TWI706585B - High power density vehicle power supply device - Google Patents

Abstract

The present invention is a high-power density vehicle power supply device, which is mainly formed with a bottom plate in a casing, and an upper casing cover and a lower casing cover are respectively provided on the top and bottom of the casing. An accommodating space is formed between the upper shell cover, and a water-cooling channel is formed between the bottom plate and the lower shell cover; the accommodating space of the casing is provided with a power conversion module, and the heating element on the power conversion module And it forms thermal contact with the bottom plate of the casing. When the cooling water in the water cooling channel flows, it can dissipate the heat generating components of the power conversion module; the above design can provide a perimeter for car power supplies with limited space and size Insulation and heat dissipation solutions.

Description

High power density vehicle power supply device

The present invention is a power supply device for vehicles, in particular to an insulation and heat dissipation solution applied to power supply devices for high-power density vehicles without being limited by space.

Under the dual factors of environmental protection and energy substitution, the development of pure electric vehicles has become an inevitable trend. In addition to battery-related technologies related to endurance, speed is also one of the important indicators for the development of pure electric vehicles. Therefore, pure electric vehicles must rely on high-power vehicle power supplies for power supply. However, in the development of high-power vehicle power supplies, the working environment faced by various components is much stricter than that of ordinary power supply devices. There are special requirements on size restrictions, and the development of technology is facing greater challenges.

As electric vehicles use high-power power supplies, heat dissipation solutions involving operating efficiency are an important technical issue in the development of technology. As mentioned earlier, for electric vehicles, the working environment faced by vehicle power supplies is more severe than that of general power supply devices. In addition to the limitation of space size, the heat dissipation solution must not only meet the specification requirements, but also overcome the limitations of the working environment and space size, that is, breakthrough technical solutions are needed to solve the problem.

Therefore, the main purpose of the present invention is to provide a high-power density vehicle power supply device, which can meet the heat dissipation scheme required by the vehicle power supply in a limited space and ensure the normal operation of the vehicle power supply.

The technical means adopted to achieve the above-mentioned purpose is to make the aforementioned high-power-density vehicle power supply device include: a casing with a top and a bottom, and a bottom plate in the casing; and an upper casing cover, which is attached to the machine At the top of the shell, the shell forms a accommodating space between the inner side of the bottom plate and the upper shell cover; the lower shell cover is set on the bottom of the shell, and the shell is formed between the outside of the bottom plate and the lower shell cover A water-cooling channel; a power conversion module, which is arranged in the housing space of the cabinet, the power conversion module includes a heating element, and the heating element forms thermal contact with the bottom plate of the cabinet; When the cooling water flows, the heat generating components of the power conversion module can be dissipated.

The above design makes good use of the space inside and outside the chassis of the car power supply device, and uses the water-cooled channel and thermal contact design to provide a comprehensive heat dissipation solution for the space and size limited car power supply, and maximize the efficiency of meeting the needs of the car power supply heat radiation.

The following describes the technical means adopted by the present invention to achieve the intended purpose of the invention in conjunction with the drawings and preferred embodiments of the present invention.

Regarding a preferred embodiment of the present invention, please first refer to Figures 1 and 2, which include a casing 10 having a top, a bottom and a bottom plate 11, and the top of the casing 10 is provided with There is an upper shell cover 30, the shell 10 forms a accommodating space between the inner surface of the bottom plate 11 and the upper shell cover 30, and a power conversion module 20 is arranged in between; the shell 10 is provided with a lower shell at its bottom Cover 40, please refer to FIG. 3. The casing 10 further forms a water-cooling channel 12 between the outer surface of the bottom plate 11 and the lower casing cover 40; the power conversion module 20 includes a heating component, the heating component It is in thermal contact with the bottom plate 11 of the casing 10, and when cooling water passes through the water cooling channel 12 under the bottom plate 11, the heat generating component can be dissipated.

Please refer to FIG. 2 and FIG. 4, in this embodiment, the casing 10 is rectangular and has four side walls. The four side walls include two long side walls 101 and 103 that are opposite in parallel and located in the length direction. The two wide side walls 102 and 104 in the width direction are respectively provided with more than one fixing block 105 on the outer sides of the two wide side walls 102 and 104 to facilitate fixing the casing 10 to the vehicle. One of the long side walls 101 is formed with two connector holders 106A, 106B and a port opening 107. The connector holders 106A, 106B are respectively provided with a power connector 13, 14 and the port opening 107 A connection port 16 is provided, and the power connectors 13 and 14 and the connection port 16 are electrically connected to the power conversion module 20 respectively.

In this embodiment, the casing 10 is formed by die-casting aluminum, and an insulating layer 100 is provided in the accommodating space, so that the accommodating space is in an insulated state, and the insulating layer 100 is coated with epoxy resin. The accommodating space corresponds to the surfaces of the bottom plate 11, the two long side walls 101, 103 and the two wide side walls 102, 104.

The casing 10 is respectively formed with more than one fixing posts 108 on the inner sides of the long side walls 101 and 103 and the wide side walls 102 and 104, the fixing posts 108 are located in the vertical direction, and fixing holes are formed on the top surface. The upper casing cover 30 is fixed to the top of the casing 10. A continuous groove 109 is formed on the top sides of the long side walls 101, 103 and the wide side walls 102, 104 for providing a waterproof gasket 15 (see FIG. 2 for cooperation) to ensure that the upper housing cover 30 and the housing 10 The closed state between the two after the combination.

Still referring to FIG. 4, the other long side wall 103 of the casing 10 is respectively provided with an inlet pipe 103A and an outlet pipe 103B. The inner ends of the inlet pipe 103A and the outlet pipe 103B penetrate the long side wall 103, and the bottom plate 11 The lower water-cooling channel 12 communicates with each other. Furthermore, the water inlet pipe 103A and the water outlet pipe 103B are located at two ends of the water-cooling channel 12. Please refer to FIG. 5, in this embodiment, the water-cooling channel 12 consists of three U-shaped sections 121 to 123 connected in forward and reverse directions, and these U-shaped sections 121 to 123 cover most of the bottom surface of the bottom plate 11. The area, that is, the water cooling channel 12 will cool the bottom plate 11 in an all-round way. When the water inlet pipe 103A on the casing 10 is connected to the pipeline for feeding cooling water, the cooling water will pass through the U-shaped sections 121~123 and then be sent out from the water outlet pipe 103B, and flow between the U-shaped sections 121~123 The cooling water that is in thermal contact with the bottom plate 11 dissipates heat.

In order to make the water-cooling channel 12 exert the best heat dissipation effect on the heating components on the surface of the bottom plate 11, the housing 10 is arranged with a special space design in the accommodating space. Please refer to Figures 3 and 4, which are mainly The surface of the bottom plate 11 is provided with more than one platform on which the heating components are placed and form thermal contact. In this embodiment, the surface of the bottom plate 11 is provided with a first platform 111 and a second platform 112, the first platform 111 and The surface of the bottom plate 11 is roughly on the same level, and the second platform 112 protrudes from the surface of the bottom plate 11 to a height, that is, the second platform 112 is higher than the first platform 111, and the bottom of the second platform 112 is hollow and is connected to the water cooling channel. A U-shaped section 122 of 12 is connected (see Fig. 5 and Fig. 6). In order to balance the cooling water flow rate of the water-cooling channel 12 between the U-shaped sections 121~123, the bottom of the second platform 112 corresponds to the U A plurality of buffer columns 113 are formed at the shaped section 122, and the cross-sectional area and flow rate of the U-shaped section 122 of the water cooling channel 12 under the second platform 112 are adjusted by the buffer columns 112. A plurality of fixing holes 112A are formed at the periphery of the top surface of the second platform 112.

Please refer to FIG. 2 and FIG. 7, in this embodiment, the heating element includes a crystal heat dissipation group 50 and a magnetic element fixing group 60, which are respectively disposed on the first platform 111 in the casing 10 , On the second platform 112, and constitute a thermal contact; the crystal heat dissipation group 50 includes a heat sink 51 and a plurality of transistors 52, the transistors 52 are fixed on the surface of the heat sink 51 by welding, the electrical The crystal 52 has a plurality of pins 520, and each pin 520 is bent upward in the vertical direction for plugging in the power conversion module 20 and forming an electrical connection. A plurality of hollow fixing posts 510 are formed around the periphery of the heat sink 51, and each fixing post 510 corresponds to each fixing hole 112A on the second platform 112, respectively.

The magnetic element fixing group 60 includes more than one magnetic element 61 and two or more fixing members 62 used in pairs, and the magnetic element 61 is fixed between the two fixing members 62 in a shape-matching manner, as shown in FIG. 8, The fixing member 62 has a back plate 620. The periphery of the back plate 620 extends inwardly to form a blocking edge 621 matching the shape of the magnetic element 61. In this embodiment, the magnetic element 61 has a rectangular iron core 610 outside. The back plate 620 of the fixing member 62 is also rectangular, and its four corners respectively extend inwardly to form a relatively L-shaped retaining edge 621 for matching and covering the core 610 of the magnetic element 61.

The back plate 620 of the fixing member 62 has two parallel opposite sides, one of which extends inward to form a first clasp 622, and the other side extends inward to form a second clasp 623. The first The clasp 622 and the second clasp 623 are in a complementary relationship. In this embodiment, the first clasp 622 has a horizontal section. The end of the horizontal section forms a circular clasp 622A. The outer diameter of the clasp 622A is larger than The width of the horizontal section, the inner side of the buckle portion 622A is formed with an inner inclined wall 622B to reduce the thickness of the end portion of the buckle portion 622A and increase the thickness to the original thickness. This design makes the first clasp 622 easier to buckle Together.

The second buckle piece 623 is in the shape of a sheet, and a buckle groove 623A in the horizontal direction is formed thereon. One end of the buckle groove 623A penetrates the free end of the second buckle piece 623 to form a necked section 623B. The width of the 623B is smaller than the groove width of the buckle groove 623A, and the inner end of the necked section 623B is in an arc shape, which matches the circumference of the buckle portion 622A of the first buckle 622. An inclined surface 623C is formed on the outer side wall of the free end of the second clasp 623, which matches the inner inclined wall 622B of the clasp 622A of the first clasp 622.

Please refer to FIG. 9, when two fixing members 62 arranged in opposite directions fix the magnetic element 61 therebetween, the first clasp 622 of one fixing member 62 passes through the second fixing member 62 with its clasp 622A. The two buckle pieces 62 enter the buckle groove 623A thereon, and the buckle portion 622A will stop at the inner side of the necked section 623B of the buckle groove 623A, so that the first buckle 622 and the second buckle 623 can be buckled with each other. The first buckle 622 of the aforementioned other fixing member 62 also buckles with each other in the same manner because its buckle portion 622A passes through the second buckle 62 of one of the fixing members 62 and enters the buckle groove 623A of the second buckle 623. . Since the buckle portion 622A of the first buckle piece 622 and the second buckle piece 623 respectively have opposite inner inclined walls 622B and inclined surfaces 623C, they can pass smoothly and buckle with each other.

Still referring to FIG. 8, a wedge column 624 and a wedge groove 625 are respectively formed on the outer surface of the back plate 620 of the fixing member 62, and when it is back to back with the other fixing member 62, the wedge column can be located at a complementary position. 624 and the wedge grooves 625 are wedge-connected to each other, that is, a plurality of fixing members 62 can be connected by using the wedge structures, and a magnetic element 61 is fixed between the pair of two fixing members 62 respectively. In this embodiment, a hole is formed in the center of the back plate 620 of the fixing member 62, and a detent piece 626 protruding toward the inner side of the back plate 620 is provided in the through hole. A plurality of connections are formed between the detent piece 626 and the edge of the perforation. The ribs support the resisting piece 626 and make the resisting piece 626 slightly stretchable. In this way, the two fixing members 62 that are engaged with each other have to use the stopper piece 626 protruding from the inner side of the fixing member 62 to press against the magnetic element 61 located therebetween to enhance the fixing effect.

The fixing member 62 is further formed with a hook 627 on both ends of the top of the back plate 620, and the two hooks 627 are facing outwards. The hooks 627 can be used to fix the magnetic component 60 and the power conversion module. 20 combined with each other.

Still referring to FIG. 2, the power conversion module 20 includes a circuit board 21 on which a power conversion circuit is provided, and a plurality of hook grooves 22 and a plurality of fixing holes 23 are formed. 22 are respectively corresponding to the hooks 627 on the fixing parts 62 of the magnetic element fixing group 60, so that the magnetic element fixing group 60 uses the hooks 627 on the fixing parts 62 to be buckled in the hook grooves 22 of the circuit board 21, so that the magnetic element The fixing group 60 is combined with the circuit board 21. Regarding the above-mentioned hooks 627 of the magnetic element fixing group 60 and the hook grooves 22 provided on the circuit board 21, there may be a one-to-one correspondence, that is, the number of hook grooves 22 provided on the circuit board 21 and the magnetic element fixing group 60 The number of hooks 627 is the same. In this embodiment, the circuit board 21 is formed with a number of larger-sized hook grooves 22. Furthermore, each hook groove 22 corresponds to two fixing pieces for fixing a magnetic element 61 The hook 627 provided on the hook 62 means that a total of four hooks 627 on the two fixing members 62 are hooked together on the opposite groove edges of the same hook groove 22.

A plurality of plug-in holes 24 are formed on the circuit board 21. Each plug-in hole 24 corresponds to the aforementioned pin 520 of each transistor 52. The pin 520 of each transistor 52 is inserted into the plug-in hole 24 of the circuit board 21 and then soldered. That is, each transistor 52 is electrically connected to the power conversion circuit on the circuit board 21. The circuit board 21 is electrically connected to the power connectors 13 and 14 and the connection port 16 provided on the long side wall 101 of the casing 10.

Regarding the combination of the circuit board 21 and the crystal heat sink 50, please refer to FIG. 2. A number of screws 25 are respectively passed through the fixing holes 23 of the circuit board 21 and the fixing posts 510 on the heat sink 51 to be screwed together. To the fixing hole 112A of the second platform 112, the bottom surface of the heat sink 51 is suitable for contact with the surface of the second platform 112 at this time. The magnetic element fixing group 60 is hooked on the groove edge of the hook groove 22 of the circuit board 21 with the hook 627 on the fixing member 62, and the bottom of the magnetic element fixing group 60 is in contact with the first platform 111 in the casing 10, as shown in FIG. In this embodiment, a thermal conductive paste 26 is further provided between the magnetic element fixing group 60 and the first platform 111, so that the thermal energy generated by the magnetic element fixing group 60 can be fully conducted to the first platform 111.

Furthermore, the casing 10 is connected to the upper casing cover 30 at the top of the casing 10 by screwing, and the two are in a sealed state by the waterproof gasket 15 provided on the top of the casing 10. The bottom of the casing 10 is provided with a sealing layer 17 in the area outside the water cooling channel 12. When the bottom of the casing 10 is combined with the lower casing cover 40, it is used to ensure the sealing state between the bottom of the casing 10 and the lower casing cover 40. In the embodiment, the sealing layer 17 is composed of a liquid sealing paste, which can maintain an ideal airtight state when the joint surface between the bottom of the casing 10 and the lower casing cover 40 is not completely flat.

It can be seen from the above specific implementation aspects of the present invention that the structure has at least the following features: 1. The present invention forms a water-cooling channel at the bottom of the case, and uses thermal contact to dissipate heat from the heating components in the case. This design is not only a breakthrough In addition to space constraints, it can also maximize heat dissipation efficiency in the smallest space. 2. In the present invention, epoxy resin is coated as an insulating layer in the housing space of the casing, which is mainly to meet the needs of high-power models of customer size specifications. The insulation distance between electronic components and the casing must be reduced. In the past, insulating sheets were used The method of isolation does not have much space-saving advantages on a die-cast aluminum housing with a relatively complicated internal structure. Therefore, the present invention coats the interior of the housing with epoxy resin so that the bottom of the housing space in the housing is The sidewalls are equipped with insulating ability, which greatly increases the space available for other components. 3. The present invention uses single-specification fixing pieces to be used in pairs to fix magnetic components, which not only simplifies the components, but also expands the number of fixed magnetic components as needed, and can be easily combined with other devices (such as power conversion modules) , The assembly is very simple and fast.

The above are only the preferred embodiments of the present invention, and do not limit the present invention in any form. Although the present invention has been disclosed as above in preferred embodiments, it is not intended to limit the present invention. Anyone familiar with the field, Without departing from the scope of the technical solution of the present invention, when the technical content disclosed above can be used to make slight changes or modification into equivalent embodiments with equivalent changes, but any content that does not depart from the technical solution of the present invention is based on the technical essence of the present invention Any simple modifications, equivalent changes and modifications made to the above embodiments still fall within the scope of the technical solutions of the present invention.

101, 103, 102, 104, long side walls 10 of the cabinet 100 wide sidewall insulating layer 103A 103B inlet pipe 105 outlet pipe fixing block 106A, 106B is connected to port window 108 holder 107 fixed column 11 bottom plate 111 of the first groove 109 internet 112 12 water cooling channels of the second internet 112A fixing hole 113 of the cushion pins 121 ~ 123 U-shaped section 13, 14 power connector 15 watertight gasket 17 sealing layer 16 port 20 power conversion module 21 circuit board 22 plug hole 24 slot 23 hook fixing hole a thermally conductive paste 25 on the screw 26 housing 30 cover 50 cover case the group crystal cooling fins 510 4051 52 column transistor 520 fixed pin 60 fixed to the magnetic element 61 of the magnetic element 610 sets the core member 62 is fixed to the back plate 620 621 stop edge of the inner wall 622 of the first ramp 622B 622A cleat fastening portion 623 of the second cleat snap groove 623A 623B 623C necking ramp section 624 wedge 625 wedge groove 626 column latch plate 627 abuts the hook fastener

Figure 1 is an external view of a preferred embodiment of the present invention. Figure 2 is an exploded view of a preferred embodiment of the present invention. 3 is a schematic diagram of the relative relationship between the casing and the lower casing cover of a preferred embodiment of the present invention. Figure 4 is a perspective view of a casing of a preferred embodiment of the present invention. Fig. 5 is a schematic view of the bottom of the casing of a preferred embodiment of the present invention. Figure 6 is a cross-sectional view of a casing of a preferred embodiment of the present invention. Fig. 7 is a schematic diagram of a heat generating component provided in a casing of a preferred embodiment of the present invention. Fig. 8 is an exploded view of a magnetic element fixing group according to a preferred embodiment of the present invention. Fig. 9 is a combined plan view of a magnetic element fixing group according to a preferred embodiment of the present invention. Figure 10 is a combined cross-sectional view of a preferred embodiment of the present invention.

10 on the bottom plate 111 of the first housing 11 platform 12 platform to the water cooling passage 112 second waterproof packing 15 sealing layer 17 plug hole 24 slot 22 hook 21 of the circuit board 26 thermally conductive paste 30 under the cover 40 housing cover 51 fins 52 connected transistor 520 Foot 60 Magnetic element fixation group 61 Magnetic element 62 Fixing part 627 hook button

Claims (9)

A high-power-density vehicle power supply device includes: a casing with a top and a bottom, and a bottom plate in the casing; an upper casing cover, which is arranged on the top of the casing, and the casing is disposed on the top of the casing. An accommodating space is formed between the inner side of the bottom plate and the upper casing cover, and an insulating layer is arranged in the accommodating space, and the insulating layer is formed by coating epoxy resin; the lower casing cover is arranged at the bottom of the casing, The casing forms a water-cooling channel between the outer side of the bottom plate and the lower casing cover; a power conversion module is arranged in the housing space of the casing, the power conversion module includes a heating element, and the heating element It is in thermal contact with the bottom plate of the casing. In the high-power-density vehicle power supply device described in claim 1, more than one platform is provided on the surface of the bottom plate of the casing for setting the heating components of the power conversion module and forming thermal contacts; the heating components include a magnetic element A fixing group, the magnetic element fixing group includes more than one magnetic element and two or more fixing parts used in pairs, and the magnetic element is fixed between the two fixing parts in a matching shape; the fixing part has a back plate, the The peripheral edge of the back plate extends inwardly to form a retaining edge matching the shape of the magnetic element; the back plate of the fixing member extends inward on two opposite sides to form a first clasp and a second clasp in a complementary relationship . According to the high-power-density vehicle power supply device of claim 2, a first platform and a second platform are provided on the bottom plate surface of the chassis, the magnetic element fixing group is provided on the first platform, and the heating assembly further includes A crystal heat dissipation group, the crystal heat dissipation group is arranged on the second platform; the second platform protrudes at a height from the surface of the bottom plate, and the bottom of the second platform is hollow and communicates with the water cooling channel; The water cooling channel is composed of a plurality of U-shaped sections connected in forward and reverse directions, and one of the U-shaped sections is located below the second platform. For the high-power density vehicle power supply device described in claim 3, a plurality of buffer columns are formed at the bottom of the second platform corresponding to the U-shaped section. According to the high-power density vehicle power supply device of claim 2, the first clasp of the fixing member has a horizontal section, the end of the horizontal section is formed with a circular buckle, and the outer diameter of the buckle is greater than the width of the horizontal section ; The second buckle is sheet-shaped, on which is formed a buckle groove in the horizontal direction, one end of the buckle groove penetrates the free end of the second buckle to form a necking section, the width of the necking section is smaller than the buckle The groove is wide, and the inner end of the necking section is in the shape of an arc, which matches the periphery of the buckle of the first clasp. According to the high-power density vehicle power supply device of claim 3, the crystal heat dissipation group includes a heat sink and a plurality of transistors, the transistors are respectively fixed on the surface of the heat sink, and the transistors each have a plurality of Each pin is bent upward in the vertical direction for plugging into the power conversion module and forming an electrical connection; the power conversion module includes a circuit board on which a plurality of plug-in holes and multiple plug-in holes are formed. There are hook grooves, and the pins of the plug-in hole power supply crystals are correspondingly inserted and form electrical connections; the fixing parts of the magnetic element fixing group are respectively formed with a hook at the top end of the back plate, and the two hooks are facing outwards. And correspondingly hooked on the opposite groove edge of the hook groove of the circuit board. For the high-power density vehicle power supply device described in claim 6, a plurality of fixing holes are formed at the periphery of the top surface of the second platform in the casing; a plurality of hollow fixing posts are formed at the periphery of the heat sink, and each fixing The posts correspond to the fixing holes on the second platform; a plurality of fixing holes are formed on the circuit board, and each fixing hole corresponds to the fixing post on the heat sink and the fixing hole on the second platform, and a screw is provided in between. Mutual screw together. According to the high-power density vehicle power supply device of claim 5, the magnetic element has a rectangular iron core outside, and the back plate of the fixing member is also rectangular, and the four corners respectively extend inward to form a relatively L-shaped The retaining edge is used to match and cover the core of the magnetic element. The high-power-density vehicle power supply device according to any one of claims 1 to 8, wherein the casing is rectangular and has four side walls, the four side walls including two long side walls that are parallel to each other and located in a length direction and parallel Two wide side walls opposite to each other in a width direction, one of the long side walls is formed with a water inlet pipe and a water outlet pipe. The water inlet pipe and the water outlet pipe are respectively connected with two ends of the water cooling channel; the other long side of the cabinet More than one connector holder and a port opening are formed on the side walls, the connector holder is provided with a power connector, the port opening is provided with a port, the power connector and the port are respectively It is electrically connected to the power conversion module.

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