Liquid cooling heat exchanger, liquid cooling heat exchange assembly and converter

Abstract

The invention discloses a liquid cooling heat exchanger, a liquid cooling heat exchange assembly and a converter, the liquid cooling converter comprises a heat exchange part, the heat exchange part comprises a first heat exchange module and a second heat exchange module which are arranged side by side front and back, and each module is provided with a plurality of first heat exchange runners and second heat exchange runners which are vertically arranged side by side and are consistent in length; the liquid inlet part is provided with a liquid inlet flow channel protruding and bending upwards and comprises a first liquid inlet section and a second liquid inlet section which are communicated, a liquid inlet is formed in the bottom of the first liquid inlet section and communicated with the first heat exchange end of each first heat exchange flow channel, and the second liquid inlet section is communicated with the first heat exchange end of each second heat exchange flow channel; the bent part of the liquid inlet runner is not lower than the first heat exchange end of the highest heat exchange runner, and the liquid inlet is not higher than the first heat exchange end of the lowest first heat exchange runner; the liquid outlet part is provided with a liquid outlet flow channel which protrudes and bends upwards and comprises a first liquid outlet section and a second liquid outlet section which are communicated, the first liquid outlet section is communicated with the second heat exchange end of each first heat exchange flow channel, and the bottom of the second liquid outlet section is provided with a liquid outlet which is communicated with the second heat exchange end of each second heat exchange flow channel; the bent position of the liquid outlet flow channel is not lower than the second heat exchange end of the highest heat exchange flow channel, and the liquid outlet is not higher than the second heat exchange end of the lowest second heat exchange flow channel. The liquid cooling heat exchanger can keep good heat dissipation performance and operation stability under the gas-containing working condition.

Description

Technical Field

[0001] This invention relates to the field of liquid-cooled heat exchanger technology, specifically to a liquid-cooled heat exchanger, a liquid-cooled heat exchange component, and a converter. Background Technology

[0002] In electrical equipment, such as energy storage converter modules, liquid cooling can efficiently remove the heat generated by electronic components, ensuring the entire electrical system operates smoothly and stably. This liquid cooling method requires an external cold source system to circulate the liquid cooling medium, while components like liquid cooling plates are installed within the electrical equipment to dissipate heat from the electronic components. However, conventional liquid cooling systems, when using liquid cooling plates, typically only dissipate heat from the electronic components directly in contact with the plate. The heat generated by these components diffuses throughout the entire internal space of the electrical equipment, resulting in less than ideal overall heat dissipation. To address this, existing technologies incorporate a fan and a liquid-cooled heat exchanger to form an air-liquid heat exchange assembly. The liquid-cooled heat exchanger, like the liquid cooling plate, is equipped with liquid cooling pipes to circulate the liquid cooling medium. The heat exchanger also features heat exchange fins or perforated heat exchange sections. A fan directs airflow into the heat exchange section of the liquid-cooled heat exchanger, converting hot air into cold air and circulating it within the electrical equipment's casing.

[0003] However, in electrical equipment with liquid-cooled plates and liquid-cooled heat exchangers, the gas in the liquid-cooled piping can affect the heat dissipation performance and operational stability of the liquid-cooling system, especially during initial startup when liquid cooling medium is injected or after prolonged periods of inactivity. Current technology typically relies on the circulating power of the cold source system to carry and expel the gas from the piping. However, because the liquid-cooled heat exchanger is positioned higher than the liquid-cooled plate, air in the liquid-cooled piping tends to accumulate in the heat exchanger. Furthermore, the heat exchanger's distance from the cold source system prevents it from receiving sufficient power to expel the gas, thus reducing its heat dissipation performance and operational stability. Summary of the Invention

[0004] The purpose of this invention is to overcome the above-mentioned defects or problems in the prior art and to provide a liquid-cooled heat exchanger, a liquid-cooled heat exchange component, and a converter, which can maintain good heat dissipation performance and operational stability under gas-containing conditions.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] Technical Solution 1: A liquid-cooled heat exchanger, comprising: a heat exchange section for contacting an external fluid to achieve heat exchange, and including a first heat exchange module and a second heat exchange module arranged side-by-side in a front-back direction; the first heat exchange module and the second heat exchange module are respectively provided with a plurality of first heat exchange channels and second heat exchange channels arranged side-by-side in a vertical direction and of equal length; the two ends of each first heat exchange channel and second heat exchange channel are respectively a first heat exchange end and a second heat exchange end; a liquid inlet section, which is provided with an upwardly protruding and bent liquid inlet channel, the liquid inlet channel including a first liquid inlet section and a second liquid inlet section that are interconnected; the bottom of the first liquid inlet section is provided with an inlet suitable for receiving a liquid cooling medium, and is simultaneously connected to the first heat exchange end of each of the first heat exchange channels; the second liquid inlet section is simultaneously connected to the first heat exchange end of each of the second heat exchange channels; the first liquid inlet section and the second liquid inlet section... The connection point is the bend in the liquid inlet channel, and it is not lower than the first heat exchange end of the highest-positioned first heat exchange channel and the second heat exchange channel; the liquid inlet is not higher than the first heat exchange end of the lowest-positioned first heat exchange channel; the liquid outlet section has an upwardly protruding and bent liquid outlet channel, which includes a first liquid outlet section and a second liquid outlet section that are interconnected; the first liquid outlet section is simultaneously connected to the second heat exchange end of each of the first heat exchange channels; the bottom of the second liquid outlet section has a liquid outlet suitable for discharging liquid cooling medium, and it is simultaneously connected to the second heat exchange end of each of the second heat exchange channels; the connection point between the first liquid outlet section and the second liquid outlet section is the bend in the liquid outlet channel, and it is not lower than the second heat exchange end of the highest-positioned first heat exchange channel and the second heat exchange channel; the liquid outlet is not higher than the second heat exchange end of the lowest-positioned second heat exchange channel.

[0007] Technical Solution 2 based on Technical Solution 1: The positions of the first heat exchange channel in the first heat exchange module and the second heat exchange channel in the second heat exchange module correspond one-to-one in the vertical direction along the front-back direction.

[0008] Technical Solution 3 based on Technical Solution 2: The first heat exchange module is located after the second heat exchange module in the front-back direction, so that it is downstream of the path through which the external fluid passes through the heat exchange section relative to the second heat exchange module.

[0009] Technical Solution 4 based on Technical Solution 3: The liquid inlet and liquid outlet both include a first tube and a second tube that are attached to each other in the front-to-back direction, and a liquid passage hole is provided through the tube wall where the first tube and the second tube are attached to each other; the first tube and the second tube respectively constitute the first liquid inlet section and the second liquid inlet section or the first liquid outlet section and the second liquid outlet section, and the liquid passage hole constitutes the connection between the first liquid inlet section and the second liquid inlet section or the connection between the first liquid outlet section and the second liquid outlet section.

[0010] Technical solution five based on technical solution four: The first heat exchange module and the second heat exchange module in the heat exchange section both include a plurality of heat exchange flow channels; the heat exchange flow channels are provided with the first heat exchange channel or the second heat exchange channel inside the heat exchange flow channels, and the heat exchange flow channels are at least partially flat; the extension direction of the flat part on the heat exchange flow channels is used to limit the flow direction of the external fluid through the heat exchange section.

[0011] Technical solution six based on technical solution five: Each heat exchange channel plate is provided with a first heat exchange channel or a second heat exchange channel. The first heat exchange channel and the second heat exchange channel both include multiple heat exchange sub-channels. Each heat exchange sub-channel belonging to the first heat exchange channel or the second heat exchange channel is arranged side by side in the heat exchange channel plate along the flow direction of the external fluid through the heat exchange part.

[0012] Technical solution seven based on technical solution six: The heat exchange channel plate is long and flat, with its two ends in the length direction forming a first plate end and a second plate end, respectively, and the first plate end and the second plate end are connected to the liquid inlet and the liquid outlet, respectively.

[0013] Technical solution eight, based on technical solution seven, further includes an auxiliary heat exchange plate; the auxiliary heat exchange plate is located between the heat exchange channel plates that are adjacent in the vertical direction, and includes a plurality of first heat exchange segments that are consistent with the extension direction of the heat exchange channel plates, and a second heat exchange segment that connects the first heat exchange segments that are adjacent in the length direction of the heat exchange channel plates and extends in the vertical direction; the first heat exchange segment is closely attached to the heat exchange channel plate corresponding to its height position in the auxiliary heat exchange plate.

[0014] In addition, the present invention also provides a ninth technical solution: a liquid-cooled heat exchange component, which includes a liquid-cooled radiator and a fan, and further includes a liquid-cooled heat exchanger as described in any one of technical solutions one to eight; the liquid-cooled heat exchanger is connected to the liquid-cooled radiator to circulate a liquid cooling medium; the fan is used to drive air fluid through the heat exchange section of the liquid-cooled heat exchanger.

[0015] In addition, the present invention provides technical solution ten: a converter comprising a plurality of power devices, and further comprising the liquid-cooled heat exchange assembly described in technical solution nine; at least a portion of the power devices dissipate heat through a liquid-cooled radiator and / or a liquid-cooled heat exchanger in the liquid-cooled heat exchange assembly.

[0016] As can be seen from the above description of the present invention, compared with the prior art, the present invention has the following beneficial effects:

[0017] During the operation of a liquid cooling system, air may mix into the cooling medium, or dissolved gases may precipitate due to temperature changes. Since gases are less dense than liquids, they will naturally float in a gravitational field. In conventional liquid-cooled heat exchangers, if the heat exchange channel is located at a high level in the system and its top is not equipped with an exhaust channel higher than the channel itself, gases can easily become trapped at the highest point of the heat exchange channel, forming air pockets. These air pockets occupy the channel cross-section, reducing the effective flow area and decreasing local heat exchange efficiency. In severe cases, this can lead to localized dry burning of the channel, affecting system stability. This problem is particularly pronounced in high-level heat exchangers far from the pump source, where the circulating pressure differential is smaller and the flow velocity is lower, making it even more difficult for the gas to be carried away by the liquid.

[0018] In the liquid-cooled heat exchanger provided by technical solution one, a first heat exchange module and a second heat exchange module are set up. Each module contains multiple heat exchange channels arranged side by side in the vertical direction with the same length. The two modules are connected to the liquid inlet and liquid outlet respectively by a cross connection method. At the same time, the liquid inlet and liquid outlet channels are constructed as upward convex and bent structures, and the bend is not lower than the corresponding port of all heat exchange channels. Thus, without relying on external exhaust devices or high pump pressure, the problem of high-level gas accumulation and difficulty in discharge is effectively solved, and the flow balance between the two modules is achieved.

[0019] Specifically, the first heat exchange end of each first heat exchange channel of the first heat exchange module is connected to the first inlet section of the inlet channel, and its second heat exchange end is connected to the first outlet section of the outlet channel; the second heat exchange end of each second heat exchange channel of the second heat exchange module is connected to the second inlet section of the inlet channel, and its first heat exchange end is connected to the second outlet section of the outlet channel. This forms two intersecting flow paths: coolant enters the first heat exchange channel from the first inlet section and flows out from the first outlet section; simultaneously, coolant enters the second heat exchange channel from the second inlet section and flows out from the second outlet section. Since the first inlet section is connected to the second outlet section, and the second inlet section is connected to the first outlet section, the entire system constitutes a closed-loop intersecting parallel circuit. This configuration ensures that the heat exchange channels of both heat exchange modules have the same geometric length, forming a parallel flow path. The hydraulic resistance in each loop is consistent, guaranteeing uniform flow within the modules. Furthermore, the division into two branches significantly reduces overall system flow resistance, decreasing pump power requirements and improving responsiveness under low flow conditions. Moreover, because the two modules are interconnected through the high-point areas of their inlet and outlet channels, the system maintains a unified pressure balance. Even if slight differences in local resistance occur due to installation location or heat load variations between the two modules, the coolant can automatically adjust its distribution ratio through the high-point connection area, preventing unilateral flow deviation and improving system reliability.

[0020] More importantly, the bends in the inlet channels (i.e., the junction between the first and second inlet sections) are no lower than the first heat exchange end of the highest heat exchange channel, and the bends in the outlet channels (i.e., the junction between the first and second outlet sections) are no lower than the second heat exchange end of the highest heat exchange channel. This design ensures that the highest geometric point inside the entire heat exchanger is no longer the top of any heat exchange channel, but rather the bends in the inlet and outlet channels. Since the ports of all heat exchange channels are directly connected to a common chamber adjacent to these high points, when gas rises to its end in any heat exchange channel due to buoyancy, it can continue to migrate upwards into the high point region of the inlet or outlet channel. Under the aforementioned cross-parallel layout, gas at the top of the first heat exchange channel can rise to the high point of the first inlet or first outlet section; gas at the top of the second heat exchange channel can rise to the high point of the second inlet or second outlet section. Because the first and second inlet sections of the inlet channel are connected at a high point, and the first and second outlet sections of the outlet channel are also connected at a high point, all gases can ultimately converge into a unified high-point chamber and be discharged from the outlet end with the main flow. Furthermore, this design creates gas collection spaces on both sides of the inlet and outlet sections, resulting in a larger gas collection capacity, a shorter path, and significantly better exhaust performance than structures that only collect gas on one side of the inlet or outlet section.

[0021] Furthermore, this solution employs a double-layer air-cooled structure: the first and second heat exchange modules are arranged side-by-side, with external air flowing sequentially through both layers of heat exchange surfaces. This doubles the heat exchange area for the same projected area, and the airflow channels are regular and unobstructed. In contrast, conventional single-layer heat exchange structures require a large baffle-type manifold on one side, which not only occupies air-cooling space and obstructs airflow but also leads to a decrease in localized heat dissipation performance. This solution, by arranging the heat exchangers side-by-side, reduces the lateral space occupied by the heat exchanger, thereby conversely increasing the heat exchange area of ​​the heat exchange section and improving the overall heat exchange efficiency of the heat exchanger.

[0022] Furthermore, conventional single-layer heat exchange structures, due to the manifold being located on only one side, result in an asymmetrical distribution of liquid inlet and outlet sections with varying degrees of stress. This causes the welded joints to bear significant thermal and assembly stresses, making them prone to cracking during long-term operation. In this design, both the liquid inlet and outlet sections form a manifold structure with consistent width. Moreover, the inlet and outlet are symmetrically distributed at an oblique angle, effectively balancing the stresses caused by thermal expansion and fluid loads. This significantly improves the structural strength and sealing reliability of the welded joints, making it particularly suitable for electrical equipment applications involving high vibration and frequent start-stop cycles.

[0023] It should be noted that if only parallel flow channels are used without a unified high point design, the gas will be confined to isolated high points at the top of each flow channel and cannot be collected and discharged. If only high points are set but the flow channels are not parallel, some flow channels will still retain gas due to insufficient flow rate. This solution integrates parallel flow, parallel connection, and high point bend in a coordinated manner, allowing gas to migrate freely from any flow channel to the highest point of the system and to be effectively carried and discharged in a uniform flow field. This effectively solves the problem in existing technologies where heat exchangers located at higher positions have difficulty discharging gas due to their distance from the pump source, significantly improving the heat exchange reliability and operational stability of the heat exchanger under gas-containing conditions.

[0024] In technical solution two, the number of heat exchange channels in both modules is exactly the same, and their vertical arrangement corresponds one-to-one. In the cross-parallel flow, the coolant from the first inlet section flows through the first heat exchange channel and exits from the first outlet section, while the coolant from the second inlet section flows through the second heat exchange channel and exits from the second outlet section. Because the two modules have an equal number of channels, corresponding positions, and are designed with parallel flow paths, the total hydraulic resistance of the two loops is basically the same, and the distribution ratio of coolant between the two modules tends to be balanced. In addition, when there is a temperature gradient in the vertical direction from an external heat source (such as electronic devices), the channels at the corresponding height can respond synchronously to changes in heat load, avoiding local overheating or flow deviation caused by module asymmetry.

[0025] In technical solution three, the first heat exchange module is located after the second heat exchange module. Because the first heat exchange module is directly connected to the first inlet section of the liquid inlet, the temperature loss of the liquid cooling medium in the first heat exchange module is relatively small. This results in the first heat exchange module having a lower temperature than the second heat exchange module downstream of the liquid cooling medium flow path, thus creating a temperature gradient between the first and second heat exchange modules, where the temperature of the first heat exchange module is lower than that of the second heat exchange module. Simultaneously, the second heat exchange module comes into contact with the higher-temperature external fluid first, providing initial cooling. The external fluid, after initial cooling, continues to flow to the second heat exchange module, where the lower-temperature module further cools it. This avoids problems such as low local heat exchange efficiency, thermal stress concentration, and condensation on the heat exchange surface caused by excessive temperature differences between the external fluid and the heat exchange module.

[0026] In technical solution four, the inlet and outlet sections are constructed by first and second tubes fitting together in the front-to-back direction. A through-hole is provided on the fitting wall of the two tubes, forming the bend in the inlet or outlet flow channel. By creating a hole on the contact surface to connect the two cavities, an upwardly protruding bend flow channel is formed, avoiding the complex processes and potential leakage risks associated with traditional pipe bending, welding, or casting. Furthermore, the two tubes arranged side-by-side occupy less space in the width direction of the heat exchanger compared to a single U-shaped bend, resulting in a more compact structure for both the inlet and outlet sections. This facilitates the miniaturization and integration of the entire liquid-cooled heat exchanger.

[0027] In technical solution five, the heat exchange channel plate serves as the basic unit of the heat exchange module. It contains internal heat exchange channels and is at least partially flat, with the extension direction of the flat portion defining the flow direction of external fluids (such as air). This design integrates the liquid-cooled channels within the flat plate, allowing the coolant to flow within the plate while external air sweeps laterally across its surface. The flat structure increases the contact area with air, and the defined extension direction ensures more uniform airflow distribution, reducing flow separation and dead zones, and improving heat exchange efficiency. The parallel arrangement of the heat exchange channel plates creates regular air channels between them. When an external fan drives airflow through these channels, a stable laminar or slightly disturbed flow field is formed, maximizing the contact efficiency between air and the heat exchange surface while controlling flow resistance on the air side.

[0028] In technical solution six, each heat exchange channel is subdivided into multiple heat exchange sub-channels arranged side-by-side along the external fluid flow direction. Dividing a single, wide channel into multiple narrow sub-channels increases the contact area between the liquid and the channel wall, thus increasing the internal surface heat exchange area, while maintaining the same total flow rate. Furthermore, the reduced channel size increases the average velocity of the liquid-cooled medium within the channel and enhances fluid turbulence. Higher velocities and stronger turbulence significantly reduce the thickness of the laminar boundary layer near the pipe wall, thereby substantially increasing the convective heat transfer coefficient from the liquid to the pipe wall. In addition, the internal stiffeners of the sub-channels also provide support, improving the structural strength of the flat heat exchange channel plates against internal fluid pressure.

[0029] In technical solution seven, the heat exchange channel plate has an overall elongated and flat shape, with its two ends connected to the liquid inlet and liquid outlet, respectively. The shape of the heat exchange channel plate ensures that the liquid-cooled heat exchanger has a large heat exchange area, and the flow stability of the liquid cooling medium in the internal heat exchange channel can be improved by reducing the bending structure, thus maintaining a balanced flow and pressure at all positions along the length of the heat exchange channel plate.

[0030] In technical solution eight, an auxiliary heat exchanger is added, located between adjacent heat exchange channel plates in the vertical direction. It consists of a first heat dissipation section extending along the channel plate's extension direction and a second heat dissipation section connecting the adjacent first heat dissipation sections in the vertical direction, with the first heat dissipation section closely attached to the corresponding height of the heat exchange channel plate. The auxiliary heat exchanger effectively increases the contact area between the entire heat exchange section and the air while maintaining the elongated and flat shape of the heat exchange channel plates, thereby reducing the impact on the flow velocity and stability of the liquid cooling medium in the heat exchange channel. Furthermore, by being in close contact with the heat exchange channel plates on both sides, when the temperature of one channel plate rises due to a higher local heat load, the heat can be conducted to the auxiliary heat exchanger through the attached first heat dissipation section and then laterally diffused to channel plates at other heights via the second heat dissipation section, achieving a redistribution of heat in the vertical direction. This design achieves the dual effects of enhanced thermal conductivity and expanded heat dissipation area without significantly increasing the volume. The first heat exchange section guides the heat from the heat exchange channel plates to the second heat exchange section, which in turn increases the heat exchange area and transfers heat. Without the first heat exchange section, the contact area between the second heat exchange section and the heat exchange channel plates would be too small to achieve the desired effect.

[0031] Technical solution nine provides a liquid-cooled heat exchange component that integrates the aforementioned liquid-cooled heat exchanger with a liquid-cooled radiator (such as a liquid cooling plate) for directly cooling power devices. A fan can drive air to flow through the liquid-cooled heat exchanger in a preset direction. The temperature of the air flowing through the liquid-cooled heat exchanger decreases, thereby cooling the circulating air inside the device housing through the liquid-cooled heat exchanger, reducing the overall ambient temperature, and further improving the heat dissipation efficiency of the liquid-cooled radiator in conjunction with the heat exchanger.

[0032] Technical solution ten provides a converter that applies the aforementioned liquid-cooled heat exchange components to a system containing multiple power devices, wherein the power devices can dissipate heat through liquid-cooled radiators and / or liquid-cooled heat exchangers. This structure achieves efficient direct liquid cooling of high heat flux density power devices, while actively cooling the internal air of the equipment through vertically mounted liquid-cooled heat exchangers, preventing heat accumulation in the enclosed space. Therefore, it not only ensures the temperature stability of the power devices under high load conditions but also improves the overall converter's operational stability and long-term service life under complex conditions such as gas-filled environments or frequent start-stop cycles. Attached Figure Description

[0033] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0034] Figure 1This is a schematic diagram of the liquid-cooled heat exchange component according to an embodiment of the present invention;

[0035] Figure 2 for Figure 1 A three-dimensional structural diagram of a liquid-cooled heat exchanger;

[0036] Figure 3 for Figure 2 Internal cross-section diagram of a liquid-cooled heat exchanger Figure 1 ;

[0037] Figure 4 for Figure 2 Internal cross-section diagram of a liquid-cooled heat exchanger Figure 2 ;

[0038] Figure 5 for Figure 2 Internal cross-section diagram of a liquid-cooled heat exchanger Figure 3 ;

[0039] Figure 6 for Figure 4 An enlarged schematic diagram of part A in the middle.

[0040] Explanation of key figure labels:

[0041] Liquid-cooled heat exchanger 100;

[0042] Heat exchange section 110; First heat exchange module 111; Second heat exchange module 112; First heat exchange channel 113; Second heat exchange channel 114; First heat exchange end 115; Second heat exchange end 116; Heat exchange channel plate 117; Heat exchange sub-channel 118; First plate end 119; Second plate end 1110; Auxiliary heat exchange plate 1111; First heat exchange segment 1112; Second heat exchange segment 1113;

[0043] Liquid inlet section 120; liquid inlet channel 121; first liquid inlet section 122; second liquid inlet section 123; liquid inlet 124; liquid inlet pipe 125;

[0044] Liquid outlet section 130; liquid outlet channel 131; first liquid outlet section 132; second liquid outlet section 133; liquid outlet 134; liquid outlet pipe 135;

[0045] The first tube body 141; the second tube body 142; the liquid hole 143;

[0046] Liquid cooling radiator 200; inlet nozzle 210; outlet nozzle 220;

[0047] Fan 300. Detailed Implementation

[0048] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are preferred embodiments of the present invention and should not be considered as excluding other embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0049] Unless otherwise expressly defined, the use of terms such as "first," "second," or "third" in the claims, description, and accompanying drawings of this invention is for distinguishing different objects and not for describing a specific order.

[0050] Unless otherwise expressly defined, in the claims, description, and accompanying drawings of this invention, the use of directional terms such as "center," "lateral," "longitudinal," "horizontal," "vertical," "top," "bottom," "inner," "outer," "upper," "lower," "front," "rear," "left," "right," "clockwise," and "counterclockwise" to indicate orientation or positional relationships is based on the orientation and positional relationships shown in the accompanying drawings and is only for the convenience of describing the invention and simplifying the description, and is not intended to indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the specific scope of protection of this invention.

[0051] Unless otherwise expressly defined, the terms "fixed connection" or "fixed connection" used in the claims, description and drawings of this invention should be interpreted broadly to refer to any connection in which there is no displacement or relative rotation relationship between the two parties, including non-removable fixed connection, detachable fixed connection, integral connection and fixed connection by other means or components.

[0052] In the claims, description and accompanying drawings of this invention, the terms "comprising," "having," and variations thereof are used to mean "including but not limited to."

[0053] Example

[0054] This invention relates to a converter, which includes a housing, several power devices, and other electronic components. It also includes a liquid-cooled heat exchange assembly, wherein at least some of the power devices dissipate heat through a liquid-cooled radiator 200 and / or a liquid-cooled heat exchanger 100 within the assembly. The power devices in the converter may be IGBT modules, which can be mounted against the heat dissipation surface of the liquid-cooled radiator 200 in the liquid-cooled heat exchange assembly, and further cooled by air-assisted cooling through the liquid-cooled heat exchanger 100.

[0055] Specifically, refer to Figure 1The liquid-cooled heat exchange assembly includes a liquid-cooled radiator 200, a fan 300, and a liquid-cooled heat exchanger 100. The liquid-cooled heat exchanger 100 is connected to the liquid-cooled radiator 200 to circulate a liquid cooling medium. Typically, the converter, as a complete device, may also include a cold source system that provides a liquid cooling medium to the liquid-cooled heat exchange assembly. This liquid cooling medium can be a coolant commonly used in the liquid cooling field. In this embodiment, the liquid-cooled radiator 200 is plate-shaped, with several series and / or parallel radiator channels inside, and one side surface forming a heat dissipation surface. The power devices of the converter can be mounted against this heat dissipation surface for easy heat dissipation through the liquid-cooled radiator 200. The liquid-cooled radiator 200 is equipped with an inlet nozzle and an outlet nozzle for communicating with a cold source to realize the circulation of liquid cooling medium. The inlet nozzle is used to connect the low-temperature liquid cooling medium supplied by the cold source into the internal radiator flow channel of the liquid-cooled radiator 200, and the outlet nozzle is used to transport the liquid cooling medium that has increased in temperature after heat exchange in the liquid-cooled radiator 200 back to the cold source for further cooling.

[0056] The liquid-cooled heat exchanger 100 can be directly mounted and fixed on the liquid-cooled radiator 200, and the internal flow channels of the liquid-cooled heat exchanger 100 and the liquid-cooled radiator 200 can be connected by welding or other methods. In this embodiment, the heat dissipation surface of the liquid-cooled heat exchanger 100 is vertically positioned on one side of the liquid-cooled radiator 200, which places the liquid-cooled heat exchanger 100 at a high position relative to the liquid-cooled radiator 200 in the entire liquid cooling system. The reason for this arrangement is that the liquid-cooled heat exchanger 100 needs to use the fan 300 to drive airflow to achieve air-cooled auxiliary heat dissipation of the internal space of the converter. The vertical arrangement can effectively deliver the air cooled by the liquid-cooled heat exchanger 100 in a forward direction towards the power devices and other electronic devices in the converter. These other electronic devices can be PCB boards and components such as capacitors and resistors mounted on the PCB boards. These electronic devices also generate a lot of heat during the operation of the converter, but since they cannot be directly attached to the liquid-cooled radiator 200 for heat dissipation, they need to be cooled by air. In this embodiment, the fan 300 is disposed on one side of the liquid-cooled heat exchanger 100. It can be directly fixedly mounted on the liquid-cooled heat exchanger 100, or it can be fixedly mounted on the liquid-cooled radiator 200 or the housing of the converter. In addition, in this liquid-cooled heat exchange assembly, one liquid-cooled radiator 200 can be provided, and multiple liquid-cooled heat exchangers 100 and fans 300 can be provided. At the same time, one liquid-cooled heat exchanger 100 can be arranged corresponding to one fan 300, so as to realize simultaneous air cooling of the internal space of the converter from multiple directions.

[0057] However, during the operation of a liquid cooling system, air may be mixed into the liquid cooling medium, or dissolved gases may precipitate due to temperature changes. Since the density of gas is less than that of liquid, it will naturally float in a gravitational field. In a conventional liquid-cooled heat exchanger 100, if the heat exchange channel is located at a high position in the system and its top is not equipped with an exhaust channel higher than the channel itself, gas can easily stagnate at the highest point of the heat exchange channel, forming air pockets. These air pockets occupy the channel cross-section, reducing the effective flow area and decreasing local heat exchange efficiency. In severe cases, this can lead to localized dry burning of the channel, affecting system stability. This problem is particularly pronounced in high-level heat exchangers far from the pump source, where the circulating pressure difference is small and the flow velocity is low, making it even more difficult for gas to be carried away by the liquid. This embodiment improves this problem through structural modifications to the liquid-cooled heat exchanger 100. The specific structure of the liquid-cooled heat exchanger 100 is described below.

[0058] Reference Figure 2 The liquid-cooled heat exchanger 100 includes a heat exchange section 110, a liquid inlet section 120, a liquid outlet section 130, and auxiliary heat exchange plates 1111.

[0059] Reference Figure 3 and Figure 4The heat exchange section 110 is used to contact external fluid to achieve heat exchange, and includes a first heat exchange module 111 and a second heat exchange module 112 arranged side by side in the front-back direction. The first heat exchange module 111 and the second heat exchange module 112 are respectively provided with a plurality of first heat exchange channels 113 and second heat exchange channels 114 arranged side by side in the vertical direction and of the same length. The two ends of each first heat exchange channel 113 and second heat exchange channel 114 are a first heat exchange end 115 and a second heat exchange end 116, respectively. In this embodiment, the external fluid is air, and the air flow direction is restricted by the fan 300 that cooperates with the liquid-cooled heat exchanger 100 and the air flow pipe in the heat exchange section 110. In this embodiment, the air passes through the heat exchange section 110 of the liquid-cooled heat exchanger 100 in the front-back direction. During the process of air passing through the heat exchange section 110, the air comes into contact with the heat exchange section 110. A liquid cooling medium circulates in the heat exchange channels within the heat exchange section 110. The low-temperature liquid cooling medium exchanges heat with the air at the interface between the heat exchange section 110 and the air, carrying away the air's heat and thus lowering the air temperature after passing through the heat exchange section 110. The heat exchange section 110 includes two identical heat exchange modules: a first heat exchange module 111 and a second heat exchange module 112. In the first heat exchange module 111, each first heat exchange channel 113 is arranged side-by-side in a vertical direction, and all channels have the same length. Similarly, in the second heat exchange module 112, each second heat exchange channel 114 is arranged side-by-side in a vertical direction, and all channels have the same length. In this embodiment, the arrangement direction of each first heat exchange channel 113 and second heat exchange channel 114 is vertical, and the length direction is horizontal. The shape of the first heat exchange channel 113 and second heat exchange channel 114 is a straight line extending in the horizontal direction. Both ends of the length direction of the first heat exchange channel 113 and second heat exchange channel 114 form a first heat exchange end 115 and a second heat exchange end 116 that are respectively connected to the liquid inlet 120 and the liquid outlet 130.

[0060] In this embodiment, the positions of the first heat exchange channel 113 in the first heat exchange module 111 and the second heat exchange channel 114 in the second heat exchange module 112 correspond one-to-one in the vertical direction along the front-to-back direction. (Refer to...) Figure 3 and Figure 4The number of first heat exchange channels 113 in the first heat exchange module 111 is the same as the number of second heat exchange channels 114 in the second heat exchange module 112, and the arrangement interval of the first heat exchange channels 113 is the same as the arrangement interval of the second heat exchange channels 114. Furthermore, the first heat exchange module 111 and the second heat exchange module 112 are arranged in a front-to-back direction, thus there is a one-to-one correspondence between the first heat exchange channels 113 and the second heat exchange channels 114. The number of heat exchange channels in both modules is completely identical, and their vertical arrangement positions correspond one-to-one. In the cross-parallel flow, the coolant from the first inlet section 122 flows through the first heat exchange channel 113 and exits from the first outlet section 132, while the coolant from the second inlet section 123 flows through the second heat exchange channel 114 and exits from the second outlet section 133. Since the two modules have an equal number of flow channels, corresponding positions, and are designed with parallel flow paths, the total hydraulic resistance of the two circuits is basically the same, and the distribution ratio of coolant between the two modules tends to be balanced. In addition, when there is a temperature gradient in the vertical direction from an external heat source (such as electronic devices), the flow channel at the corresponding height can respond synchronously to changes in heat load, avoiding local overheating or flow deviation caused by module asymmetry.

[0061] Furthermore, in this embodiment, the first heat exchange module 111 is located after the second heat exchange module 112 in the front-to-back direction, so that it is downstream of the path of the external fluid passing through the heat exchange section 110 relative to the second heat exchange module 112. As mentioned above, in this embodiment, the fan 300 is located in front of the liquid-cooled heat exchanger 100, and air enters the heat exchange section 110 from the front of the liquid-cooled heat exchanger 100. Under this premise, by setting the first heat exchange module 111 after the second heat exchange module 112, the air will first pass through the second heat exchange module 112 and then through the first heat exchange module 111. The first heat exchange module 111 is located after the second heat exchange module 112. Since the first heat exchange module 111 is directly connected to the first liquid inlet section 122 in the liquid inlet section 120, the temperature loss of the liquid cooling medium in the first heat exchange module 111 is relatively small. This results in the first heat exchange module 111 having a lower temperature than the second heat exchange module 112 downstream of the liquid cooling medium flow path, thus creating a temperature gradient between the first and second heat exchange modules 111 and 112, where the temperature of the first heat exchange module 111 is lower than that of the second heat exchange module 112. Simultaneously, the second heat exchange module 112 will come into contact with the higher-temperature external fluid first, providing initial cooling. After initial cooling, the external fluid continues to flow to the second heat exchange module 112, where the lower-temperature module further cools the external fluid. This avoids problems such as low local heat exchange efficiency, thermal stress concentration, and condensation on the heat exchange surface caused by excessive temperature differences between the external fluid and the heat exchange module.

[0062] Reference Figure 3 and Figure 4The heat exchange section 110 includes a plurality of heat exchange channel plates 117 in both the first heat exchange module 111 and the second heat exchange module 112. Each heat exchange channel plate 117 has a first heat exchange channel 113 or a second heat exchange channel 114 inside, and at least part of the heat exchange channel plate 117 is flat. The extension direction of the flat portion of the heat exchange channel plate 117 is used to define the flow direction of external fluid through the heat exchange section 110. In this embodiment, the heat exchange channel plate 117 is elongated and flat, with its two ends forming a first end 119 and a second end 1110, respectively. The first end 119 and the second end 1110 are connected to the liquid inlet section 120 and the liquid outlet section 130, respectively. Specifically, the heat exchange channel is physically realized by providing a tubular structure with both ends extending through the heat exchange channel plate 117. At least a portion of the heat exchange channel plate 117 is flat, and this flat structure can extend horizontally. Thus, by arranging the heat exchange channel plates 117 side-by-side in the vertical direction, channels for airflow can be formed between corresponding flat structures in adjacent heat exchange channel plates 117. In this embodiment, the heat exchange channel plate 117 is generally flat, with its length in the left-right direction, its width in the front-back direction, and its thickness in the vertical direction. Its length is much greater than its width, and its width is much greater than its thickness. When heat exchange channel plates 117 of this shape are arranged side-by-side to form the heat exchange section 110, gaps are formed between adjacent heat exchange channel plates 117 in the vertical direction. These gaps allow air to pass through, and the upper and lower interfaces of each gap—that is, the lower surface of the heat exchange channel plate 117 above the gap and the upper surface of the heat exchange channel plate 117 below the gap—form a heat exchange interface in contact with air. When a liquid cooling medium flows through the heat exchange channel inside the heat exchange channel plate 117, heat exchange can be performed through the heat exchange interface. In addition, the heat exchange channel plates 117 have a first end plate 119 and a second end plate 1110 formed at both ends in the left and right directions, respectively. The first end plate 119 and the second end plate 1110 can be fixedly connected to the liquid inlet 120 and the liquid outlet 130 by welding.

[0063] The heat exchange channel plate 117, as the basic unit of the heat exchange module, has internal heat exchange channels and is at least partially flat. The extension direction of the flat portion is used to define the flow direction of external fluids (such as air). This design integrates the liquid cooling channels into the flat plate body, allowing the coolant to flow within the plate while external air sweeps laterally across the surface of the flat plate. The flat structure increases the contact area with air, and the defined extension direction makes the airflow distribution more uniform, reducing flow separation and dead zones, and improving heat exchange efficiency. The parallel arrangement of the heat exchange channel plates 117 forms regular air channels between the plates. When the external fan 300 drives air to flow through these channels, a stable laminar or slightly disturbed flow field can be formed, maximizing the contact efficiency between air and the heat exchange surface while controlling the flow resistance on the air side. The overall shape of the heat exchange channel plate 117 is a long, flat strip, with its two ends connected to the liquid inlet 120 and the liquid outlet 130, respectively. The shape of the heat exchange channel plate 117 ensures that the liquid-cooled heat exchanger 100 has a large heat exchange area, and the flow stability of the liquid cooling medium in the internal heat exchange channel can be improved by reducing the bending structure, so as to maintain the flow and pressure balance at each position along the length of the heat exchange channel plate 117.

[0064] In this embodiment, each heat exchange channel plate 117 is provided with a first heat exchange channel 113 or a second heat exchange channel 114. Both the first heat exchange channel 113 and the second heat exchange channel 114 include multiple heat exchange sub-channels 118. Each heat exchange sub-channel 118 belonging to the same first heat exchange channel 113 or second heat exchange channel 114 is arranged side-by-side in the heat exchange channel plate 117 along the flow direction of the external fluid through the heat exchange section 110. (Refer to...) Figure 6 The heat exchange channel plate 117 is generally flat, thus it can be divided into multiple heat exchange sub-channels 118 arranged side by side along the width direction. All the heat exchange sub-channels 118 located in the same heat exchange channel plate 117 cooperate to form a complete heat exchange channel. At the same time, the liquid inlet end of these heat exchange sub-channels 118 cooperates to form the first heat exchange end 115 of the heat exchange channel, and the liquid outlet end cooperates to form the second heat exchange end 116 of the heat exchange channel. Each heat exchange channel is subdivided into multiple heat exchange sub-channels 118 arranged side by side along the external fluid flow direction. Dividing a single, wide channel into multiple narrow sub-channels, while keeping the total flow rate constant, increases the contact area between the liquid and the inner wall of the channel, that is, increases the inner surface heat exchange area; on the other hand, the reduced channel size increases the average flow velocity of the liquid cooling medium in the channel and enhances the turbulence of the fluid. Higher flow velocities and stronger turbulence can significantly reduce the thickness of the laminar boundary layer near the pipe wall, thereby greatly improving the convective heat transfer coefficient from the liquid to the pipe wall. In addition, the internal stiffeners of the segmented sub-channels also play a supporting role, improving the structural strength of the flat heat exchange channel plate 117 against the internal fluid pressure.

[0065] In addition, refer to Figure 3 , Figure 4 and Figure 6 The auxiliary heat exchange fins 1111 are located between adjacent heat exchange channel plates 117 in the vertical direction, and include several first heat exchange segments 1112 extending in the same direction as the heat exchange channel plates 117, and second heat exchange segments 1113 extending vertically and connecting the adjacent first heat exchange segments 1112 in the length direction of the heat exchange channel plates 117. The first heat exchange segments 1112 are closely attached to the heat exchange channel plates 117 corresponding to their height positions in the auxiliary heat exchange fins 1111. Specifically, the adjacent heat exchange channel plates 117 in the vertical direction form gaps. At this time, the part of the air in contact with the heat exchange section 110 is the upper and lower interface of each gap. Therefore, the heat exchange area in contact with the heat exchange section 110 is still not large enough, and the heat exchange efficiency is difficult to meet the requirements. For this reason, the auxiliary heat exchange fins 1111 are provided, which are located between adjacent heat exchange channel plates 117 in the vertical direction, that is, at these gaps. The first heat exchange segment 1112 in the auxiliary heat exchange plate 1111 extends horizontally, and the second heat exchange segment 1113 extends vertically. These first heat exchange segments 1112 are arranged in a staggered manner within a gap, so as to contact the heat exchange channel plates 117 above and below the gap, respectively. Meanwhile, the second heat exchange segment 1113 extends vertically and longitudinally to increase the heat exchange area of ​​the heat exchange section 110 and establish heat transfer channels between adjacent heat exchange channel plates 117. The auxiliary heat exchange plate 1111 is added between adjacent heat exchange channel plates 117 in the vertical direction. It consists of a first heat dissipation section along the extension direction of the channel plate and a second heat dissipation section connecting adjacent first heat dissipation sections in the vertical direction, with the first heat dissipation section closely attached to the heat exchange channel plate 117 at the corresponding height. The auxiliary heat exchange fin 1111 effectively increases the contact area between the entire heat exchange section 110 and the air while maintaining the elongated and flat shape of the heat exchange channel fin 117, thereby reducing the impact on the flow velocity and stability of the liquid cooling medium in the heat exchange channel. Furthermore, by being in close contact with the heat exchange channel fins 117 on both sides, when the temperature of one channel fin rises due to a higher local heat load, the heat can be conducted to the auxiliary heat exchange fin 1111 through the first heat dissipation section, and then laterally diffused to channel fins of other heights via the second heat dissipation section, achieving a redistribution of heat in the vertical direction. This design achieves the dual effects of enhanced thermal conductivity and expanded heat dissipation area without significantly increasing the volume. The first heat exchange segment 1112 guides the heat from the heat exchange channel fin 117 to the second heat exchange segment 1113, which in turn increases the heat exchange area and transfers heat. If the first heat exchange segment 1112 is not set, the contact area between the second heat exchange segment 1113 and the heat exchange flow channel plate 117 is too small to achieve the expected effect.

[0066] It should be understood that the heat exchange channel plate 117 and the auxiliary heat exchange plate 1111 mentioned above can be made of metal materials with good thermal conductivity, and the connection method can be welding or other suitable methods.

[0067] Reference Figure 3 and Figure 4 The liquid inlet section 120 is provided with an upwardly protruding and bent liquid inlet channel 121. The liquid inlet channel 121 includes a first liquid inlet section 122 and a second liquid inlet section 123 that are interconnected. The bottom of the first liquid inlet section 122 is provided with a liquid inlet 124 suitable for receiving liquid cooling medium, and is simultaneously connected to the first heat exchange end 115 of each of the first heat exchange channels 113. The second liquid inlet section 123 is simultaneously connected to the first heat exchange end 115 of each of the second heat exchange channels 114. The connection between the first liquid inlet section 122 and the second liquid inlet section 123 is the bend of the liquid inlet channel 121, and it is not lower than the first heat exchange end 115 of the highest first heat exchange channel 113 and the second heat exchange channel 114. The liquid inlet 124 is not higher than the first heat exchange end 115 of the lowest first heat exchange channel 113.

[0068] Furthermore, the liquid outlet section 130 is provided with an upwardly protruding and bent liquid outlet channel 131, the liquid outlet channel 131 including a first liquid outlet section 132 and a second liquid outlet section 133 that are interconnected; the first liquid outlet section 132 is simultaneously connected to the second heat exchange end 116 of each of the first heat exchange channels 113; the bottom of the second liquid outlet section 133 is provided with a liquid outlet 134 suitable for discharging liquid cooling medium, and is simultaneously connected to the second heat exchange end 116 of each of the second heat exchange channels 114; the connection between the first liquid outlet section 132 and the second liquid outlet section 133 is the bend of the liquid outlet channel 131, and it is not lower than the second heat exchange end 116 of the highest first heat exchange channel 113 and the second heat exchange channel 114; the liquid outlet 134 is not higher than the second heat exchange end 116 of the lowest second heat exchange channel 114.

[0069] Specifically, both the inlet section 120 and the outlet section 130 include a first tube 141 and a second tube 142 that are fitted together in the front-to-back direction. A liquid passage hole 143 is provided through the tube wall where the first tube 141 and the second tube 142 are fitted together. The first tube 141 and the second tube 142 respectively constitute the first inlet section 122 and the second inlet section 123 or the first outlet section 132 and the second outlet section 133 in the inlet section 120 or the outlet section 130. The liquid passage hole 143 constitutes the connection between the first inlet section 122 and the second inlet section 123 or the connection between the first outlet section 132 and the second outlet section 133.

[0070] Reference Figure 3 and Figure 4Both the liquid inlet section 120 and the liquid outlet section 130 are formed by the cooperation of a first tube 141 and a second tube 142. Taking the liquid inlet section 120 as an example, the first tube 141 is located on the rear side of the liquid-cooled heat exchanger 100, and the second tube 142 is located on the front side of the liquid-cooled heat exchanger 100, closely attached to the first tube 141. A first liquid inlet section 122 is formed inside the liquid inlet channel 121, and a second liquid inlet section 123 is formed inside the liquid inlet channel 121. At the same time, a liquid passage hole 143 is provided at the top position of the sidewalls of the first tube 141 and the second tube 142 that are closely attached to each other. The liquid passage hole 143 penetrates the sidewalls of the first tube 141 and the second tube 142 in the front-back direction, thereby connecting the internal chambers of the first tube 141 and the second tube 142 in the front-back direction. In this embodiment, the liquid passage 143 is positioned higher than the first heat exchange end 115 of the highest-positioned first heat exchange channel 113 in the first heat exchange module 111. Since the first heat exchange module 111 and the second heat exchange module 112 have the same structure and corresponding positions, the liquid passage 143 is also positioned higher than the first heat exchange end 115 of the highest-positioned second heat exchange channel 114 in the second heat exchange module 112. Simultaneously, a liquid inlet pipe 125 is provided at the bottom of the first tube body 141, which connects to the first liquid inlet section 122 in the liquid inlet channel 121 via a liquid inlet port 124 located at the bottom of the first tube body 141. Furthermore, in this embodiment, the liquid inlet port 124 is positioned lower than the first heat exchange end 115 of the lowest-positioned first heat exchange channel 113 in the first heat exchange module 111.

[0071] Taking the liquid outlet section 130 as an example, the first tube 141 is located on the rear side of the liquid-cooled heat exchanger 100, and the second tube 142 is located on the front side of the liquid-cooled heat exchanger 100, closely attached to the first tube 141. A first liquid outlet section 132 is formed inside the liquid outlet channel 131 within the first tube 141, and a second liquid outlet section 133 is formed inside the liquid outlet channel 131 within the second tube 142. Simultaneously, a liquid passage hole 143 is provided at the top of the sidewalls of the first tube 141 and the second tube 142 that are closely attached to each other. This liquid passage hole 143 penetrates the sidewalls of the first tube 141 and the second tube 142 in the front-back direction, thereby connecting the internal chambers of the first tube 141 and the second tube 142 in the front-back direction. In this embodiment, the position of the liquid passage hole 143 is higher than the position of the second heat exchange end 116 of the highest first heat exchange channel 113 in the first heat exchange module 111. Since the first heat exchange module 111 and the second heat exchange module 112 have the same structure and corresponding positions, the position of the liquid passage 143 is also higher than the position of the second heat exchange end 116 of the highest second heat exchange channel 114 in the second heat exchange module 112. Meanwhile, a liquid outlet pipe 135 is provided at the bottom of the first tube body 141, and this liquid outlet pipe 135 is connected to the first liquid outlet section 132 in the liquid outlet channel 131 through a liquid outlet 134 located at the bottom of the first tube body 141. Furthermore, in this embodiment, the position of the liquid outlet 134 is lower than the position of the second heat exchange end 116 of the lowest second heat exchange channel 114 in the second heat exchange module 112.

[0072] In this embodiment, refer to Figure 1 The liquid-cooled heat exchanger 100 is vertically mounted on one side of the liquid-cooled radiator 200, opposite the heat dissipation surface of the liquid-cooled radiator 200. The bottoms of the inlet pipe 125 and outlet pipe 135 of the liquid-cooled heat exchanger 100 are welded to the liquid-cooled radiator 200, thereby connecting the inlet flow channel 121, heat exchange flow channel, and outlet flow channel 131 of the liquid-cooled heat exchanger 100 with the internal flow channels of the liquid-cooled radiator 200. The placement of the inlet pipe 125 and outlet pipe 135 allows for a higher height of the heat exchange section 110 of the liquid-cooled heat exchanger 100, facilitating direct air cooling of higher-positioned electrical components. Furthermore, as a preferred embodiment, the internal flow channel of the liquid-cooled radiator 200 can be connected in series with the flow channel in the liquid-cooled heat exchanger 100. That is, after the liquid cooling medium enters the liquid-cooled radiator 200 from the inlet, it will all pass through the liquid-cooled heat exchanger 100 and then flow back from the liquid-cooled heat exchanger 100 to the liquid-cooled radiator 200.

[0073] During operation, the liquid cooling medium enters the inlet channel 121 of the inlet section 120 from the inlet pipe 125. As it fills the first inlet section 122 of the inlet channel 121, it flows into the first heat exchange channel 113 of the first heat exchange module 111. Simultaneously, the liquid cooling medium passes through the liquid passage 143 into the second inlet section 123, and flows into the second heat exchange channel 114 of the second heat exchange module 112. Afterward, the liquid cooling medium enters the outlet channel 131 of the outlet section 130 from the first heat exchange channel 113 and the second heat exchange channel 114. After entering the first outlet section 132, the liquid cooling medium moves upward until it enters the second outlet section 133 from the liquid passage 143. Finally, the liquid cooling medium is discharged from the outlet 134 of the second outlet section 133 into the outlet pipe 135.

[0074] This embodiment relates to a liquid-cooled heat exchanger 100. By setting a first heat exchange module 111 and a second heat exchange module 112, each module includes multiple heat exchange channels arranged side by side in the vertical direction with the same length. The two modules are connected to the liquid inlet 120 and the liquid outlet 130 respectively by a cross connection. At the same time, the liquid inlet channel 121 and the liquid outlet channel 131 are constructed as upward convex and bent structures, and the bend is not lower than the corresponding port of all heat exchange channels. Thus, without relying on external exhaust devices or high pump pressure, the problem of high-level gas accumulation and difficulty in discharge is effectively solved, and the flow balance between the two modules is achieved.

[0075] Specifically, the first heat exchange end 115 of each first heat exchange channel 113 of the first heat exchange module 111 is connected to the first inlet section 122 of the inlet channel 121, and its second heat exchange end 116 is connected to the first outlet section 132 of the outlet channel 131; the second heat exchange end 116 of each second heat exchange channel 114 of the second heat exchange module 112 is connected to the second inlet section 123 of the inlet channel 121, and its first heat exchange end 115 is connected to the second outlet section 133 of the outlet channel 131. This forms two intersecting flow paths: coolant enters the first heat exchange channel 113 from the first inlet section 122, flows through it, and exits from the first outlet section 132; simultaneously, coolant enters the second heat exchange channel 114 from the second inlet section 123, flows through it, and exits from the second outlet section 133. Because the first inlet section 122 is connected to the second outlet section 133, and the second inlet section 123 is connected to the first outlet section 132, the entire system forms a closed-loop cross-parallel circuit. With this configuration, the heat exchange channels of both heat exchange modules have the same geometric length, forming parallel flow channels with consistent hydraulic resistance in their respective circuits, ensuring uniform flow within the modules. Furthermore, due to the division into two branches, the overall system flow resistance is significantly reduced, not only decreasing pump power requirements but also improving response under low flow conditions. Moreover, because the two modules are interconnected through the high-point areas of the inlet and outlet channels 131, the system maintains a unified pressure balance. Even if the two modules experience slight differences in local resistance due to installation location or heat load differences, the coolant can automatically adjust its distribution ratio through the high-point connection area, preventing unilateral flow deviation and improving system reliability.

[0076] More importantly, the bend in the liquid inlet channel 121 (i.e., the junction of the first liquid inlet section 122 and the second liquid inlet section 123) is not lower than the first heat exchange end 115 of the highest heat exchange channel, and the bend in the liquid outlet channel 131 (i.e., the junction of the first liquid outlet section 132 and the second liquid outlet section 133) is not lower than the second heat exchange end 116 of the highest heat exchange channel. This design ensures that the highest geometric point inside the entire heat exchanger is no longer the top of any heat exchange channel, but rather the bend areas of the liquid inlet channel 121 and the liquid outlet channel 131. Since the ports of all heat exchange channels are directly connected to a common chamber adjacent to these high points, when gas rises to its end in any heat exchange channel due to buoyancy, it can continue to migrate upwards into the high point region of the liquid inlet or liquid outlet channel 131. In the aforementioned cross-parallel layout, the gas at the top of the first heat exchange channel 113 can rise to the high point of the first inlet section 122 or the first outlet section 132; the gas at the top of the second heat exchange channel 114 can rise to the high point of the second inlet section 123 or the second outlet section 133. Since the first inlet section 122 and the second inlet section 123 inside the inlet channel 121 are connected at their high points, and the first outlet section 132 and the second outlet section 133 inside the outlet channel 131 are also connected at their high points, all the gas can ultimately converge into a unified high-point chamber and be discharged from the outlet end with the main flow. Furthermore, this design allows both sides of the inlet section 120 and the outlet section 130 to form gas collection spaces, resulting in a larger gas collection capacity, a shorter path, and significantly better exhaust capacity than structures that only collect gas on one side of the inlet section 120 or the outlet section 130.

[0077] Furthermore, this solution employs a double-layer air-cooled structure: the first and second heat exchange modules 112 are arranged side-by-side, with external air flowing sequentially through the two heat exchange surfaces. This doubles the heat exchange area for the same projected area, and the airflow channels are regular and unobstructed. In contrast, conventional single-layer heat exchange structures require a large baffle-type manifold on one side, which not only occupies air-cooling space and obstructs airflow but also leads to a decrease in local heat dissipation performance. This solution, by arranging the heat exchangers side-by-side, reduces the lateral space occupied by the heat exchanger, thereby conversely increasing the heat exchange area of ​​the heat exchange section 110 and improving the overall heat exchange efficiency of the heat exchanger.

[0078] Furthermore, conventional single-layer heat exchange structures, due to the manifold being located on only one side, result in an asymmetrical distribution of the inlet section 120 and the outlet section 130 with varying degrees of stress. This causes the welded joint to bear significant thermal and assembly stresses, making it prone to cracking during long-term operation. In this design, both the inlet section 120 and the outlet section 130 form a manifold structure with consistent inlet and outlet widths. Moreover, the inlet port 124 and the outlet port 134 are symmetrically distributed at an oblique angle, effectively balancing the stresses caused by thermal expansion and fluid loads. This significantly improves the structural strength and sealing reliability of the welded joints, making it particularly suitable for electrical equipment applications involving high vibration and frequent start-stop cycles.

[0079] It should be noted that if only parallel flow channels are used without a unified high point design, the gas will be confined to isolated high points at the top of each flow channel and cannot be collected and discharged; if only high points are set but the flow channels are not parallel, some flow channels will still retain gas due to insufficient flow rate. This solution integrates parallel flow, parallel connection, and high point bend in a coordinated manner, allowing gas to migrate freely from any flow channel to the highest point of the system and to be effectively carried and discharged in a uniform flow field. This effectively solves the problem in the prior art where heat exchangers located at higher positions have difficulty discharging gas due to their distance from the pump source, significantly improving the heat exchange reliability and operational stability of the heat exchanger under gas-containing conditions. The description of the above specification and embodiments is used to explain the scope of protection of this invention, but does not constitute a limitation on the scope of protection of this invention. Modifications, equivalent substitutions, or other improvements to the embodiments of this invention or some of its technical features that can be obtained by those skilled in the art through logical analysis, reasoning, or limited experimentation based on the teachings of this invention or the above embodiments, combined with common knowledge, general technical knowledge in the art, and / or existing technology, should all be included within the scope of protection of this invention.

Claims

1. A liquid-cooled heat exchanger (100), characterized in that, include: A heat exchange section (110) is used to contact an external fluid to achieve heat exchange, and includes a first heat exchange module (111) and a second heat exchange module (112) arranged side by side in the front-back direction; the first heat exchange module (111) and the second heat exchange module (112) are respectively provided with a plurality of first heat exchange channels (113) and second heat exchange channels (114) arranged side by side in the vertical direction and of the same length; the two ends of each first heat exchange channel (113) and second heat exchange channel (114) are respectively a first heat exchange end (115) and a second heat exchange end (116); The liquid inlet section (120) has an upwardly protruding and bent liquid inlet channel (121), which includes a first liquid inlet section (122) and a second liquid inlet section (123) that are interconnected. The bottom of the first liquid inlet section (122) is provided with a liquid inlet (124) suitable for receiving liquid cooling medium, and is simultaneously connected to the first heat exchange end (115) of each of the first heat exchange channels (113). The second liquid inlet section (123) is connected to each of the second heat exchange channels. The first heat exchange end (115) of the channel (114) is simultaneously connected; the connection between the first liquid inlet section (122) and the second liquid inlet section (123) is the bend of the liquid inlet channel (121), and it is not lower than the first heat exchange end (115) of the highest first heat exchange channel (113) and the second heat exchange channel (114); the liquid inlet (124) is not higher than the first heat exchange end (115) of the lowest first heat exchange channel (113); The liquid outlet section (130) is provided with an upwardly protruding and bent liquid outlet channel (131), which includes a first liquid outlet section (132) and a second liquid outlet section (133) that are interconnected. The first liquid outlet section (132) is simultaneously connected to the second heat exchange end (116) of each of the first heat exchange channels (113). The bottom of the second liquid outlet section (133) is provided with a liquid outlet (134) suitable for discharging liquid cooling medium, and is connected to each of the second heat exchange channels. The second heat exchange end (116) of the channel (114) is simultaneously connected; the connection between the first liquid outlet section (132) and the second liquid outlet section (133) is the bend of the liquid outlet channel (131), and it is not lower than the second heat exchange end (116) of the highest first heat exchange channel (113) and the second heat exchange channel (114); the liquid outlet (134) is not higher than the second heat exchange end (116) of the lowest second heat exchange channel (114).

2. The liquid-cooled heat exchanger (100) as described in claim 1, characterized in that, The positions of the first heat exchange channel (113) in the first heat exchange module (111) and the second heat exchange channel (114) in the second heat exchange module (112) correspond one-to-one in the front-to-back direction in the vertical direction.

3. The liquid-cooled heat exchanger (100) as described in claim 1, characterized in that, The first heat exchange module (111) is located behind the second heat exchange module (112) in the front-back direction, so that it is downstream of the path of the external fluid passing through the heat exchange section (110) relative to the second heat exchange module (112).

4. A liquid-cooled heat exchanger (100) as described in claim 1, characterized in that, The liquid inlet (120) and liquid outlet (130) each include a first tube (141) and a second tube (142) that are attached to each other in the front-back direction. A liquid passage hole (143) is provided through the tube wall where the first tube (141) and the second tube (142) are attached to each other. The first tube (141) and the second tube (142) respectively constitute the first liquid inlet section (122) and the second liquid inlet section (123) or the first liquid outlet section (132) and the second liquid outlet section (133) in the liquid inlet (120) or the liquid outlet section (130). The liquid passage hole (143) constitutes the connection between the first liquid inlet section (122) and the second liquid inlet section (123) or the connection between the first liquid outlet section (132) and the second liquid outlet section (133).

5. A liquid-cooled heat exchanger (100) as described in claim 1, characterized in that, The heat exchange section (110) includes a first heat exchange module (111) and a second heat exchange module (112), each of which includes a plurality of heat exchange flow channels (117). The heat exchange flow channels (117) are provided with a first heat exchange channel (113) or a second heat exchange channel (114) inside, and the heat exchange flow channels (117) are at least partially flat. The extension direction of the flat portion on the heat exchange flow channels (117) is used to define the flow direction of external fluid through the heat exchange section (110).

6. A liquid-cooled heat exchanger (100) as described in claim 5, characterized in that, Each heat exchange channel plate (117) is provided with a first heat exchange channel (113) or a second heat exchange channel (114). The first heat exchange channel (113) and the second heat exchange channel (114) each include a plurality of heat exchange sub-channels (118). Each heat exchange sub-channel (118) belonging to the same first heat exchange channel (113) or second heat exchange channel (114) is arranged side by side in the heat exchange channel plate (117) along the flow direction of the external fluid through the heat exchange part (110).

7. A liquid-cooled heat exchanger (100) as described in claim 6, characterized in that, The heat exchange channel plate (117) is long and flat, with its two ends in the length direction forming a first plate end (119) and a second plate end (1110), respectively. The first plate end (119) and the second plate end (1110) are connected to the liquid inlet (120) and the liquid outlet (130), respectively.

8. A liquid-cooled heat exchanger (100) as described in claim 6, characterized in that, It also includes an auxiliary heat exchange plate (1111); the auxiliary heat exchange plate (1111) is located between the heat exchange channel plates (117) that are adjacent in the vertical direction, and it includes a plurality of first heat exchange segments (1112) that are consistent with the extension direction of the heat exchange channel plates (117), and a second heat exchange segment (1113) that connects the first heat exchange segments (1112) that are adjacent in the length direction of the heat exchange channel plates (117) and extends in the vertical direction; the first heat exchange segment (1112) is closely attached to the heat exchange channel plate (117) corresponding to its height position in the auxiliary heat exchange plate (1111).

9. A liquid-cooled heat exchange assembly, comprising a liquid-cooled radiator (200) and a fan (300), characterized in that, It also includes a liquid-cooled heat exchanger (100) as described in any one of claims 1-8; the liquid-cooled heat exchanger (100) is connected to the liquid-cooled radiator (200) to circulate the liquid cooling medium; the fan (300) is used to drive air fluid through the heat exchange section (110) of the liquid-cooled heat exchanger (100).

10. A converter comprising a plurality of power devices, characterized in that, It also includes the liquid-cooled heat exchange assembly as described in claim 9; at least a portion of the power devices dissipate heat through the liquid-cooled radiator (200) and / or the liquid-cooled heat exchanger (100) in the liquid-cooled heat exchange assembly.

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