Power conversion device and method for manufacturing the same

Abstract

The present application relates to a power conversion device and a manufacturing method thereof. The power conversion device includes: a housing that encloses an accommodation cavity, and a pouring port and an exhaust port are formed on the housing, and both the pouring port and the exhaust port communicate with the accommodation cavity; and a circuit board disposed in the accommodation cavity, the circuit board has a first surface for mounting electronic components, and the pouring port is closer to the first surface than the exhaust port. In view of the fact that the pouring port is closer to the first surface than the exhaust port, during the process of filling the accommodation cavity with the pouring liquid, the liquid level formed by the pouring liquid in the accommodation cavity will finally reach the exhaust port, avoiding the liquid level reaching the exhaust port before the accommodation cavity is filled with the pouring liquid and blocking the exhaust port, preventing the exhaust port from being unable to exhaust effectively due to blockage, thereby ensuring that all the air in the accommodation cavity can be discharged from the exhaust port to the outside, avoiding the residual gas in the accommodation cavity affecting the uniformity of the filling of the pouring liquid, that is, improving the glue injection uniformity.

Description

Technical Field

[0001] This application relates to the field of new energy technologies, and particularly to a power conversion device and a manufacturing method thereof. Background Art

[0002] With the rapid development of new energy technologies, solar energy has been widely applied to daily production and life due to its advantages such as pollution-free and sustainable utilization. Generally, the solar light energy can be converted into electrical energy through photovoltaic power generation technology. The direct current generated by the photovoltaic power generation technology is then converted into alternating current through a power conversion device, and this alternating current can become available electrical energy and be input into the power grid through a connector. In order to enable the power conversion device to be used in various harsh environments, it is usually necessary to inject a casting liquid into the power conversion device to form a protective seal. However, for traditional power conversion devices, there is usually a defect that the casting liquid is unevenly filled. Summary of the Invention

[0003] One technical problem solved by this application is how to improve the casting uniformity of the power conversion device.

[0004] A power conversion device includes:

[0005] A housing that encloses a receiving cavity, and a casting port and an exhaust port are opened on the housing, and both the casting port and the exhaust port communicate with the receiving cavity; and

[0006] A circuit board disposed in the receiving cavity, the circuit board having a first surface for mounting electronic components, and the casting port is closer to the first surface than the exhaust port.

[0007] In one embodiment, the casting port and the exhaust port are spaced apart by ΔH in a direction perpendicular to the first surface.

[0008] In one embodiment, the first surface has a blank area where no electronic components are mounted, and the orthographic projection of the casting port in a direction perpendicular to the first surface falls within the blank area.

[0009] In one embodiment, the first surface has a DC area and an AC area, the DC area is for mounting DC electronic components, and the AC area is for mounting AC electronic components; along a direction perpendicular to the first surface, the orthographic projection of the casting port falls within the DC area, and the orthographic projection of the exhaust port falls within the AC area.

[0010] In one embodiment, it further includes a connector assembly, the housing has an installation side for mounting the connector assembly, and the distance between the casting port and the installation side is less than a first preset distance.

[0011] In one embodiment, the housing has a first corner where two sides intersect, and the exhaust port is disposed near the first corner.

[0012] In one embodiment, the housing has a profiling structure, which includes a first region and a second region. The first region is closer to the first surface than the second region, and the exhaust port is disposed at a position in the second region near the first corner.

[0013] In one embodiment, the housing has a profiling structure, which includes a first region and a second region. The first region is closer to the first surface than the second region. The pouring port is disposed in the first region, and the exhaust port is disposed in the second region.

[0014] In one embodiment, the first region includes a second corner with a rounded corner, and the pouring port is disposed near the second corner. The pouring port is circular.

[0015] In one embodiment, the second region includes a third corner, and the exhaust port is disposed near the third corner.

[0016] In one embodiment, the centers of both the pouring port and the exhaust port maintain a preset distance, and the value range of the preset distance is from 120 mm to 200 mm.

[0017] In one embodiment, the housing includes a first shell and a second shell that jointly enclose the accommodation cavity. Both the pouring port and the exhaust port are disposed on the first shell, and the circuit board is carried on the second shell.

[0018] In one embodiment, an annular groove is formed on the second shell. The annular groove surrounds the circuit board and cooperates with a flange on the first shell for accommodating a sealing material.

[0019] In one embodiment, the second shell includes a limiting member for carrying the circuit board. The limiting member has a first limiting surface and a second limiting surface that are connected at an angle. The circuit board has a second surface opposite to the first surface. The first limiting surface abuts against the second surface in a direction perpendicular to the first surface, so that there is a spaced gap between the circuit board and the second shell in a direction perpendicular to the first surface, and the second limiting surface abuts against the circuit board in a direction perpendicular to the direction perpendicular to the first surface.

[0020] In one embodiment, the limiting member is an edge limiting member, and the edge limiting member is arranged at the edge of the second housing. The second limiting surface of the edge limiting member abuts against the edge of the circuit board, so as to form a flow channel communicating with the spaced gap between the edge of the circuit board and the second housing.

[0021] In one embodiment, the limiting member is an intermediate limiting member, and the intermediate limiting member is arranged in the middle of the second housing. The intermediate limiting member includes a support member and a column body arranged in the middle of the support member. The first limiting surface of the intermediate limiting member is the upper surface of the support member, and the second limiting surface of the intermediate limiting member is the outer surface of the column body. The column body penetrates through the circuit board.

[0022] In one embodiment, a sealing member is further included, and the sealing member is used to block the pouring port and the exhaust port.

[0023] In one embodiment, an indicator light is further included, and the indicator light includes a light emitting part and a sealing part. The light emitting part is arranged on the first surface, and the sealing part covers the light emitting part and fits with the first surface.

[0024] In one embodiment, the indicator light further includes a light guide column, and the light guide column is connected to the sealing part and is used to guide the optical signal of the light emitting part to the outer surface of the housing.

[0025] A manufacturing method for processing the power conversion device described in any one of the above, includes the following steps:

[0026] Set the power conversion device at a first angle with the horizontal plane as the reference plane, and the pouring port is lower than the exhaust port in the vertical direction;

[0027] Inject a pouring liquid into the accommodating cavity through the pouring port; and

[0028] Block the pouring port and the exhaust port.

[0029] In one embodiment, the first angle is 0°.

[0030] In one embodiment, the first angle is 15° to 30°.

[0031] In one embodiment, the method further includes injecting a pouring liquid into the accommodating cavity through a one-way valve.

[0032] One technical effect of an embodiment of the present application is that, in view that the pouring gate is closer to the first surface than the exhaust port, during the process of filling the accommodating cavity with the pouring liquid, the liquid level formed by the pouring liquid in the accommodating cavity will finally reach the exhaust port, avoiding the liquid level reaching the exhaust port before the accommodating cavity is filled with the pouring liquid and blocking the exhaust port, preventing the exhaust port from being unable to exhaust effectively due to blockage, thereby ensuring that all the air in the accommodating cavity can be discharged from the exhaust port to the outside, avoiding the residual gas in the accommodating cavity from affecting the uniformity of the pouring liquid filling, that is, improving the glue injection uniformity. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 FIG. is a three-dimensional structural schematic diagram of a power conversion device of the first prior art.

[0034] Figure 2 FIG. is a three-dimensional structural schematic diagram of a power conversion device of the second prior art.

[0035] Figure 3 FIG. is a three-dimensional structural schematic diagram of a power conversion device provided by an embodiment.

[0036] Figure 4 is Figure 3 a three-dimensional structural schematic diagram of the power conversion device shown from another perspective.

[0037] Figure 5 is Figure 3 a first exemplary exploded structural schematic diagram of the power conversion device shown.

[0038] Figure 6 is Figure 3 a second exemplary exploded structural schematic diagram of the power conversion device shown.

[0039] Figure 7 is Figure 6 an enlarged structural schematic diagram at A in

[0040] Figure 8 is Figure 3 a three-dimensional sectional structural schematic diagram of the power conversion device shown.

[0041] Figure 9 is Figure 3 a planar structural schematic diagram of the power conversion device shown.

[0042] Figure 10 is Figure 3 a three-dimensional structural schematic diagram of the power conversion device shown inclined relative to the horizontal plane.

[0043] Figure 11 is a Figure 3 process flow block diagram of the manufacturing method of the power conversion device shown provided by an embodiment.

[0044] Reference numerals: power conversion device 10, housing 100, accommodation cavity 130, first housing 110, first region 111, casting port 1111, second corner 1112, second region 112, exhaust port 1121, third corner 1123, second housing 120, annular groove 121, limiting member 122, first limiting surface 1221, second limiting surface 1222, edge limiting member 1223, intermediate limiting member 1224, support member 1225, column 1226, first corner 140, installation side 150, first side 101, second side 102, third side 103, fourth side 104, circuit board 200, first surface 210, blank area 211, DC area 212, AC area 213, second surface 220, spacing gap 230, flow channel 240, transformer 300, connector assembly 400, DC assembly 410, AC assembly 420, seal 500, indicator light 600, sealing portion 620, light guide column 630. Detailed implementation manners

[0045] To make the above objects, features, and advantages of the present application more obvious and understandable, the following will describe the detailed implementation manners of the present application with reference to the accompanying drawings. Many specific details are set forth in the following description to facilitate a full understanding of the present application. However, the present application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar improvements without departing from the connotation of the present application. Therefore, the present application is not limited by the specific embodiments disclosed below.

[0046] In the description of the present application, it should be understood that if terms such as "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc. appear, the orientation or positional relationship indicated by these terms is based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as a limitation of the present application.

[0047] In addition, if terms such as "first" and "second" appear, these terms are only for descriptive purposes and should not be construed as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include at least one of such features. In the description of the present application, if the term "plurality" appears, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise specifically defined.

[0048] In this application, unless otherwise clearly defined and limited, if terms such as "installed", "connected", "joined", "fixed", etc. appear, these terms should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or integrated; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two components or the interaction relationship between two components, unless otherwise clearly defined. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0049] In this application, unless otherwise clearly defined and limited, if there is a description such as a first feature being "on" or "under" a second feature, its meaning can be that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. Moreover, the first feature being "above", "over" and "on top of" the second feature can be that the first feature is directly above or obliquely above the second feature, or merely means that the horizontal height of the first feature is higher than that of the second feature. The first feature being "under", "beneath" and "underneath" the second feature can be that the first feature is directly below or obliquely below the second feature, or merely means that the horizontal height of the first feature is less than that of the second feature.

[0050] It should be noted that if an element is referred to as "fixed to" or "disposed on" another element, it can be directly on the other element or there can also be an intermediate element. If an element is considered to be "connected" to another element, it can be directly connected to the other element or there may be an intermediate element at the same time. If so, the terms "vertical", "horizontal", "up", "down", "left", "right" and similar expressions used in this application are only for the purpose of illustration and do not represent the only implementation.

[0051] In the field of photovoltaic power generation technology, the direct current generated by photovoltaic power generation is converted into alternating current through a power conversion device. This alternating current can become available electric energy directly input into the power grid or be stored using an energy storage device. In order to enable the power conversion device to be used in various harsh environments, not only the housing of the power conversion device needs to be sealed, but usually a casting liquid needs to be injected into the power conversion device to seal the electronic devices in the power conversion device to form a protective effect.

[0052] In Figure 1 In the prior art shown, the pouring port a is arranged on the side of the housing, so that the pouring port a is far from the side of the power conversion device opposite to the pouring port a, resulting in difficulty in effectively filling the side of the power conversion device opposite to the pouring port a with the casting liquid, thus making it difficult to ensure the uniformity of pouring. In Figure 2In the prior art shown, the pouring port b and the exhaust port c are both in the same plane, and the exhaust port c is in the middle of the housing of the power conversion device. In this way, it will be difficult for the gas in the power conversion device to gather into the exhaust port c and be discharged. Therefore, the residual gas in the power conversion device will affect the uniformity of pouring.

[0053] Referring to Figure 3 、 Figure 5 and Figure 6 In an embodiment of the present application, a power conversion device 10 includes a housing 100 and a circuit board 200. The housing 100 defines an accommodation cavity 130. The circuit board 200 is disposed in the accommodation cavity 130. A pouring port 1111 and an exhaust port 1121 are formed on the housing 100, and both the pouring port 1111 and the exhaust port 1121 communicate with the accommodation cavity 130. The circuit board 200 has a first surface 210 and a second surface 220, and the first surface 210 and the second surface 220 are two surfaces opposite to each other in a direction perpendicular to the first surface. Along the direction perpendicular to the first surface, the first surface 210 faces the pouring port 1111 and the exhaust port 1121, and the first surface 210 is also used for mounting other electronic components. Along the direction perpendicular to the first surface, the pouring port 1111 is closer to the first surface 210 than the exhaust port 1121.

[0054] In a possible implementation, as Figure 3 shown, the pouring port 1111 and the exhaust port 1121 may be separated by ΔH in a direction perpendicular to the first surface. The value range of ΔH may be from 10 mm to 15 mm. For example, the specific value of ΔH may be 10 mm, 12.5 mm or 15 mm, etc.

[0055] As Figure 5 shown, the power conversion device 10 further includes a transformer 300, and the transformer 300 may be disposed on the first surface 210. The pouring liquid can be injected into the accommodation cavity 130 from the pouring port 1111. The solidified pouring liquid can seal and protect the housing 100 and the electronic components, ensuring that the power conversion device 10 can be applied to various harsh environments such as humid heat, acid-base, rain, snow and ice, and can also improve the anti-impact performance of the power conversion device 10. During the process of injecting the pouring liquid from the pouring port 1111, the air in the accommodation cavity 130 will gradually be discharged from the exhaust port 1121.

[0056] The pouring liquid can be an electrically insulating material. For example, the pouring liquid can be a glue made of silicone material, etc. In this way, the solidified pouring liquid has good elasticity to bear large stresses. It can be understood that as long as the material has electrical insulation performance and elasticity after curing, it can be used as the pouring liquid.

[0057] Since the pouring gate 1111 is closer to the first surface 210 than the exhaust port 1121, during the process of filling the accommodating cavity 130 with the pouring liquid, the liquid level formed by the pouring liquid in the accommodating cavity 130 will finally reach the exhaust port 1121, preventing the liquid level from reaching the exhaust port 1121 before the accommodating cavity 130 is filled with the pouring liquid and blocking the exhaust port 1121, thus preventing the exhaust port 1121 from being blocked and unable to exhaust effectively, ensuring that all the air in the accommodating cavity 130 can be discharged from the exhaust port 1121 to the outside, avoiding the residual gas in the accommodating cavity 130 from affecting the uniformity of the pouring liquid filling, that is, improving the glue injection uniformity.

[0058] Refer to Figure 3 、 Figure 4 and Figure 9 In some embodiments, the housing 100 has a first corner 140 where two sides of the housing 100 intersect. It can be understood that the part within a preset distance from the intersection line where the two sides of the housing 100 intersect is the first corner 140. The two sides of the housing 100 are respectively denoted as the first side 101 and the second side 102 of the housing 100. For example, the position on the housing 100 that is 20 mm to 30 mm away from the first side 101 and 20 mm to 35 mm away from the second side 102 belongs to the first corner 140. The preset distance from the first side 101 can be specifically 20 mm or 25 mm, etc., and the preset distance from the second side 102 can be specifically 25 mm or 30 mm, etc. The length of the first side 101 can be greater than the length of the second side 102, that is, the first side 101 is the long side and the second side 102 is the short side. Of course, the lengths of the first side 101 and the second side 102 can also be equal.

[0059] The exhaust port 1121 is arranged at a position close to the first corner 140. For example, the center of the exhaust port 1121 can be located at the first corner 140, or at least part of the exhaust port 1121 is located at the first corner 140. The exhaust port 1121 can be circular or the like. Thus, during the process of filling the accommodating cavity 130 with the pouring liquid, since the first corner 140 is the intersection of two directions, the air at each position in the accommodating cavity 130 is more likely to converge to the first corner 140 from different directions, so that there is a relatively large air pressure near the exhaust port 1121, ensuring that the gas is quickly discharged from the exhaust port 1121, avoiding the gas remaining in the accommodating cavity 130 and affecting the uniformity of the pouring liquid filling, and finally improving the glue injection uniformity.

[0060] Refer to Figure 4 、 Figure 5 and Figure 6, in some embodiments, the housing 100 may be a profiling structure, and the housing 100 may be made of an electrically insulating material such as plastic. The first surface 210 of the circuit board 200 is arranged towards the profiling structure in a direction perpendicular to the first surface. The profiling structure can be understood as an uneven structure suitable for accommodating electronic components with different protruding heights relative to the circuit board 200 in the accommodating cavity 130. For example, the profiling structure may be a rough structure, that is, by setting a preset height between a certain part of the housing 100 and the circuit board 200 to accommodate multiple electronic components with protruding heights within a certain range relative to the circuit board 200. Another example is that the profiling structure may be a fine structure, that is, by setting preset heights between different parts of the housing 100 and the circuit board 200 to accommodate each electronic component with a different protruding height relative to the circuit board 200. By setting the profiling structure, the amount of casting liquid used can be saved.

[0061] The profiling structure may have rounded corners, which can improve the uniformity of the casting liquid flow rate, prevent gas from remaining in the accommodating cavity 130 and affecting the uniformity of the casting liquid filling, and thus prevent holes from existing in the solid formed after the casting liquid solidifies.

[0062] Continue to refer to Figure 4 、 Figure 5 and Figure 6 , the profiling structure includes a first region 111 and a second region 112. The first region 111 is closer to the first surface 210 than the second region 112. It can be generally understood that the first region 111 is arranged lower than the second region 112 in the vertical direction. The pouring port 1111 is arranged in the first region 111, and the exhaust port 1121 is arranged in the second region 112. Thus, the pouring port 1111 is closer to the first surface 210 than the exhaust port 1121, and the pouring port 1111 is lower than the exhaust port 1121. The exhaust port 1121 is arranged at a position in the second region 112 close to the first corner 140. This enables the gas to quickly discharge from the exhaust port 1121 and avoid remaining in the accommodating cavity 130, thereby improving the glue injection uniformity.

[0063] Refer to Figure 4 、 Figure 5 、 Figure 6 and Figure 9, in some embodiments, the first region 111 includes a second corner 1112 where two sides of the first region 111 intersect. It can be understood that the part within a preset distance from the intersection line of the two sides of the first region 111 is the second corner 1112. The two sides of the first region 111 are respectively denoted as the third side 103 and the fourth side 104 of the first region 111. For example, the position on the first region 111 that is 10 mm to 20 mm away from the third side 103 and 15 mm to 25 mm away from the fourth side 104 belongs to the second corner 1112. The preset distance from the third side 103 can be specifically 15 mm or 20 mm, etc., and the preset distance from the fourth side 104 can be specifically 20 mm or 25 mm, etc.

[0064] The pouring gate 1111 is disposed at a position close to the second corner 1112. For example, the center of the pouring gate 1111 can be located within the second corner 1112, or the pouring gate 1111 is at least partially located within the second corner 1112. The pouring gate 1111 can be circular, and of course, it can also be square or regular polygon, etc. The second corner 1112 has a rounded corner. By setting the rounded corner to avoid dead corners, it will be beneficial to improve the fluidity of the pouring liquid in the accommodating cavity 130. On the one hand, it enables the pouring liquid to quickly fill the accommodating cavity 130 and improve the injection efficiency; on the other hand, it is also beneficial for the quickly flowing pouring liquid to expel the gas in the accommodating cavity 130 from the exhaust port 1121, thereby avoiding residual gas from affecting the uniformity of injection. When the pouring gate 1111 is circular, the circular pouring gate 1111 is adapted to the rounded corner, which can save the area of the housing 100 and make the housing 100 easier to process.

[0065] Refer to Figure 4 、 Figure 5 and Figure 6 , the second region 112 includes a third corner 1123 where two sides of the second region 112 intersect. It can be understood that the part within a preset distance from the intersection line of the two sides of the second region 112 is the third corner 1123. The definition of the third corner 1123 can refer to the above-mentioned second corner 1112. The exhaust port 1121 is disposed at the third corner 1123. In this way, the air in the accommodating cavity 130 is also easier to converge to the third corner 1123, avoiding gas remaining in the accommodating cavity 130 and affecting the uniformity of the pouring liquid filling, and finally improving the injection uniformity.

[0066] Refer to Figure 4 、 Figure 5 and Figure 6, considering that the pouring port 1111 is arranged in the first area 111, and the exhaust port 1121 is arranged in the second area 112, the centers of the pouring port 1111 and the exhaust port 1121 maintain a preset distance, the value range of the preset distance is 120mm to 140mm, and the specific value of the preset distance can be 120mm, 130mm or 140mm, etc. Such arrangement of the pouring port 1111 and the exhaust port 1121 is also conducive to the appropriate flow distance of the pouring liquid, thereby optimizing the exhaust effect and ultimately improving the uniformity of the injection.

[0067] Exemplarily, the calibers of the pouring port 1111 and the exhaust port 1121 may be 5 mm to 15 mm, and the calibers of the pouring port 1111 and the exhaust port 1121 may not be equal. For example, the caliber of the pouring port 1111 may be smaller than the caliber of the exhaust port 1121, so that the exhaust port 1121 has a relatively large caliber, which is beneficial to reduce the flow resistance of the gas flowing through the exhaust port 1121, thereby improving the exhaust effect and ultimately improving the uniformity of the injection.

[0068] See also Figure 5 In some embodiments, the first surface 210 of the circuit board 200 has a blank area 211, on which no electronic components are installed, and the orthographic projection of the pouring port 1111 in a direction perpendicular to the first surface falls on the blank area 211. It can be understood that the pouring port 1111 is located directly above the blank area 211, so that the pouring port 1111 is offset from the electronic components on the circuit board 200. The pouring liquid flowing out of the pouring port 1111 is prevented from directly falling on the electronic components, thereby preventing the pressure of the pouring liquid from directly acting on the electronic components and causing damage to the electronic components, and ultimately improving the safety of the injection.

[0069] See also Figure 5 and Figure 6 In some embodiments, the first surface 210 has a DC region 212 and an AC region 213. The DC region 212 is used to install DC electronic components. DC electronic components are components on the DC side. Of course, the DC region 212 can also be installed with AC electronic components. DC electronic components usually rarely have a packaging shell, so most DC electronic components are exposed electronic components. The AC region 213 is used to install AC electronic components. AC electronic components are components on the AC side. AC electronic components usually have a packaging shell, so most AC electronic components are packaged electronic components.

[0070] Since most of the DC electronic components are exposed electronic components, the positive projection of the pouring port 1111 in the direction perpendicular to the first surface can fall within the DC area 212, that is, the pouring port 1111 is located directly above the DC area 212 and the DC electronic components. In this way, the pouring liquid flowing out of the pouring port 1111 can cover the DC area 212 and the DC electronic components earlier and more, enabling the gas to flow out of the DC area 212 earlier, avoiding bubbles remaining in the DC area 212, improving the covering effect of the pouring liquid on the DC area 212 and the DC electronic components, and thus forming a more secure encapsulation and protection for the exposed DC electronic components.

[0071] Since most of the AC electronic components are already encapsulated electronic components, the AC electronic components themselves already have relatively high protection performance and have relatively low requirements for encapsulation with pouring liquid. The positive projection of the exhaust port 1121 in the direction perpendicular to the first surface can fall within the AC area 213, that is, directly above the AC area 213 and the AC electronic components, so that the gas in the accommodation cavity 130 gathers near the AC area 213 and is discharged from the exhaust port 1121.

[0072] Refer to Figure 3 and Figure 5 As shown in

[0073] Refer to Figure 5 、 Figure 6 and Figure 8, in some embodiments, the housing 100 may include a first housing 110 and a second housing 120. The first housing 110 and the second housing 120 jointly enclose a receiving cavity 130. The pouring port 1111 and the exhaust port 1121 are also provided on the first housing 110, and the circuit board 200 is carried on the second housing 120. An annular groove 121 is formed on the second housing 120, and the annular groove 121 is arranged around the circuit board 200. During the installation process of the first housing 110 and the second housing 120, the flange on the first housing 110 can be made to cooperate with the annular groove 121. It can be understood that the flange is also annular, so that the flange on the first housing 110 can be inserted into the annular groove 121. During the assembly process of the power conversion device 10, the flange on the first housing 110 can be first made to cooperate with the annular groove 121, and then a sealing material is accommodated in the annular groove 121. On the one hand, the sealing material seals the annular groove 121 and the receiving cavity 130; on the other hand, the sealing material also connects the first housing 110 and the second housing 120 to form a complete housing 100. After the housing 100 is assembled, a pouring liquid can be injected into the receiving cavity 130 through the pouring port 1111 to encapsulate the entire power conversion device 10. The sealing material can be glue or the like.

[0074] Refer to Figure 6 , Figure 7 and Figure 8 , in some embodiments, the second housing 120 includes a limiting member 122. The limiting member 122 is used to carry the circuit board 200. The limiting member 122 has a first limiting surface 1221 and a second limiting surface 1222, and the first limiting surface 1221 and the second limiting surface 1222 are connected at an angle. For example, the first limiting surface 1221 and the second limiting surface 1222 may be perpendicular to each other. The first limiting surface 1221 abuts against the second surface 220 in a direction perpendicular to the first surface, so that the first limiting surface 1221 plays a role in carrying the circuit board 200, and there is also a gap 230 between the circuit board 200 and the second housing 120 in a direction perpendicular to the first surface. The second limiting surface 1222 abuts against the circuit board 200 in a direction perpendicular to the direction perpendicular to the first surface.

[0075] Refer to Figure 6 , Figure 7 and Figure 8, for example, the limiting member 122 is an edge limiting member 1223. The edge limiting member 1223 is arranged at the edge of the second housing 120. The second limiting surface 1222 of the edge limiting member 1223 abuts against the edge of the circuit board 200, so that a flow channel 240 for communicating the spaced gap 230 is formed between the edge of the circuit board 200 and the second housing 120. Obviously, the flow channel 240 is arranged around the circuit board 200. During the process that the pouring liquid flows from the pouring port 1111 into the accommodating cavity 130, the pouring liquid on the side where the first surface 210 of the circuit board 200 is located will enter into the spaced gap 230 through the flow channel 240, so that the pouring liquid enters into the side where the second surface 220 of the circuit board 200 is located, so that the pouring liquid covers the first surface 210 and the second surface 220, and then the pouring liquid covers the entire circuit board 200, finally improving the encapsulation effect of the circuit board 200.

[0076] See Figure 6 、 Figure 7 and Figure 8 , or, the limiting member 122 is an intermediate limiting member 1224. The intermediate limiting member 1224 is arranged in the middle of the second housing 120. The intermediate limiting member 1224 includes a support member 1225 and a column 1226. The column 1226 is arranged in the middle of the support member 1225. The number of the support member 1225 and the column 1226 can both be one. The column 1226 can be inserted on the support member 1225 and protrude relative to the support member 1225; the number of the support members 1225 can be multiple, and the number of the column 1226 can be one. A plurality of support members 1225 are arranged around the column 1226. The first limiting surface 1221 is the upper surface of the support member 1225, and the outer surface of the column 1226 is the second limiting surface 1222. The column 1226 penetrates through the circuit board 200, so that the column 1226 is arranged in the through hole of the circuit board 200.

[0077] According to the actual situation requirements, the intermediate limiting member 1224 and the edge limiting member 1223 can be used alone, that is, the second housing 120 only includes the intermediate limiting member 1224 or only includes the edge limiting member 1223. The intermediate limiting member 1224 and the edge limiting member 1223 can also be used simultaneously, that is, the second housing 120 includes the intermediate limiting member 1224 and the edge limiting member 1223 at the same time. The number of the intermediate limiting member 1224 and the edge limiting member 1223 is multiple.

[0078] See Figure 3 and Figure 4, in some embodiments, the power conversion device 10 further includes a seal 500 for blocking the pouring port 1111 and the exhaust port 1121. When the accommodating cavity 130 is completely filled with the pouring liquid and the pouring liquid is solidified and formed, the pouring port 1111 and the exhaust port 1121 can be blocked by the seal 500, thereby preventing external dust and liquid from invading the accommodating cavity 130.

[0079] Refer to Figure 3 and Figure 5 , in some embodiments, the power conversion device 10 further includes an indicator light 600, which includes a light-emitting part 610 and a sealing part 620. The light-emitting part 610 is disposed on the first surface 210, and the sealing part 620 covers the light-emitting part 610 and fits with the first surface 210. The sealing part 620 can protect the light-emitting part 610 and prevent the pouring liquid from covering the light-emitting part 610. The light generated by the indicator light 600 can pass through the housing 100 with light-transmitting performance or through the light-transmitting holes on the housing 100, so that the working condition of the circuit board 200 can be determined according to the lighting state of the indicator light 600. Further, the indicator light 600 may further include a light guide column 630, and the light guide column 630 is connected to the sealing part 620. The light guide column 630 is used to guide the optical signal of the light-emitting part 610 to the outer surface of the housing 100, so that the lighting condition of the indicator light 600 can be tracked more conveniently.

[0080] Refer to Figure 10 and Figure 11 , the present application also provides a manufacturing method of the power conversion device 10, and the manufacturing method mainly includes the following steps:

[0081] S710, set the power conversion device 10 at a first angle α with the horizontal plane as the reference plane, and the pouring port 1111 is lower than the exhaust port 1121 in the vertical direction.

[0082] S720, inject the pouring liquid into the accommodating cavity 130 through the pouring port 1111.

[0083] S730, block the pouring port 1111 and the exhaust port 1121.

[0084] In some embodiments, for example, the power conversion device 10 can be placed horizontally on a horizontal plane. At this time, the value of the first angle α is 0°. For another example, the power conversion device 10 can be placed obliquely on the horizontal plane. At this time, the value range of the first angle α is from 15° to 30°, and the specific value of the first angle α can be 15°, 20° or 30°, etc. Of course, when the power conversion device 10 is tilted, it is necessary to make the pouring port 1111 lower than the exhaust port 1121 in the vertical direction. By placing the power conversion device 10 obliquely, the distance between the exhaust port 1121 and the pouring port 1111 in the vertical direction can be further increased, which is more conducive to improving the fluidity of the pouring liquid and also conducive to the discharge of gas from the exhaust port 1121, thereby improving the pouring uniformity of the power conversion device 10.

[0085] For the convenience of description, the two relatively arranged long sides of the power conversion device 10 are respectively denoted as the first long side and the second long side, and the two relatively arranged short sides of the power conversion device 10 are respectively denoted as the first short side and the second short side. During the tilting process, the power conversion device 10 can be fixed by a fixture. For example, the first short side of the power conversion device 10 can be arranged parallel to the horizontal plane, so that the position of the second short side of the power conversion device 10 relative to the horizontal plane is higher than the first short side. At this time, the long side of the power conversion device 10 forms a first angle α with the horizontal plane. Figure 9 This is the case where the first short side of the power conversion device 10 is parallel to the horizontal plane. For another example, the first long side of the power conversion device 10 can be arranged parallel to the horizontal plane, so that the position of the second long side of the power conversion device 10 relative to the horizontal plane is higher than the first long side. At this time, the short side of the power conversion device 10 forms a first angle α with the horizontal plane. For yet another example, the intersection position of the two long sides and short sides of the power conversion device 10 can be placed on the fixture, so that both the long side and the short side of the power conversion device 10 can form a first angle α relative to the horizontal plane.

[0086] In some embodiments, during the process of injecting glue into the accommodation cavity 130 through the pouring port 1111, the glue can be injected into the accommodation cavity 130 through a one-way valve, and the one-way valve has the function of preventing the glue from flowing back. For example, the one-way valve is arranged at the pouring port 1111. The one-way valve only allows the pouring liquid to enter the accommodation cavity 130 from the outside and prevents the pouring liquid in the accommodation cavity 130 from flowing out of the one-way valve to the outside. In this way, it can effectively prevent the pouring liquid in the accommodation cavity 130 from overflowing from the pouring port 1111, so that the pouring liquid can quickly fill the accommodation cavity 130, thereby improving the pouring efficiency and avoiding the waste of the pouring liquid.

[0087] The technical features of the above-described embodiments can be combined arbitrarily. For the sake of brevity of description, not all possible combinations of the various technical features in the above-described embodiments are described. However, as long as there is no contradiction in the combination of these technical features, it should be considered as falling within the scope described in this specification.

[0088] The above-described embodiments merely represent several implementation manners of the present application. The description thereof is relatively specific and detailed, but it should not be construed as a limitation on the scope of the patent application. It should be noted that for those of ordinary skill in the art, without departing from the concept of the present application, several modifications and improvements can still be made, and these all belong to the protection scope of the present application. Therefore, the protection scope of the patent of the present application shall be subject to the appended claims.

Claims

1. A power conversion device, characterized in that: include: A shell is arranged to form a receiving cavity, a pouring port and an exhaust port are provided on the shell, and both the pouring port and the exhaust port are connected to the receiving cavity; and A circuit board is arranged in the accommodating cavity, the circuit board has a first surface for mounting electronic components, the first surface is arranged toward the pouring port and the exhaust port in a direction perpendicular to the first surface, and the pouring port is closer to the first surface than the exhaust port; The shell includes a first shell and a second shell which together enclose the accommodating cavity, the pouring port and the exhaust port are both arranged on the first shell, and the first shell is an uneven contour structure; the contour structure includes a first area and a second area, the first area is closer to the first surface than the second area, the pouring port is arranged in the first area, and the exhaust port is arranged in the second area.

2. The power conversion device according to claim 1, characterized in that: The pouring port and the exhaust port are spaced apart by ΔH in a direction perpendicular to the first surface.

3. The power conversion device according to claim 1, characterized in that: The first surface has a blank area where no electronic components are installed, and the orthographic projection of the pouring port in a direction perpendicular to the first surface falls on the blank area.

4. The power conversion device according to claim 1, characterized in that: The first surface has a DC area and an AC area, the DC area is used to install DC electronic components, and the AC area is used to install AC electronic components; along the direction perpendicular to the first surface, the orthographic projection of the pouring port falls on the DC area, and the orthographic projection of the exhaust port falls on the AC area.

5. The power conversion device according to claim 1, characterized in that: A connector assembly is also included, the housing has a mounting side for mounting the connector assembly, and the distance between the pouring port and the mounting side is less than a first preset distance.

6. The power conversion device according to claim 1, characterized in that: The shell has a first corner where two sides intersect, and the exhaust port is arranged near the first corner.

7. The power conversion device according to claim 6, characterized in that: The exhaust port is disposed in the second region at a position close to the first corner.

8. The power conversion device according to claim 1, characterized in that: The exhaust port is circular.

9. The power conversion device according to claim 1, characterized in that: The first region includes a second corner with a rounded corner, the pouring gate is arranged near the second corner, and the pouring gate is circular.

10. The power conversion device according to claim 1, characterized in that: The second area includes a third corner, and the exhaust port is arranged close to the third corner.

11. The power conversion device according to claim 1, characterized in that: The centers of the pouring port and the exhaust port maintain a preset distance, and the preset distance ranges from 120 mm to 200 mm.

12. The power conversion device according to claim 1, characterized in that: The circuit board is carried on the second shell.

13. The power conversion device according to claim 12, characterized in that: An annular groove is formed on the second shell, and the annular groove is arranged around the circuit board. The annular groove cooperates with the flange on the first shell to accommodate the sealing material.

14. The power conversion device according to claim 12, characterized in that: The second shell includes a limiting member for supporting the circuit board, the limiting member having a first limiting surface and a second limiting surface connected at an angle, the circuit board having a second surface opposite to the first surface, the first limiting surface abuts against the second surface along a direction perpendicular to the first surface, so that there is a gap between the circuit board and the second shell along the direction perpendicular to the first surface, and the second limiting surface abuts against the circuit board along the direction perpendicular to the first surface.

15. The power conversion device according to claim 14, characterized in that: The limiting member is an edge limiting member, which is arranged at the edge of the second shell, and the second limiting surface of the edge limiting member abuts against the edge of the circuit board to form a flow channel connecting the interval gap between the edge of the circuit board and the second shell.

16. The power conversion device according to claim 14, characterized in that: The limiting member is an intermediate limiting member, which is arranged in the middle of the second shell. The intermediate limiting member includes a supporting member and a column arranged in the middle of the supporting member. The first limiting surface of the intermediate limiting member is the upper surface of the supporting member, and the second limiting surface of the intermediate limiting member is the outer surface of the column. The column passes through the circuit board.

17. The power conversion device according to claim 1, characterized in that: It also includes a sealing member, which is used to seal the pouring port and the exhaust port.

18. The power conversion device according to claim 1, characterized in that: It also includes an indicator light, which includes a light-emitting portion and a sealing portion. The light-emitting portion is arranged on the first surface, and the sealing portion covers the light-emitting portion and is in contact with the first surface.

19. The power conversion device according to claim 18, characterized in that: The indicator light further includes a light guide column, which is connected to the sealing portion and is used to guide the light signal of the light emitting portion to the outer surface of the housing.

20. The power conversion device according to any one of claims 1 to 19, characterized in that: The diameter of the pouring port is smaller than or equal to the diameter of the exhaust port.

21. A method for manufacturing a power conversion device according to any one of claims 1 to 19, characterized in that: The steps include: The power conversion device is set at a first angle with a horizontal plane as a reference plane, and the pouring port is located lower than the exhaust port in the vertical direction; injecting pouring liquid into the accommodating cavity through the pouring port; and The pouring port and the exhaust port are blocked.

22. The manufacturing method according to claim 21, characterized in that: The first angle is 0°.

23. The manufacturing method according to claim 21, characterized in that: The first angle is 15° to 30°.

24. The manufacturing method according to claim 21, characterized in that: The method further comprises injecting casting liquid into the accommodating cavity through a one-way valve.

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