board, such that the first end of the body is adapted to be electrically coupled with the second circuit board.

To further clarify the advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

Figure 1 illustrates an assembled view of a motor controller, according to an embodiment of the present disclosure;

Figures 2(a) and 2(b) illustrate exploded views of the motor controller, according to an embodiment of the present disclosure;

Figure 3 illustrates a perspective view of a connecting member, according to an embodiment of the present disclosure;

Figure 4 illustrates a partial sectional view of the motor controller, according to an embodiment of the present disclosure;

Figure 5 illustrates a perspective view of the motor controller, according to an embodiment of the present disclosure;

Figure 6 illustrates a perspective view of a first circuit board of the motor controller, according to an embodiment of the present disclosure;

Figure 7 illustrates a perspective view of a second circuit board of the motor controller, according to an embodiment of the present disclosure; and

Figure 8 illustrates a flow chart depicting a method for securing and electrically connecting the first circuit board to the second circuit board, according to an embodiment of the present disclosure.

Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have necessarily been drawn to scale. For example, the flow charts illustrate the method in terms of the most prominent steps involved to help to improve understanding of aspects of the present invention. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

DETAILED DESCRIPTION OF FIGURES

While the embodiments in the invention are subject to various modifications and alternative forms, the specific embodiment thereof has been shown by way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the invention to the particular forms disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention.

It is to be noted that a person skilled in the art would be motivated from the present invention to modify a connecting member for a motor controller as disclosed herein. Moreover, although the connecting member disclosed herein is shown as being used in the motor controller, it may be appreciated by a person skilled in the art that the connecting member may be implemented to connect two circuit boards of any electronic or electrical device mechanically and electrically without departing from the scope of this disclosure. However, such modifications should be construed to be within the scope of the invention. Accordingly, the drawings show only those specific details that are pertinent to understand the embodiments of the present invention, so as not to obscure the invention with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

Accordingly, the connecting member for the motor controller is described with reference to the figures and specific embodiments; this description is not meant to be constructed in a limiting sense.

Embodiments of the present invention will be described below in detail with reference to the accompanying drawings.

Figure 1 illustrates an assembled view of a motor controller, according to an embodiment of the present disclosure. Figures 2(a) and 2(b) illustrate exploded views of the motor controller, according to an embodiment of the present disclosure. Figure 3 illustrates a perspective view of a connecting member 100, according to an embodiment of the present disclosure. Further, Figure 4 illustrates a partial sectional view of the motor controller 200, according to an embodiment of the present disclosure while Figure 5 illustrates a perspective view of the motor controller 200, according to an embodiment of the present disclosure.

Referring to Figures 1, 2(a), 2(b), 3, 4, and 5, the motor controller 200 may be installed in an electric vehicle (EV) having an electric motor and a power source. The motor controller 200 may be connected to the electric motor and the power source. The motor controller 200 may be adapted to control one or more operations including, but not limited to, a drive operation and a control operation. The motor controller 200 may include a plurality of circuit boards 202, 204, at least one connecting member 100, and a heat sink 216. The at least one connecting member 100 is adapted to secure and electrically connect the plurality of circuit boards 202, 204. In the illustrated embodiment, the plurality of circuit boards 202, 204 may include, but is not limited to, a first circuit board 202 and a second circuit board 204. The first circuit board 202 may include at least one spacer 206 adapted to receive the second circuit board 204.

The second circuit board 204 defines at least one opening 204-1 adapted to be aligned with a cavity of the at least one spacer 206. Herein, the second circuit board 204 may be positioned over the first circuit board 202 by aligning the at least one opening 204-1 with the cavity of the at least one spacer 206. In an embodiment, the motor controller 200 may include a plurality of connecting members 100 positioned at a plurality of positions (U, V, W, B+, B-). The plurality of positions (U, V, W, B+, B-) are shown in Figure 1.

The plurality of connecting members 100 may include, but is not limited to, five connecting members 100. Three connecting members 100 are positioned at U, V, and W positions, respectively, and two connecting members 100 are positioned at B+ and B- positions, respectively. The connecting members 100 positioned at B+ and B- positions, may be adapted to receive an input power from a power source, such as a battery. Further, the three connecting members 100 positioned at U, V, W positions, may be adapted to transfer an output power to the electric motor of the EV. In the subsequent paragraphs, the at least one connecting member 100 and the plurality of connecting members 100 may be interchangeably referred to as the connecting member 100, without departing from the scope of the present disclosure.

The connecting member 100 may be adapted for securing and electrically connecting the first circuit board 202 to the second circuit board 204. The connecting member 100 may include a body 102 and a threaded portion 108 extending from the body 102. The body 102 may include a first end 104 and a second end 106 opposite to the first end 104. The second end 106 is adapted to accommodate a fastening member 212 for securing an electrical input member 214.

The second end 106 defines a plurality of tapered internal threads 112 adapted to receive the fastening member 212 for securing the electrical input member 214. The fastening member 212 may be embodied as a screw, without departing from the scope of the present disclosure. The electrical input member 214 may be connected to the power source, to supply power to the first circuit board 202 and the second circuit board 204 through the connecting member 100. In an embodiment, the electrical input member 214 may be embodied as a busbar or an external wire adapted to facilitate an external electrical connection with the power source.

In the illustrated embodiment, the body 102 has a cylindrical profile defining a flanged portion 110 extending radially outward from the body 102. The flanged portion 110 is adapted to be secured in a mechanical tool for rotating the connecting member 100 about a longitudinal axis X-X’. The flanged portion 110 is proximal to the second end 106 and adapted to support at least one sealing member 210. In another embodiment, the body 102 may have, but is not limited to, a cubical profile or hexagonal profile.

In the illustrated embodiment, the threaded portion 108 extends from the first end 104 of the body 102. The threaded portion 108 may extend from the first end 104 in a downward direction relative to the body 102. The threaded portion 108 is adapted to be engaged with the at least one spacer 206 positioned between the first circuit board 202 and the second circuit board 204. The threaded portion 108 secures the first circuit board 202 to the second circuit board 204, such that the first end 104 of the body 102 is adapted to be electrically coupled with the second circuit board 204. In an embodiment, the threaded portion 108 may be M4 threaded stud. The threaded portion 108 and body 102 may be formed of a conductive metallic material, without departing from the scope of the present disclosure.

The connecting member 100 may be embodied as a standoff, without departing from the scope of the present disclosure. The connecting member 100 may be formed of a conductive metallic material. In an embodiment, the connecting member 100 may be formed of brass. Herein, the connecting member 100 may be formed by using a forging process. In another embodiment, the connecting member 100 may be formed of aluminium. Herein, the connecting member 100 may be formed by using a thread-rolling process.

The heat sink 216 may be adapted to accommodate the first circuit board 202 having the at least one spacer 206. The first circuit board 202 and the second circuit board 204 positioned over the first circuit board 202, may generate heat during the operation of the EV. The heat sink 216 may include a plurality of fins adapted to dissipate the heat generated by the first circuit board 202 and the second circuit board 204.

The heat sink 216 may include a first face 216-1 and a second face 216-2 opposite to the first face 216-1. The first circuit board 202 may be positioned on the first face 216-1 by using a plurality of fasteners. In an embodiment, the plurality of fasteners may be M3 screws 218, as shown in Figures 2(a) and 2(b). Further, the plurality of fins may be formed on the second face 216-2. In an embodiment, the plurality of fins may be integrally formed on the second face 216-2.

The motor controller 200 may include a cover 208 coupled to the heat sink 216 via the plurality of fasteners. The plurality of fasteners may be embodied as the plurality of screws. The cover 208 may define a hollow portion adapted to enclose the first circuit board 202, the connecting member 100 and the second circuit board 204. The cover 208 may support the second end 106 of the connecting member 100. In an embodiment, the cover 208 may at least partially enclose the connecting member 100, the first circuit board 202, and the second circuit board 204. In an embodiment, the cover 208 may be formed of a metallic material. In another embodiment, the cover 208 may be formed of a polymeric material.

The at least one sealing member 210 may be disposed on the flanged portion 110. Herein, the at least one sealing member 210 is interchangeably referred to as the sealing member 210, without departing from the scope of the present disclosure. The sealing member 210 may be positioned between the cover 208 and the body 102 of the connecting member 100. The sealing member 210 may be compressed between the cover 208 and the body 102 of the connecting member 100. The sealing member 210 may prevent an ingress of foreign particles inside the motor controller 200 through the connection of the cover 208 and the body 102. The foreign particles may include, but is not limited to, water and dust. In an embodiment, the sealing member 210 may be formed of a polymeric material.

Figure 6 illustrates a perspective view of the first circuit board 202 of the motor controller 200, according to an embodiment of the present disclosure. Figure 7 illustrates a perspective view of the second circuit board 204 of the motor controller 200, according to an embodiment of the present disclosure. Referring to Figures 6 and 7, the first circuit board 202 and the second circuit board 204 may be embodied as printed circuit boards (PCBs), without departing from the scope of the present disclosure. In one embodiment, the first circuit board 202 may be embodied as a drive PCB 202 or a power PCB 202, and the second circuit board 204 may be embodied as a control PCB 204.

The first circuit board 202 is in communication with the battery to receive 48V direct current (DC). The first circuit board 202 may be adapted to convert the 48V direct current (DC) to alternating current (AC) for the electric motor for driving the EV. The first circuit board 202 may convert the 48V direct current (DC) to phase current with the help of switching metal–oxide–semiconductor field-effect transistors (MOSFETs).

The second circuit board 204 is in communication with the first circuit board 202 and a throttle unit. The second circuit board 204 may be adapted to decide how much current in which profile may be converted based on a response received from the throttle unit. This concept may be implemented in applications where high currents are required to be conducted in between multiple boards and to other modules.

The battery may supply power to the second circuit board 204 through the connecting member 100. The connecting member 100 may transfer the power to the second circuit board 204. Further, the connecting members 100 installed at the U, V, and W positions, may transfer the power from the second circuit board 204 to the electric motor. In one embodiment, the first circuit board 202 and the second circuit board 204 may metal clad PCBs.

The first circuit board 202 may accommodate the at least one spacer 206, and the second circuit board 204 may be positioned on the at least one spacer 206. The at least one spacer 206 may be positioned in between the first circuit board 202 and the second circuit board 204. The second circuit board 204 may include the at least one opening 204-1 adapted to be aligned with the cavity of the at least one spacer 206 when the second circuit board 204 is positioned over the first circuit board 202. A bergstik connector may be soldered to the first circuit board 202, and the second circuit board 204 may include a mating connector adapted to receive the bergstik connector. The bergstik connector is adapted to be mated with the mating connector when the second circuit board 204 is positioned over the first circuit board 202.

The at least one spacer 206 may be positioned on the first circuit board 202 by using a soldering process. The at least one spacer 206 may include the cavity adapted to receive the threaded portion 108 of the connecting member 100. The cavity may include a plurality of internal threads adapted to receive the threaded portion 108 of the connecting member 100. In an embodiment, the plurality of internal threads may be M4 tapped threads. The threaded portion 108 may be engaged with the plurality of internal threads to fasten the connecting member 100 in the at least one spacer 206.

In an embodiment, more than one spacer 206 may be soldered on the first circuit board 202. The number of spacers 206 may be equivalent to the number of connecting members 100. The at least one spacer 206 may be formed of a conductive metallic material. In an embodiment, the at least one spacer 206 may be formed of brass. Herein, the at least one spacer 206 may be formed by using the forging process. In another embodiment, the at least one spacer 206 may be formed of aluminium. Herein, the connecting member 100 may be formed by using the thread-rolling process.

The engagement of the at least one spacer 206 and the connecting member 100 ensures a mechanical connection to secure the first circuit board 202 with the second circuit board 204. Further, the at least one spacer 206 and the connecting member 100 are formed of the conductive metallic material, such that an electrical connection may be formed between the first circuit board 202 and the second circuit board 204. Thus, the at least one spacer 206 and the connecting member 100 may mechanically secure and electrically connect the first circuit board 202 with the second circuit board 204. This means the connecting member 100 performs the dual function of electrically and mechanically connecting the first circuit board 202 to the second circuit board 204. This reduces the number of fasteners required to secure and electrically connect the first circuit board 202 with the second circuit board 204, thereby reducing the time and cost associated with the installation of the first circuit board 202 with the second circuit board 204.

The present disclosure also relates to a method 600 for securing and electrically connecting the first circuit board 202 to the second circuit board 204, as shown in Figure 8. The order in which the method steps are described below is not intended to be construed as a limitation, and any number of the described method steps can be combined in any appropriate order to execute the method or an alternative method. Additionally, individual steps may be deleted from the method without departing from the spirit and scope of the subject matter described herein.

The method 600 begins at step 602 in which the first circuit board 202 may be installed on the heat sink 216 of the motor controller 200. The first circuit board 202 may include the at least one spacer 206 adapted to support the second circuit board 204. The first circuit board 202 may be installed on the heat sink 216 via the plurality of fasteners.

At step 604, the at least one opening 204-1 of the second circuit board 204 may be aligned with the cavity of the at least one spacer 206. Herein, the second circuit board 204 may be positioned over the at least one spacer 206 by aligning the at least one opening 204-1 of the second circuit board 204 with the cavity of the at least one spacer 206.

At step 606, the connecting member 100 may be inserted in the aligned at least one opening 204-1 of the second circuit board 204 and the cavity of the at least one spacer 206. Herein, the cavity is adapted to receive the threaded portion 108 of the connecting member 100. The threaded portion 108 may be passed through the at least one opening 204-1, and then inserted in the cavity.

At step 608, the inserted connecting member 100 may be fastened in the cavity of the at least one spacer 206. The threaded portion 108 of the connecting member 100, may be engaged with the plurality of internal threads of the cavity to fasten the connecting member 100. The fastening of the connecting member 100 in the at least one spacer 206, may secure and electrically connect the first circuit board 202 with the second circuit board 204. In an embodiment, the connecting member 100 may be fastened by using a mechanical tool such as a spanner.

The present disclosure provides the connecting member 100 for securing the first circuit board 202 and the second circuit board 204 by establishing the electrical connection between the first circuit board 202 and the second circuit board 204. Thus, the connecting member 100 provides both the electrical connection as well as the mechanical connection. This reduces the number of components and time associated with the installation of the first circuit board 202 and the second circuit board 204, which further reduces the overall installation cost. Further, the implementation of the sealing member 210 may prevent the entry of the foreign particles inside the motor controller 200. This eliminates the occurrence of failure due to the ingress of the foreign particles and improves the performance of the motor controller 200.

While specific language has been used to describe the present subject matter, any limitations arising on account thereto, are not intended. As would be apparent to a person in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein. The drawings and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. , Claims:1. A connecting member for securing and electrically connecting a first circuit board to a second circuit board, the connecting member comprising:
a. a body (102) having a first end (104) and a second end (106) opposite to the first end (104), the second end (106) adapted to accommodate a fastening member (212) for securing an electrical input member (214); and
b. a threaded portion (108) extending from the first end (104) of the body (102) and adapted to be engaged with a spacer (206) positioned between the first circuit board (202) and the second circuit board (204),
wherein the threaded portion (108) secures the first circuit board (202) to the second circuit board (204), such that the first end (104) of the body (102) is adapted to be electrically coupled with the second circuit board (204).

2. The connecting member (100) as claimed in claim 1, wherein the body (102) has a cylindrical profile defining a flanged portion (110) extending radially outward from the body (102).

3. The connecting member (100) as claimed in claim 2, wherein the flanged portion (110) is adapted to be secured in a mechanical tool for rotating the connecting member (100) about a longitudinal axis (X-X’).

4. The connecting member (100) as claimed in claim 2, wherein the flanged portion (110) is proximal to the second end (106) and adapted to support at least one sealing member (210).

5. The connecting member (100) as claimed in claim 1, wherein the second end (106) defines a plurality of tapered internal threads (112) adapted to receive the fastening member (212) for securing the electrical input member (214).

6. The connecting member (100) as claimed in claim 1, wherein the threaded portion (108) extends in a downward direction relative to the body (102).

7. The connecting member (100) as claimed in claim 1, wherein the body (102) and the threaded portion (108) are formed of a conductive metallic material.

8. A motor controller comprising:
a. a first circuit board (202) having at least one spacer (206);
b. a second circuit board (204) defining at least one opening (204-1) adapted to be aligned with a cavity of the at least one spacer (206); and
c. at least one connecting member (100) adapted to secure and electrically connect the first circuit board (202) to the second circuit board (204), the at least one connecting member (100) comprising:
i. a body (102) having a first end (104) and a second end (106) opposite to the first end (104), the second end (106) adapted to accommodate a fastening member (212) for securing an electrical input member (214); and
ii. a threaded portion (108) extending from the first end (104) of the body (102) and adapted to be fastened in the cavity of the at least one spacer (206) positioned between the first circuit board (202) and the second circuit board (204),
wherein the threaded portion (108) secures the first circuit board (202) to the second circuit board (204), such that the first end (104) of the body (102) is adapted to be electrically coupled with the second circuit board (204).

9. The motor controller (200) as claimed in claim 8, wherein the cavity comprises a plurality of internal threads adapted to receive the threaded portion (108) of the at least one connecting member (100).

10. The motor controller (200) as claimed in claim 8, comprising a cover (208) for accommodating the second end (106) of the at least one connecting member (100), wherein the cover (208) is adapted to at least partially enclose the at least one connecting member (100), the first circuit board (202), and the second circuit board (204).

11. The motor controller (200) as claimed in claim 8, wherein the body (102) has a cylindrical profile defining a flanged portion (110) extending radially outward from the body (102).

12. The motor controller (200) as claimed in claims 10 or 11, comprising at least one sealing member (210) disposed on the flanged portion (110) and adapted to be compressed between the cover (208) and the body (102) of the at least one connecting member (100).

13. The motor controller (200) as claimed in claim 8, wherein the at least one spacer (206) and the at least one connecting member (100) are formed of a conductive metallic material to form an electrical connection with the first circuit board (202) and the second circuit board (204) respectively.

14. The motor controller (200) as claimed in claim 8, wherein the at least one connecting member (100) and the at least one spacer (206) are formed of at least one of brass and aluminium.

15. The motor controller (200) as claimed in claim 8, wherein the at least one connecting member (100) and the at least one spacer (206) are formed by using one of a forging process and a thread rolling process.

16. The motor controller (200) as claimed in claim 8,
wherein the first circuit board (202) is a drive printed circuit board (PCB); and
wherein the second circuit board (204) is a control printed circuit board (PCB).

17. A method for securing and electrically connecting a first circuit board to a second circuit board, the method comprising:
a. installing (602) the first circuit board (202) having at least one spacer (206);
b. aligning (604) at least one opening (204-1) of the second circuit board (204) with a cavity of the at least one spacer (206);
c. inserting (606) at least one connecting member (100) in the aligned at least one opening (204-1) of the second circuit board (204) and the cavity of the at least one spacer (206); and
d. fastening (608) the inserted at least one connecting member (100), wherein the at least one connecting member (100) comprises:
i. a body (102) having a first end (104) and a second end (106) opposite to the first end (104), the second end (106) adapted to accommodate a fastening member (212) for securing an electrical input member (214); and
ii. a threaded portion (108) extending from the first end (104) of the body (102) and adapted to be fastened in the cavity of the at least one spacer (206) positioned between the first circuit board (202) and the second circuit board (204),
wherein the threaded portion (108) secures the first circuit board (202) to the second circuit board (204), such that the first end (104) of the body (102) is adapted to be electrically coupled with the second circuit board (204).