Power supply module and energy storage system

Abstract

The invention provides a power supply module and an energy storage system, the power supply module comprises a shell, a connector, an inductor, a cold plate and a wind-liquid heat exchanger, the connector, the wind-liquid heat exchanger, the cold plate and the inductor are sequentially arranged in the shell along a first direction, the shell comprises a front plate and a rear plate, and the front plate and the rear plate are oppositely arranged along the first direction; the connectors are arranged between the air-liquid heat exchanger and the front plate in the first direction, and each connector comprises a cold plate inlet, a heat exchanger inlet, a cold plate outlet and a heat exchanger outlet; in the second direction, the cold plate inlet and the cold plate outlet are adjacently arranged, and the heat exchanger inlet and the heat exchanger outlet are adjacently arranged; in the third direction, one of the cold plate inlet and the cold plate outlet is arranged adjacent to the heat exchanger inlet, the other one of the cold plate inlet and the cold plate outlet is arranged adjacent to the heat exchanger outlet, and the third direction, the second direction and the first direction are perpendicular to one another. The power supply module is small in size, has a good heat dissipation effect on various heating devices, and can reduce the heat dissipation cost.

Description

[0001] This application claims the priority of the Chinese patent application filed with the State Intellectual Property Office of China on June 7, 2023, with application number 202310673189.X, and the priority of the Chinese patent application with the invention name “Power Module and Energy Storage System”, all contents of which are incorporated by reference in this application. Technical Field

[0002] The present application relates to the technical field of power conversion, and in particular to a power supply module and an energy storage system. Background Art

[0003] With the vigorous development of the new energy industry, the output power of power conversion devices is gradually increasing. Therefore, higher requirements are placed on the heat dissipation capacity of power conversion devices. There are multiple devices in the power conversion device, and different devices have different heating conditions. The existing heat dissipation system cannot take into account the heat dissipation requirements of multiple devices, or when the heat dissipation system can meet the heat dissipation requirements of multiple devices, the energy consumption and cost of the heat dissipation system are high, and the volume of the heat dissipation system is large, which makes it difficult to miniaturize the power conversion device. Summary of the invention

[0004] The present application provides a power module and an energy storage system.

[0005] In a first aspect, an embodiment of the present application provides a power module, which includes a shell and a connector, an inductor, a cold plate and an air-to-liquid heat exchanger. Along a first direction, the connector, the air-to-liquid heat exchanger, the cold plate and the inductor are arranged in sequence inside the shell, the shell includes a front plate and a rear plate, the front plate and the rear plate are arranged relative to each other along the first direction, the connector is arranged between the air-to-liquid heat exchanger and the front plate along the first direction, the connector includes a cold plate inlet, a heat exchanger inlet, a cold plate outlet and a heat exchanger outlet, wherein along a second direction, the cold plate inlet is arranged adjacent to the cold plate outlet, the heat exchanger inlet is arranged adjacent to the heat exchanger outlet, and the second direction is perpendicular to the first direction; along a third direction, one of the cold plate inlet and the cold plate outlet is arranged adjacent to the heat exchanger inlet, the other of the cold plate inlet and the cold plate outlet is arranged adjacent to the heat exchanger outlet, and the third direction is perpendicular to the second direction and the first direction.

[0006] In the power module provided in the present application, on the one hand, the cold plate in the power module is used to dissipate heat for high-heat generating devices, which can meet the heat dissipation requirements of high-heat generating devices and have a good heat dissipation effect on high-heat generating devices. The air-liquid heat exchanger in the power module is used to dissipate heat for medium and low-heat generating devices. The power module in the present application adopts a composite heat dissipation method combining a cold plate and an air-liquid heat exchanger, which not only meets the heat dissipation requirements of various heat generating devices, can have a good heat dissipation effect on the power module, but also can reduce the heat dissipation cost of the power module and reduce the total volume of the cold plate and the air-liquid heat exchanger. The heat dissipation system composed of the cold plate and the air-liquid heat exchanger has a simple structure, fewer parts, and is easy to install in the shell.

[0007] On the other hand, the cold plate and the air-liquid heat exchanger are connected to the same connector and receive and discharge the heat exchange medium through the same connector. The cold plate and the air-liquid heat exchanger are centrally connected to the connector, which reduces the number of connectors and allows the heat dissipation pipeline layout in the power module to be more regular.

[0008] On the other hand, the connector, the air-to-liquid heat exchanger, the cold plate, and the inductor are sequentially arranged inside the housing along the first direction. This arrangement can fully utilize the internal space of the housing and facilitate reducing the size of the power module. The reasonable layout of the components inside the housing is conducive to improving the reliability of the power module.

[0009] In a possible implementation, the shell includes a first side plate and a second side plate, the first side plate and the second side plate are arranged relative to each other along the second direction, the connector, the air-to-liquid heat exchanger, the cold plate, and the inductor are arranged between the first side plate and the second side plate, wherein along the second direction, the distance between the connector and the first side plate is smaller than the distance between the connector and the second side plate, the distance between the connector and the first side plate is smaller than the distance between the air-to-liquid heat exchanger and the first side plate, the distance between the connector and the second side plate is larger than the distance between the air-to-liquid heat exchanger and the second side plate, and at least one of the distance between the cold plate inlet and the cold plate outlet or the distance between the heat exchanger inlet and the heat exchanger outlet is smaller than the distance between the air-to-liquid heat exchanger and the first side plate.

[0010] First, the connector is arranged closer to the first side panel to facilitate the installation of the power module and its application in the energy storage cabinet. Secondly, the distance between the heat exchanger inlet and the heat exchanger outlet is small, and the heat exchanger inlet and the heat exchanger outlet are arranged compactly. The distance between the cold plate inlet and the cold plate outlet is small, and the cold plate inlet and the cold plate outlet are arranged compactly, which facilitates reducing the size of the connector along the second direction. In addition, the connector is located in the corner between the first side panel and the front panel, which improves the utilization rate of the internal space of the shell and reduces the impact on other devices and pipeline arrangements.

[0011] In one possible implementation, the connector includes a first sub-cavity and a second sub-cavity, the first sub-cavity and the second sub-cavity are adjacent to each other and arranged at intervals along the second direction, the first sub-cavity is used to connect the cold plate inlet and the heat exchanger inlet, and the second sub-cavity is used to connect the cold plate outlet and the heat exchanger outlet.

[0012] By setting the first sub-cavity and the second sub-cavity to realize the parallel operation of the cold plate and the air-to-liquid heat exchanger, the heat dissipation efficiency of the power module is improved. The cold plate inlet and the heat exchanger inlet receive the heat exchange medium through the first sub-cavity, and the cold plate outlet and the heat exchanger outlet discharge the heat exchange medium through the second sub-cavity, which not only reduces the number of joints and pipes connecting the connector to the outside world, but also reduces the volume of the connector, which is convenient for miniaturization of the power module.

[0013] In a possible implementation, the connector includes a connecting seat, a first cover plate and a partition plate, and the connecting seat includes a first groove. Along the first direction, the cold plate inlet, the cold plate outlet, the heat exchanger inlet and the heat exchanger outlet respectively pass through the bottom of the first groove. The partition plate is located in the first groove and is used to separate the first groove along the second direction. The outer peripheral surface of the first cover plate is fixedly connected to the groove wall of the first groove, and the first cover plate is fixedly connected to the partition plate on one side facing the bottom of the first groove. The bottom of the first groove and the first cover plate are arranged at intervals along the first direction. A first cavity is formed between the connecting seat and the first cover plate, and the partition plate separates the first cavity into a first sub-cavity and a second sub-cavity.

[0014] In a possible implementation, the connector includes a first sub-cavity, a second sub-cavity, and a third sub-cavity. The first sub-cavity and the third sub-cavity are adjacent to and spaced apart from each other along the third direction. The first sub-cavity or the third sub-cavity is adjacent to and spaced apart from the second sub-cavity along the second direction. The first sub-cavity is used to connect the heat exchanger inlet, the second sub-cavity is used to connect the heat exchanger outlet and the cold plate inlet, and the third sub-cavity is used to connect the cold plate outlet.

[0015] By setting the first sub-cavity, the second sub-cavity and the third sub-cavity to realize the series operation of the cold plate and the air-liquid heat exchanger, the heat dissipation energy consumption of the power module can be reduced. The first sub-cavity and the third sub-cavity are used to receive and discharge the heat exchange medium respectively, and the second sub-cavity is used to realize the connection between the cold plate and the air-liquid heat exchanger, which reduces the number of joints and pipes connected to the outside world by the connector, and can also reduce the volume of the connector, which is convenient for the small size of the power module.

[0016] In addition, since the cold plate is mainly used to dissipate heat for high-heat devices, and the air-liquid heat exchanger is mainly used to dissipate heat for medium- and low-heat devices, the temperature difference before and after the cold plate is large, and the temperature difference before and after the air-liquid heat exchanger is small. In this application, by controlling the heat exchange medium to flow through the air-liquid heat exchanger and the cold plate in sequence, the heat dissipation of the heat-generating devices by the two heat dissipation methods can be taken into account, which is conducive to better heat dissipation of various heat-generating devices.

[0017] In a possible implementation, the connector further includes a second cavity and a drainage hole. The second cavity is adjacent to the first sub-cavity or the second sub-cavity and arranged at intervals along the first direction, and the drainage hole is connected to the second cavity. A second cavity is provided on the side of the connection seat away from the first cavity. If the connector leaks, the leaked heat exchange medium will be collected in the second cavity and discharged to the outside of the second cavity through the drainage hole. The provision of the second cavity performs secondary sealing on the connector to reduce the risk of leakage damaging the components in the shell. The heat exchange medium discharged from the drainage hole can be discharged to the outside of the shell through a pipeline.

[0018] In a possible implementation, the connector includes a first cover plate, a connecting seat, a second cover plate and a partition plate, the first cover plate and the second cover plate are respectively arranged on both sides of the connecting seat along the first direction, and are respectively surrounded by the two sides of the connecting seat to form a first cavity and a second cavity, the partition plate is located in the first cavity and is used to separate the first cavity into the first sub-cavity and the second sub-cavity, the connecting seat includes the cold plate inlet, the cold plate outlet, the heat exchanger inlet and the heat exchanger outlet, and the cold plate inlet, the cold plate outlet, the heat exchanger inlet and the heat exchanger outlet pass through the connecting seat along the first direction; wherein, the first cover plate includes a liquid inlet hole and The liquid outlet hole, the liquid inlet hole and the liquid outlet hole respectively penetrate the first cover plate along the first direction, the liquid inlet hole is used to connect at least one of the cold plate inlet or the heat exchanger inlet, and the liquid outlet hole is used to connect at least one of the cold plate outlet or the heat exchanger outlet; the second cover plate includes a first opening, a second opening, a third opening and a fourth opening, the first opening, the second opening, the third opening and the fourth opening respectively penetrate the second cover plate along the first direction, and along the first direction, the first opening, the second opening, the third opening and the fourth opening are respectively arranged relative to the cold plate inlet, the cold plate outlet, the heat exchanger inlet and the heat exchanger outlet.

[0019] Wherein, the power module also includes a cold plate liquid inlet pipe, a cold plate liquid outlet pipe, a heat exchanger liquid inlet pipe and a heat exchanger liquid outlet pipe. One end of the cold plate liquid inlet pipe, the cold plate liquid outlet pipe, the heat exchanger liquid inlet pipe and the heat exchanger liquid outlet pipe are respectively connected to the cold plate inlet, the heat exchanger inlet, the cold plate outlet and the heat exchanger outlet. The other end of the cold plate liquid inlet pipe extends into the second cavity through the first opening and is fixed to the inner wall of the cold plate inlet. The other end of the cold plate liquid outlet pipe extends into the second cavity through the second opening and is fixed to the inner wall of the cold plate outlet. The other end of the heat exchanger liquid inlet pipe extends into the second cavity through the third opening and is fixed to the inner wall of the heat exchanger inlet. The other end of the heat exchanger liquid outlet pipe extends into the second cavity through the fourth opening and is fixed to the inner wall of the heat exchanger outlet.

[0020] Along the first direction, the first opening is arranged opposite to the cold plate inlet, and the distance between the first opening and the cold plate inlet is short. When the cold plate liquid inlet pipe is connected to the cold plate inlet, the pipe is short and does not need to be bent, which not only saves costs, but also reduces the risk of bending and breaking of the cold plate liquid inlet pipe, and improves the reliability of the connection between the cold plate liquid inlet pipe and the cold plate inlet. Similarly, along the first direction, the second opening is arranged opposite to the cold plate outlet, the third opening is arranged opposite to the heat exchanger inlet, and the fourth opening is arranged opposite to the heat exchanger outlet, which can also save costs and improve the reliability of the connection between the cold plate liquid outlet pipe, the heat exchanger liquid inlet pipe, and the heat exchanger liquid outlet pipe and the connecting seat.

[0021] In a possible implementation, the power module includes a liquid inlet connector and a liquid outlet connector, the liquid inlet connector and the liquid outlet connector are fixed to the first cover plate and are respectively connected to the liquid inlet hole and the liquid outlet hole, the front plate includes a through hole, the through hole passes through the front plate along the first direction, wherein, along the first direction, the projection of the through hole covers the projection of the liquid inlet connector and the projection of the liquid outlet connector, and the projection of the first cover plate covers the projection of the through hole; along the third direction, the length of the liquid inlet connector and the liquid outlet connector is greater than the distance between the first cover plate and the front plate.

[0022] Among them, along the first direction, the liquid inlet connector and the liquid outlet connector extend from the inside of the shell through the through hole to the outside of the shell. The power module can be connected to the external cooling component outside the shell. On the one hand, the operating space outside the shell is larger, which is convenient for connecting the two liquid cooling pipes of the cooling component to the liquid inlet connector and the liquid outlet connector. On the other hand, the connection between the power module and the liquid cooling pipe is set on the outside of the shell. If the heat exchange medium leaks due to loose connection between the connector and the pipe during long-term operation of the power module, the leaked heat exchange medium is located outside the shell to avoid damage to the components inside the shell.

[0023] In addition, the projection of the first cover plate along the first direction covers the projection of the through hole, and the area of ​​the first cover plate is larger than the area of ​​the through hole. The area of ​​the through hole is small, which is convenient for ensuring the sealing of the housing.

[0024] In a possible implementation, when the cold plate and the air-liquid heat exchanger are connected in parallel, the liquid inlet joint and the liquid outlet joint are adjacent and spaced apart along the second direction. When the cold plate and the air-liquid heat exchanger are connected in series, the liquid inlet joint and the liquid outlet joint are adjacent and spaced apart along the third direction.

[0025] In a possible implementation, the power module also includes a circuit board and a plurality of power tubes, the shell includes a top plate and a bottom plate, the top plate and the bottom plate are arranged relative to each other along the third direction, the circuit board is arranged between the top plate and the bottom plate at intervals, the plurality of power tubes and the cold plate are arranged on a side of the circuit board facing the bottom plate, and the cold plate is in contact with at least one of the power tubes along the first direction.

[0026] In the power module provided by the present application, the power tube is a high heat generating device, and the cold plate is used to dissipate heat for the power tube to improve the cooling efficiency of the power tube. The first direction is a direction parallel to the circuit board, and the cold plate and the power tube are fitted along the first direction, which can reduce the size of the power module along the third direction.

[0027] In a possible implementation, the power module includes a plurality of connected cold plates, the plurality of cold plates are arranged at intervals along the first direction, the plurality of power tubes include a plurality of columns of power tubes arranged at intervals along the first direction, each column of power tubes includes a plurality of power tubes arranged in sequence along the second direction, and the plurality of power tubes in each column of power tubes are in contact with the same cold plate.

[0028] In the power module provided by the present application, a cold plate can be used to cool at least one column of power tubes, thereby improving the utilization rate of the cold plate. In addition, in the present application, by providing multiple cold plates to cool multiple columns of power tubes, the multiple columns of power tubes in the power module can be better cooled, thereby improving the reliability of the power module.

[0029] In a possible implementation, at least one of the cold plates is arranged between two adjacent columns of the power tubes, and the at least one cold plate includes two sides along the first direction, one side of the at least one cold plate is respectively in contact with a plurality of power tubes in one column of the power tubes, and the other side of the at least one cold plate is respectively in contact with a plurality of power tubes in another column of the power tubes. Both sides of the cold plate along the first direction are used to cool the power tubes, and one cold plate can cool two columns of power tubes, thereby improving the utilization rate of the cold plate.

[0030] In a possible implementation, along the third direction, the distance between the air-liquid heat exchanger and the top plate is greater than the distance between the cold plate and the top plate, the distance between at least one of the cold plate inlet or the cold plate outlet and the top plate is smaller than the distance between the air-liquid heat exchanger and the top plate, and the distance between at least one of the heat exchanger inlet or the heat exchanger outlet and the bottom plate is smaller than the distance between the cold plate and the bottom plate. The air-liquid heat exchanger and the cold plate are staggered along the third direction, and the cold plate inlet, cold plate outlet, heat exchanger inlet, and heat exchanger outlet are relatively concentrated, which is convenient for reducing the size of the connector.

[0031] In a possible implementation, the air-to-liquid heat exchanger includes a plurality of interconnected heat exchange plates. When the air-to-liquid heat exchanger is located between the connector and the circuit board along the first direction, and the air-to-liquid heat exchanger is arranged between the top plate and the bottom plate at intervals along the third direction, the plurality of heat exchange plates are arranged at intervals along the first direction.

[0032] Along the third direction, the projection of the air-liquid heat exchanger does not overlap with the projection of the circuit board. The air-liquid heat exchanger and the circuit board are staggered, and the air-liquid heat exchanger will not hinder the components mounted on the circuit board. The space utilization rate of the circuit board is high, which is conducive to improving the performance of the power module.

[0033] Generally, in order to carry more onboard components, the volume of the circuit board is relatively large. And because the inductor is located on the side of the circuit board close to the rear plate along the first direction X, the distance between the air-liquid heat exchanger and the front plate is relatively small, and generally no components are placed between the air-liquid heat exchanger and the front plate. At this time, the multiple heat exchange plates of the air-liquid heat exchanger are arranged at intervals along the first direction, and the air-liquid heat exchanger is ventilated along the third direction. The air in the shell passes through the gap between two adjacent heat exchange plates along the third direction and exchanges heat with the heat exchange plates, thereby cooling the air in the shell. Arranging multiple heat exchange plates along the first direction is more conducive to heat dissipation of the power module.

[0034] In a possible implementation, the air-to-liquid heat exchanger includes a plurality of interconnected heat exchange plates. When the projection of the air-to-liquid heat exchanger along the third direction coincides with the projection of the circuit board along the third direction, and the projection of the air-to-liquid heat exchanger along the third direction is staggered with the projection of the cold plate along the third direction, the plurality of heat exchange plates are arranged at intervals along the third direction.

[0035] The air-liquid heat exchanger is overlapped with the circuit board along the third direction, and on-board components are arranged on both sides of the air-liquid heat exchanger in the front and rear directions along the first direction. At this time, multiple heat exchange plates are arranged in the third direction, and the air-liquid heat exchanger is ventilated in the first direction, which can take into account the heat dissipation of the on-board components in front and behind the circuit board in the first direction.

[0036] In a possible implementation, the power module includes a plurality of the inductors and a plurality of fans, the plurality of inductors are arranged at intervals along the second direction, and the plurality of fans are arranged at intervals along the second direction; along the first direction, the fan is located between the inductor and the circuit board. The fan plays a turbulent role, and the fan can provide power for the air to flow to the liquid heat exchanger to improve the heat dissipation effect of the air-liquid heat exchanger. The fan is located between the inductor and the circuit board, which not only does not hinder the installation of various devices, but also can achieve a better heat dissipation effect.

[0037] In a possible implementation, the power module also includes a first baffle, a second baffle and a third baffle, the first baffle and the second baffle are respectively located on both sides of the circuit board along the second direction, and the third baffle is located between the top plate and the fan along the third direction; the first baffle is respectively connected to the circuit board and the first side plate on both sides along the second direction, and the second baffle is respectively connected to the circuit board and the second side plate on both sides along the second direction; when the third baffle is respectively connected to the circuit board and the inductor on both sides along the first direction, the air-liquid heat exchanger is located between the connector and the circuit board along the first direction or the projection of the air-liquid heat exchanger along the third direction coincides with the projection of the circuit board along the third direction.

[0038] The first baffle, the second baffle and the third baffle can guide the air to circulate through the bottom and top of the circuit board. The third baffle is used to cover the gap between the inductor and the circuit board to prevent the air from flowing through the gap between the circuit board and the bottom plate along the first direction and not passing through the inductor after being blocked by the inductor, resulting in poor heat dissipation effect of the inductor. After the third baffle is set, the third baffle blocks the air from flowing from the gap between the inductor and the circuit board to the top plate, which is conducive to improving the heat dissipation effect of the inductor.

[0039] The first baffle and the second baffle are used to cover the gaps between the circuit board and the first side plate and the second side plate, respectively, to prevent the air flowing in the gap between the circuit board and the top plate along the first direction from directly passing through the gaps between the circuit board and the first side plate and the gaps between the circuit board and the second side plate to flow to the gap between the circuit board and the bottom plate, resulting in poor heat dissipation of the front-end heating device. In this application, by setting the first baffle and the second baffle, the air flowing above the circuit board needs to flow to the bottom of the circuit board through the gap between the circuit board and the front plate, and the air flows within the entire range of the shell, which is more conducive to the heat dissipation of various heating devices by the air-to-liquid heat exchanger.

[0040] In a possible implementation, the power module also includes a first baffle, a second baffle and a third baffle, the first baffle and the second baffle are respectively located on both sides of the circuit board along the second direction, and the third baffle is located between the top plate and the fan along the third direction; the first baffle is respectively connected to the circuit board and the first side plate on both sides along the second direction, and the second baffle is respectively connected to the circuit board and the second side plate on both sides along the second direction, when the third baffle is respectively connected to the circuit board and the rear plate on both sides along the first direction, the projection of the air-liquid heat exchanger along the third direction coincides with the projection of the circuit board along the third direction.

[0041] When the projection of the air-to-liquid heat exchanger along the third direction coincides with the projection of the circuit board along the third direction, the arrangement of the first baffle, the second baffle and the third baffle can guide the air to flow in the gap between the circuit board and the bottom plate along the first direction from the front plate toward the rear plate, and then flow in the gap between the circuit board and the first side plate and the gap between the circuit board and the second side plate along the first direction from the rear plate toward the front plate.

[0042] The third baffle is used to cover the gap between the back plate and the circuit board. The third baffle limits the air flow under the circuit board. At this time, the air first passes through the inductor along the first direction and flows to the back plate, and then flows toward the first side plate and the second side plate, which is beneficial to improve the heat dissipation effect of the inductor and ensure the heat dissipation effect of other heating components.

[0043] The first baffle and the second baffle are used to cover the gap between the circuit board and the first side plate and the second side plate, respectively, to limit the air flow under the circuit board, and circulate through the circuit board and the two sides of the circuit board along the second direction, which is conducive to the heat dissipation of various heating devices by the air-to-liquid heat exchanger. In this heat dissipation mode, since the air mainly flows along the first direction, the ventilation direction of the air-to-liquid heat exchanger is set in the first direction, that is, multiple heat exchange plates are arranged at intervals along the third direction, which is conducive to the air-to-liquid heat exchanger to achieve a better heat dissipation effect.

[0044] In a second aspect, an embodiment of the present application provides an energy storage system, which includes an energy storage cabinet, a battery pack and the power module as described above, the battery pack is connected to the power module and supplies power to a load through the power module, the energy storage cabinet includes a cabinet body, a cabinet door and a cooling assembly, the cabinet door is used to close the cabinet body, the power module and the battery pack are stacked and placed inside the cabinet body, and the cooling assembly is connected to the cold plate inlet, the heat exchanger inlet, the cold plate outlet and the heat exchanger outlet of the connector through two liquid cooling pipes. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the embodiments of the present application will be described below.

[0046] Figure 1 A schematic diagram of an energy storage system provided in one embodiment of the present application;

[0047] Figure 2 A schematic diagram of an energy storage cabinet provided in one embodiment of the present application;

[0048] Figure 3 A three-dimensional diagram of a power module provided in one embodiment of the present application;

[0049] Figure 4 A schematic diagram of a power module provided in one embodiment of the present application;

[0050] Figure 5 An exploded view of a connector provided in one embodiment of the present application;

[0051] Figure 6 An exploded view of a connector provided in one embodiment of the present application;

[0052] Figure 7 A schematic diagram of a first cover plate provided in one embodiment of the present application;

[0053] Figure 8 An exploded view of a connector provided in one embodiment of the present application;

[0054] Fig. 9 An exploded view of a connector provided in one embodiment of the present application;

[0055] Fig.10 A three-dimensional diagram of a circuit board, a cold plate and an air-to-liquid heat exchanger provided in one embodiment of the present application;

[0056] Fig.11 A front view of a circuit board, a cold plate and an air-to-liquid heat exchanger provided in one embodiment of the present application;

[0057] Fig.12 A rear view of a circuit board, a cold plate and an air-to-liquid heat exchanger provided in one embodiment of the present application;

[0058] Fig.13 A top view of a circuit board, a cold plate, and an air-to-liquid heat exchanger provided in one embodiment of the present application;

[0059] Fig.14 A schematic diagram of a power module provided in one embodiment of the present application;

[0060] Fig.15 A schematic diagram of a power module provided in one embodiment of the present application;

[0061] Fig.16 A front view of a circuit board, a cold plate and an air-to-liquid heat exchanger provided in one embodiment of the present application;

[0062] Fig.17 A top view of a circuit board, a cold plate, and an air-to-liquid heat exchanger provided in one embodiment of the present application;

[0063] Fig.18 A schematic diagram of a power module provided in one embodiment of the present application;

[0064] Fig.19 A schematic diagram of a power module provided in one embodiment of the present application;

[0065] Fig. 20 A schematic diagram of a power module provided in accordance with an embodiment of the present application. DETAILED DESCRIPTION

[0066] The technical solutions in the embodiments of the present application will be described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all of the embodiments.

[0067] In this document, the terms "first", "second", etc. are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of this application, unless otherwise specified, "plurality" means two or more.

[0068] In addition, in this article, directional terms such as "upper" and "lower" are defined relative to the orientation of the structure schematically placed in the drawings. It should be understood that these directional terms are relative concepts. They are used for relative description and clarification, and they can change accordingly according to the change of the orientation of the structure.

[0069] For ease of understanding, the English abbreviations and related technical terms involved in the embodiments of the present application are explained and described below.

[0070] DC: Direct Current. DC-DC means direct current to direct current, that is, input direct current and output direct current.

[0071] AC: Alternating Current. AC-DC means alternating current to direct current, DC-AC means direct current to alternating current, and AC-AC means alternating current to alternating current.

[0072] IGBT: It is the abbreviation of Insulated Gate Bipolar Transistor, which refers to insulated gate bipolar transistor.

[0073] MOSFET: The abbreviation of Metal-Oxide-Semiconductor Field-Effect Transistor, refers to metal-oxide semiconductor field effect transistor, also known as MOS tube.

[0074] Figure 1 Schematic diagram of an energy storage system provided in one embodiment of the present application. The energy storage system includes an energy storage cabinet 1, a battery pack 11 and a power module 10, wherein the battery pack 11 is connected to the power module 10 and supplies power to the load 2 through the power module 10.

[0075] Among them, the energy storage system may include one or more battery packs 11. The battery pack 11 is used to store electrical energy and supply power to the load 2. The power module 10 is a module that can realize the power conversion function. The power module 10 can realize at least one function of DC-DC conversion, AC-AC conversion, AC-DC conversion, and DC-AC conversion. Exemplarily, the power module 10 can be a converter or other power conversion device. Among them, the converter includes a rectifier (AC-DC), an inverter (DC-AC), an AC converter (AC-AC), and a DC converter (DC-DC). The power module 10 is used to convert the electrical energy output by the battery pack 11 into direct current or alternating current required by the load 2.

[0076] Load 2 can be any electrical equipment that uses the energy storage system as a power source, such as transportation vehicles, communication base stations, household and industrial energy storage equipment. Exemplarily, the power module 10 can realize AC-DC conversion. The direct current output by the battery pack 11 is converted into alternating current by the power module 10 and then used for electricity in daily life and production. Or the power module 10 can realize AC-AC conversion and AC-DC conversion. The direct current output by the battery pack 11 is converted into AC-AC and AC-DC in turn and then used for electricity in daily life and production.

[0077] See also Figure 2 , Figure 2 Schematic diagram of an energy storage cabinet 1 provided in one embodiment of the present application. In one embodiment, the energy storage cabinet 1 further includes a cabinet body 12, a cabinet door 13 and a cooling assembly 14. The cabinet door 13 is used to close the cabinet body 12. The power module 10 and the battery pack 11 are stacked and placed inside the cabinet body 12. The front plate 110 of the housing 100 of the power module 10 faces the cabinet door 13. The cooling assembly 14 is connected to the cold plate inlet 211, the heat exchanger inlet 213, the cold plate outlet 212 and the heat exchanger outlet 214 of the connector 200 through two liquid cooling pipes 15 (combined with reference Figure 5 and Figure 6 ).

[0078] The cabinet door 13 can be closed or opened relative to the cabinet body 12. Generally, the cabinet body 12 includes a battery compartment and a power compartment. The battery compartment is used to accommodate the battery pack 11, and the power compartment is used to accommodate the power module 10. In one embodiment, the power compartment also accommodates a distribution module for power distribution. In one embodiment, the battery compartment and the power compartment are arranged side by side along the height direction of the energy storage cabinet 1.

[0079] The cooling assembly 14 is used to cool the heat exchange medium discharged from the cold plate outlet 212 and the heat exchanger outlet 214 of the connector 200 and transport the cooled heat exchange medium to the power module 10 through the cold plate inlet 211 and the heat exchanger inlet 213. Exemplarily, the two liquid cooling pipes 15 are respectively a liquid cooling pipe 15a and a liquid cooling pipe 15b, wherein the liquid cooling pipe 15a is used to connect the cooling assembly 14 with the cold plate outlet 212 and the heat exchanger outlet 214, and the heat exchange medium discharged from the cold plate outlet 212 and the heat exchanger outlet 214 is input to the cooling assembly 14 through the liquid cooling pipe 15a. The liquid cooling pipe 15b is used to connect the cooling assembly 14 with the cold plate inlet 211 and the heat exchanger inlet 213, and the cooling assembly 14 transports the cooled heat exchange medium to the cold plate inlet 211 and the heat exchanger inlet 213 through the liquid cooling pipe 15b.

[0080] In one embodiment, the cooling assembly 14 is fixed to a side of the cabinet door 13 facing the power module 10. That is, the cooling assembly 14 is fixed to the inner side of the cabinet door 13, and the inner space of the energy storage cabinet 1 can be fully utilized.

[0081] In one embodiment, the cabinet door 13 is rotatably connected to the cabinet body 12 via a rotating member. The cabinet door 13 can be easily closed and opened by providing the rotating member.

[0082] In one embodiment, the connector 200 is disposed near the rotating member (eg Figure 2 The liquid cooling pipe 15 is connected to the connector 200 near the connection between the cabinet door 13 and the cabinet body 12, and the liquid cooling pipe 15 does not hinder the closing and opening of the cabinet door 13, making the closing and opening of the cabinet door 13 more convenient.

[0083] In one embodiment, the power module 10 can also be connected to an external power source 3 (such as Figure 1 As shown in FIG. 1 , the power module 10 receives power from the external power supply 3 and converts the received power to charge the battery pack. The external power supply 3 can be a mains power supply, a generator, solar energy, wind energy, a battery, etc.

[0084] In one embodiment, the energy storage cabinet 1 includes two power modules 10, which are respectively a power module 10a and a power module 10b (as shown in FIG. Figure 1As shown). Among them, the power module 10a is a power storage converter (Power Conversion System, PCS), and the energy storage converter is a DC-AC bidirectional converter, that is, the energy storage converter has AC-DC conversion and DC-AC conversion functions. The power module 10b is a module that can realize DC-DC conversion. Exemplarily, the external power supply 3 is a power grid, and the power module 10a connects the power grid and the battery pack 11. The power module 10a converts the AC power provided by the power grid into DC power and charges the battery pack 11. The electric energy output by the battery pack 11 supplies power to the load 2 through the power module 10a or the power module 10b. In one embodiment, the power module 10a is connected to the power module 10b, and the electric energy output by the battery pack 11 is processed by the power module 10b and the power module 10a in turn and is used to power the load 2.

[0085] In one embodiment, the battery pack 11 can be charged when the electricity price of the city electricity is low, and can supply power to the load 2 when the electricity price of the city electricity is high, so as to reduce the consumption of electricity. In one embodiment, during the off-peak period of electricity consumption, the excess electric energy in the power grid can be stored in the battery pack 11 through the power module 10. During the peak period of electricity consumption, the electric energy of the battery pack 11 is fed back into the power grid through the power module 10.

[0086] In one embodiment, the external power source 3 is a photovoltaic panel (such as Figure 1 As shown). The energy storage cabinet 1 is connected to the photovoltaic panel, which converts solar energy into electrical energy, and charges the battery pack 11 after power conversion through the power module 10. Among them, the photovoltaic panel can be connected to the power grid to connect the generated electricity to the grid. The photovoltaic panel can also be directly connected to the electrical equipment to directly power the electrical equipment with the generated electricity. In one embodiment, when the electrical energy output by the photovoltaic panel exceeds the demand of the power grid or the demand of the electrical equipment for electrical energy, the energy storage cabinet 1 can store the excess electrical energy generated by the photovoltaic panel in the battery pack 11 through the power module 10. When the electrical energy output by the photovoltaic panel is less than the demand of the power grid or the demand of the electrical equipment for electrical energy, the battery pack 11 outputs the stored electrical energy to the power grid through the power module 10.

[0087] In one embodiment, the power module 10 can also be applied to other energy storage systems other than the energy storage system described above. Exemplarily, the power module 10 can be applied to a vehicle-mounted energy storage system. The vehicle-mounted energy storage system includes a vehicle-mounted battery pack 11 and a power module 10. The power module 10 can realize AC-AC conversion. The DC power output by the vehicle-mounted battery pack 11 is converted by the power module 10 to supply power to the corresponding vehicle-mounted load 2. Among them, the vehicle-mounted load 2 includes at least one of a compressor, a battery heating module, a seat heating module, a power system, a dashboard, a control display screen, a headlight, and a USB interface.

[0088] The power module 10 can also be applied to other scenarios where power conversion is performed. For example, the power module 10 can be applied to a charging pile. The power module 10 is a charging module in the charging pile. The charging pile receives 220V AC power from the city or 380V AC power for industrial use. The power module 10 converts 220V AC power or 380V AC power into DC power and then powers energy storage devices in electronic equipment such as vehicles.

[0089] The power module 10 generates heat when working. In order to ensure the stable operation of the power module 10, it is usually necessary to dissipate heat from the power module. However, a variety of devices are provided in the power module 10, and the heating conditions of different devices are different. Exemplarily, the power module 10 includes devices such as power tubes, inductors and capacitors. Generally, the heat flux density of the power tube is the largest, the heat flux density of the inductor is second, and the heat flux density of the capacitor is the smallest. The existing heat dissipation system cannot take into account the heat dissipation requirements of multiple devices, or when the heat dissipation system can meet the heat dissipation requirements of multiple devices, the energy consumption and cost of the heat dissipation system are large, and the volume of the heat dissipation system is large, which makes it difficult to miniaturize the power module 10.

[0090] The power module 10 provided in the present application can not only meet the heat dissipation requirements of different devices, but also save costs.

[0091] The power module 10 in the present application is described in detail below.

[0092] See also Figure 3 , Figure 4 , Figure 5 and Figure 6 . Figure 3 A three-dimensional diagram of a power module 10 provided in accordance with an embodiment of the present application. Figure 4 A schematic diagram of a power module 10 provided in accordance with an embodiment of the present application. Figure 5 and Figure 6 All of them are exploded views of the connector 200 provided in one embodiment of the present application.

[0093] The present application provides a power module 10, which includes a housing 100, a connector 200, an inductor 500, a cold plate 300, and an air-to-liquid heat exchanger 400 (such as Figure 3 and Figure 4 ). Along the first direction X, the connector 200, the air-liquid heat exchanger 400, the cold plate 300, and the inductor 500 are sequentially arranged inside the housing 100. The housing 100 includes a front plate 110 and a rear plate 120, and the front plate 110 and the rear plate 120 are arranged opposite to each other along the first direction X. Along the first direction X, the connector 200 is arranged between the air-liquid heat exchanger 400 and the front plate 110. The connector 200 includes a cold plate inlet 211, a heat exchanger inlet 213, a cold plate outlet 212, and a heat exchanger outlet 214 (as shown in FIG. Figure 5 and Figure 6). In the second direction Y, the cold plate inlet 211 and the cold plate outlet 212 are arranged adjacent to each other, and the heat exchanger inlet 213 and the heat exchanger outlet 214 are arranged adjacent to each other, and the second direction Y is perpendicular to the first direction X. In the third direction Z, one of the cold plate inlet 211 and the cold plate outlet 212 is arranged adjacent to the heat exchanger inlet 213, and the other of the cold plate inlet 211 and the cold plate outlet 212 is arranged adjacent to the heat exchanger outlet 214, and the third direction Z is perpendicular to the second direction Y and the first direction X.

[0094] The housing 100 is used to form a closed space to accommodate components such as the connector 200, the inductor 500, the cold plate 300, and the air-to-liquid heat exchanger 400. The housing 100 isolates the components inside the housing 100 from the external environment, thereby preventing external corrosive substances, dust, and water vapor from long-term contact with the inductor 500 and other components, which may lead to reduced long-term working reliability of the power module 10, increased failure rate, and shortened component life. By setting the housing 100, the reliability of the power module 10 can be improved.

[0095] The inductor 500 is one of the components used in the power module 10 to achieve power conversion. The inductor 500 is located between the rear plate 120 and the cold plate 300 along the first direction X (eg Figure 4 Generally, the inductor 500 is relatively large in size, and the inductor 500 is disposed at one end of the housing 100 along the first direction X close to the rear plate 120 to avoid obstructing the arrangement of other components in the housing 100 and facilitate miniaturization of the power module 100.

[0096] The cold plate 300 is used to cool the heat generating components in the power module 10, especially the heat generating components with high heat generation. Figure 4 As shown). A heat exchange medium flows in the cold plate 300. The heat exchange medium in the cold plate 300 is attached to the heat generating device and exchanges heat with the heat generating device to cool the heat generating device. In one embodiment, the cold plate 300 can also cool the heat generating device by cooling the air in the housing 100 and then cooling the heat generating device through the air in the housing 100.

[0097] The air-to-liquid heat exchanger 400 is used to cool the heating device in the power module 10. A heat exchange medium circulates in the air-to-liquid heat exchanger 400. The heat exchange medium in the air-to-liquid heat exchanger 400 can perform heat exchange with the air in the housing 100 to cool the air in the housing 100, and the air with a lower temperature can cool the heating device when it flows through the heating device. The air with a lower temperature absorbs the heat of the heating device and its temperature rises. The air with a higher temperature can be cooled again when it flows through the air-to-liquid heat exchanger 400. In one embodiment, the power module 10 also includes heating devices such as capacitors, relays, transformers, lightning arresters, and Hall. The air-to-liquid heat exchanger 400 can be used to cool heating devices such as the inductor 500, capacitors, relays, transformers, lightning arresters, and Hall.

[0098] The cold plate 300 and the air-to-liquid heat exchanger 400 are both connected to the connector 200 (eg Figure 4 ). The connector 200 is located in the housing 100 and is located at one end of the housing 100 near the front plate 110 along the first direction X. In one embodiment, the connector 200 is fixed to the front plate 110. Generally, a gap is provided between the air-liquid heat exchanger 400 and the front plate 110 to facilitate the installation of the air-liquid heat exchanger 400 and to prevent the air-liquid heat exchanger 400 from contacting the front plate 110 and damaging the air-liquid heat exchanger 400. At this time, the connector 200 is arranged in the gap between the air-liquid heat exchanger 400 and the front plate 110, so that the internal space of the housing 100 can be fully utilized.

[0099] The cold plate inlet 211 in the connector 200 is used to communicate with the inlet of the cold plate 300 and to deliver the heat exchange medium to the cold plate 300. The cold plate outlet 212 is used to communicate with the outlet of the cold plate 300 and to receive the heat exchange medium discharged from the cold plate 300. The heat exchanger inlet 213 is used to communicate with the inlet of the air-to-liquid heat exchanger 400 and to deliver the heat exchange medium to the air-to-liquid heat exchanger 400. The heat exchanger outlet 214 is used to communicate with the outlet of the air-to-liquid heat exchanger 400 and to receive the heat exchange medium discharged from the air-to-liquid heat exchanger 400.

[0100] The arrangement direction of the cold plate inlet 211 and the cold plate outlet 212 is parallel to the arrangement direction of the heat exchanger inlet 213 and the heat exchanger outlet 214 (eg Figure 5 and Figure 6 As shown). The cold plate inlet 211 and the heat exchanger inlet 213 are arranged along the third direction Z, and the cold plate outlet 212 and the heat exchanger outlet 214 are arranged along the third direction Z, or the cold plate inlet 211 and the heat exchanger outlet 214 are arranged along the third direction Z, and the cold plate outlet 212 and the heat exchanger inlet 213 are arranged along the third direction Z. The cold plate inlet 211, the heat exchanger inlet 213, the cold plate outlet 212 and the heat exchanger outlet 214 in the connector 200 are arranged relatively regularly. The regular arrangement of various inlets and outlets on the connector 200 is conducive to reducing the size of the connector 200.

[0101] In one embodiment, the first direction X is the length direction of the power module 10 , the second direction Y is the width direction of the power module 10 , and the third direction Z is the height direction of the power module 10 .

[0102] The power module 10 provided in the present application, on the one hand, is provided with a cold plate 300 and an air-to-liquid heat exchanger 400 in the power module 10, which can achieve a good heat dissipation effect on the power module 10. The cold plate 300 has a strong heat dissipation capability for the heat generating device. The cold plate 300 is used to dissipate heat for the high heat generating device, which can meet the heat dissipation requirements of the high heat generating device and achieve a good heat dissipation effect for the high heat generating device. The air-to-liquid heat exchanger 400 is used to dissipate heat for various heat generating devices in the housing 100.

[0103] It is understandable that if the power module 10 only includes the air-to-liquid heat exchanger 400 for heat dissipation, the air-to-liquid heat exchanger 400 needs a larger volume to meet the heat dissipation requirements of various heat-generating components in the housing 100. In the present application, since the high-heat-generating components are cooled by the cold plate 300, the heat generation of other heat-generating components in the housing 100 is relatively low. At this time, the air-to-liquid heat exchanger 400 has a smaller volume to achieve a better heat dissipation effect for other heat-generating components.

[0104] It is understandable that if the power module 10 only includes a cold plate 300 for heat dissipation, each heat generating device needs to be provided with a cold plate 300, and the number of cold plates 300 is large, which increases the cost of the power module 10 and the complexity of the heat dissipation system formed by the cold plates 300. In the present application, the cold plate 300 is used to cool high heat generating devices, and other heat generating devices can be cooled by the air-to-liquid heat exchanger 400, which reduces the heat dissipation cost of the power module 10. The heat dissipation system formed by the cold plate 300 and the air-to-liquid heat exchanger 400 has a simple structure, fewer parts, and is easy to install in the housing 100.

[0105] The power module 10 provided in the present application dissipates heat from the power module 10 through a composite heat dissipation system of a cold plate 300 combined with an air-to-liquid heat exchanger 400, which can not only achieve a good heat dissipation effect on various heat-generating components in the shell 100, but also reduce the heat dissipation cost of the power module 10, reduce the complexity of the heat dissipation system in the power module 10, and reduce the size of the power module 10.

[0106] On the other hand, the cold plate 300 and the air-to-liquid heat exchanger 400 are connected to the same connector 200 and receive and discharge the heat exchange medium through the same connector 200. The cold plate 300 and the air-to-liquid heat exchanger 400 are centrally connected to the connector 200, which reduces the number of connectors 200 and allows the heat dissipation pipeline layout in the power module 10 to be more regular.

[0107] On the other hand, the connector 200, the air-to-liquid heat exchanger 400, the cold plate 300, and the inductor 500 are sequentially arranged inside the housing 100 along the first direction X. This arrangement can fully utilize the internal space of the housing 100 and facilitate reducing the volume of the power module 10. The reasonable layout of the components inside the housing 100 is conducive to improving the reliability of the power module 10.

[0108] In a possible implementation, the housing 100 includes a first side plate 130 and a second side plate 140, the first side plate 130 and the second side plate 140 are arranged relative to each other along the second direction Y, and the connector 200, the air-to-liquid heat exchanger 400, the cold plate 300, and the inductor 500 are arranged between the first side plate 130 and the second side plate 140. In the second direction Y, the distance between the connector 200 and the first side plate 130 is smaller than the distance between the connector 200 and the second side plate 140. In the second direction Y, the connector 200 is closer to the first side plate 130 than the second side plate 140.

[0109] In one embodiment, the power module 10 is installed in the energy storage cabinet 1 (combined with Figure 2 and Figure 4 ), compared with the second side plate 140, the first side plate 130 is closer to the rotating member between the cabinet door 13 and the cabinet body 12. The connector 200 is arranged closer to the first side plate 130 so that the connector 200 is connected to the cooling assembly 14.

[0110] In a possible implementation, along the second direction Y, the distance between the connector 200 and the first side plate 130 is smaller than the distance between the air-to-liquid heat exchanger 400 and the first side plate 130 (eg, Figure 4 ), the distance between the connector 200 and the second side plate 140 is greater than the distance between the air-liquid heat exchanger 400 and the second side plate 140. The air-liquid heat exchanger 400 is spaced apart from both the first side plate 130 and the second side plate 140 along the second direction Y. The gap between the air-liquid heat exchanger 400 and the first side plate 130 is used to install the air-liquid heat exchanger 400 and to arrange the connecting pipeline between the air-liquid heat exchanger 400 and the connector 200. The gap between the air-liquid heat exchanger 400 and the second side plate 140 is used to install the air-liquid heat exchanger 400.

[0111] Generally, in order to ensure the heat dissipation effect of the air-liquid heat exchanger 400, the length of the air-liquid heat exchanger 400 along the second direction Y is longer, and the distance between the air-liquid heat exchanger 400 and the first side plate 130 and the second side plate 140 is smaller. In the power module 10 provided in the present application, the distance between the connector 200 and the first side plate 130 is smaller than the distance between the air-liquid heat exchanger 400 and the first side plate 130, the distance between the connector 200 and the first side plate 130 is smaller, and the distance between the connector 200 and the second side plate 140 is larger, and the connector 200 is closer to the first side plate 130. On the one hand, the connector 200 is located in the corner between the first side plate 130 and the front plate 110, which improves the utilization rate of the internal space of the shell 100 and reduces the impact on other devices and pipeline arrangements. On the other hand, the connection route between the connector 200 and the cooling assembly 14 is shorter, making the pipeline arrangement in the energy storage cabinet 1 more concise.

[0112] In a possible implementation, along the second direction Y, at least one of the distance between the cold plate inlet 211 and the cold plate outlet 212 or the distance between the heat exchanger inlet 213 and the heat exchanger outlet 214 is smaller than the distance between the air-to-liquid heat exchanger 400 and the first side plate 130 (combined with Figure 4 and Figure 5 ).

[0113] In one embodiment, along the second direction Y, the distance between the cold plate inlet 211 and the cold plate outlet 212 is smaller than the distance between the air-to-liquid heat exchanger 400 and the first side plate 130. Since the distance between the air-to-liquid heat exchanger 400 and the first side plate 130 is small, the distance between the cold plate inlet 211 and the cold plate outlet 212 is smaller than the distance between the air-to-liquid heat exchanger 400 and the first side plate 130, so that the cold plate inlet 211 and the cold plate outlet 212 are arranged compactly, which facilitates reducing the size of the connector 200 along the second direction Y.

[0114] In one embodiment, along the second direction Y, the distance between the heat exchanger inlet 213 and the heat exchanger outlet 214 is smaller than the distance between the air-liquid heat exchanger 400 and the first side plate 130. Since the distance between the air-liquid heat exchanger 400 and the first side plate 130 is small, the distance between the heat exchanger inlet 213 and the heat exchanger outlet 214 is smaller than the distance between the air-liquid heat exchanger 400 and the first side plate 130, so that the heat exchanger inlet 213 and the heat exchanger outlet 214 are arranged compactly, which facilitates reducing the size of the connector 200 along the second direction Y.

[0115] In one embodiment, along the second direction Y, the distance between the cold plate inlet 211 and the cold plate outlet 212, and the distance between the heat exchanger inlet 213 and the heat exchanger outlet 214 are smaller than the distance between the air-to-liquid heat exchanger 400 and the first side plate 130, so that the size of the connector 200 along the second direction Y can be smaller.

[0116] In one embodiment, the power module 10 further includes a cold plate liquid inlet pipe 310 and a cold plate liquid outlet pipe 320 (eg, Figure 4 and Figure 5 As shown). The cold plate liquid inlet pipe 310 is used to connect the inlet of the cold plate 300 and the cold plate inlet 211 of the connector 200. The cold plate liquid outlet pipe 320 is used to connect the outlet of the cold plate 300 and the cold plate outlet 212 of the connector 200. The distance between the cold plate inlet 211 and the cold plate outlet 212 is small, so that the cold plate liquid inlet pipe 310 and the cold plate liquid outlet pipe 320 are relatively concentrated, which is convenient for sealing the connection between the cold plate liquid inlet pipe 310 and the connector 200 and the connection between the cold plate liquid outlet pipe 320 and the connector 200.

[0117] In one embodiment, the power module 10 further includes a heat exchanger liquid inlet pipe 430 and a heat exchanger liquid outlet pipe 440 (eg, Figure 4 and Figure 5 ). The heat exchanger liquid inlet pipe 430 is used to connect the inlet of the air-fluid heat exchanger 400 and the heat exchanger inlet 213 of the connector 200. The heat exchanger liquid outlet pipe 440 is used to connect the outlet of the air-fluid heat exchanger 400 and the heat exchanger outlet 214 of the connector 200. The distance between the heat exchanger inlet 213 and the heat exchanger outlet 214 is small, so that the heat exchanger liquid inlet pipe 430 and the heat exchanger liquid outlet pipe 440 are relatively concentrated, which is convenient for sealing the connection between the heat exchanger liquid inlet pipe 430 and the connector 200 and the connection between the heat exchanger liquid outlet pipe 440 and the connector 200.

[0118] In a possible implementation, the connector 200 includes a first sub-cavity 201 and a second sub-cavity 202 (eg, Figure 5 and Figure 6 As shown in FIG. 1 , the first sub-cavity 201 and the second sub-cavity 202 are adjacent and arranged at intervals along the second direction Y. The first sub-cavity 201 is used to connect the cold plate inlet 211 and the heat exchanger inlet 213, and the second sub-cavity 202 is used to connect the cold plate outlet 212 and the heat exchanger outlet 214. Among them, the flow path of the cold plate 300 and the flow path of the air-liquid heat exchanger 400 are operated in parallel. The cold plate 300 and the air-liquid heat exchanger 400 receive the heat exchange medium through the first sub-cavity 201 and discharge the heat exchange medium through the second sub-cavity 202. Along the third direction Z, the cold plate inlet 211 and the heat exchanger inlet 213 are arranged adjacent to each other, and the cold plate outlet 212 and the heat exchanger outlet 214 are arranged adjacent to each other.

[0119] The first sub-cavity 201 and the second sub-cavity 202 are provided to realize the parallel operation of the cold plate 300 and the air-to-liquid heat exchanger 400, thereby improving the heat dissipation efficiency of the power module 10. The two liquid cooling pipes 15 of the cooling assembly 14 are respectively connected to the first sub-cavity 201 and the second sub-cavity 202, so that the cooling assembly 14 can be connected with the cold plate inlet 211, the heat exchanger inlet 213, the cold plate outlet 212 and the heat exchanger outlet 214. On the one hand, the number of pipes between the cooling assembly 14 and the connector 200 is reduced, and on the other hand, the number of joints on the connector 200 for connecting with the liquid cooling pipes 15 of the cooling assembly 14 is reduced, thereby reducing the volume of the connector 200 and facilitating the miniaturization of the power module 10.

[0120] In one embodiment, the connector 200 includes a connection base 210, a first cover plate 220 and a partition plate 240 (eg, Figure 5 and Figure 6 As shown), the connecting seat 210 includes a first groove. Along the first direction X, the cold plate inlet 211, the cold plate outlet 212, the heat exchanger inlet 213 and the heat exchanger outlet 214 respectively penetrate the bottom of the first groove. The partition 240 is located in the first groove and is used to separate the first groove along the second direction Y. The outer peripheral surface of the first cover plate 220 is fixedly connected to the groove wall of the first groove, and the first cover plate 220 is fixedly connected to the partition 240 on one side facing the bottom of the first groove. Among them, the bottom of the first groove and the first cover plate 220 are arranged at intervals along the first direction X. A first cavity 251 is formed between the connecting seat 210 and the first cover plate 220, and the partition 240 separates the first cavity 251 into a first sub-cavity 201 and a second sub-cavity 202.

[0121] In a possible implementation, the connector 200 further includes a second cavity 252 and a drainage hole 215 (eg, Figure 5 and Figure 6 As shown in the figure, the second cavity 252 is adjacent to the first sub-cavity 201 or the second sub-cavity 202 and arranged at intervals along the first direction X, and the drainage hole 215 is connected to the second cavity 252. Among them, the second cavity 252 and the first cavity 251 are arranged along the first direction. The second cavity 252 is isolated from the first cavity 251. The power module 10 also includes a cold plate liquid inlet pipe 310, a cold plate liquid outlet pipe 320, a heat inlet pipe 410 and a heat exchanger liquid outlet pipe 440. One end of the cold plate liquid inlet pipe 310, the cold plate liquid outlet pipe 320, the heat inlet pipe 410 and the heat exchanger liquid outlet pipe 440 are all connected to the connection seat 210 of the connector 200.

[0122] Generally, in order to prevent the leakage of the heat exchange medium from affecting the normal operation of the components in the power module 10, a sealing process is usually performed at the connection between the cold plate liquid inlet pipe 310, the cold plate liquid outlet pipe 320, the heater liquid inlet pipe 410, and the heat exchanger liquid outlet pipe 440 and the connection base 210. In one embodiment, the cold plate liquid inlet pipe 310, the cold plate liquid outlet pipe 320, the heater liquid inlet pipe 410, and the heat exchanger liquid outlet pipe 440 are welded to the connection base 210 and are sealed with the connection base 210 through the weld.

[0123] However, during the use of the power module 10, the connection between the cold plate liquid inlet pipe 310, the cold plate liquid outlet pipe 320, the heat exchanger liquid inlet pipe 410 and the heat exchanger liquid outlet pipe 440 and the connecting seat 210 may have a poor seal problem, and the heat exchange medium may leak to the side of the connecting seat 210 away from the first cavity 251. In the power module 10 provided in the present application, a second cavity 252 is provided on the side of the connecting seat 210 away from the first cavity 251, and the leaked heat exchange medium will be collected in the second cavity 252 and discharged to the outside of the second cavity 252 through the drainage hole 215. The provision of the second cavity 252 performs secondary sealing on the connector 200, reducing the risk of leakage damaging the components in the housing 100. In one embodiment, the heat exchange medium discharged from the drainage hole 215 can be discharged to the outside of the housing 100 through a pipeline.

[0124] In one embodiment, the volume of the second cavity 252 is smaller than the volume of the first cavity 251. The first cavity 251 has a larger volume, which can ensure that the heat exchange medium can be smoothly supplied to the cold plate 300 and the air-to-liquid heat exchanger 400, and the heat exchange medium discharged from the cold plate 300 and the air-to-liquid heat exchanger 400 can be smoothly discharged to the outside of the connector 200. The second cavity 252 is mainly used to prevent the leaked heat exchange medium from entering the housing 100. The second cavity 252 is used to temporarily store the heat exchange medium. The heat exchange medium in the second cavity 252 is quickly discharged to the outside of the housing 100 through the drain hole 215. The smaller volume of the second cavity 252 can also prevent the leaked heat exchange medium from damaging the components in the housing 100. Reducing the volume of the second cavity 252 is conducive to reducing the size of the connector 200.

[0125] In a possible implementation, the connector 200 includes a first cover plate 220, a connection seat 210, a second cover plate 230, and a partition plate 240 (eg, Figure 5 and Figure 6As shown in FIG. 1 , the first cover plate 220 and the second cover plate 230 are arranged on both sides of the connection base 210 along the first direction X, and are respectively surrounded by both sides of the connection base 210 to form a first cavity 251 and a second cavity 252. The partition plate 240 is located in the first cavity 251 and is used to separate the first cavity 251 into a first sub-cavity 201 and a second sub-cavity 202. The connection base 210 includes a cold plate inlet 211, a cold plate outlet 212, a heat exchanger inlet 213 and a heat exchanger outlet 214, and the cold plate inlet 211, the cold plate outlet 212, the heat exchanger inlet 213 and the heat exchanger outlet 214 penetrate the connection base 210 along the first direction X. The first cover plate 220 includes a liquid inlet 221 and a liquid outlet 222. The liquid inlet 221 and the liquid outlet 222 penetrate the first cover plate 220 along the first direction X, respectively. The liquid inlet 221 is used to connect to at least one of the cooling inlet 211 or the heat exchange inlet 213, and the liquid outlet 222 is used to connect to at least one of the cold plate outlet 212 or the heat exchanger outlet 214. The second cover plate 230 includes a first opening 231, a second opening 232, a third opening 233 and a fourth opening 234. The first opening 231, the second opening 232, the third opening 233 and the fourth opening 234 penetrate the second cover plate 230 along the first direction X, respectively. Along the first direction X, the first opening 231, the second opening 232, the third opening 233 and the fourth opening 234 are arranged opposite to the cold plate inlet 211, the cold plate outlet 212, the heat exchanger inlet 213 and the heat exchanger outlet 214, respectively.

[0126] The liquid inlet hole 221 and the liquid outlet hole 222 on the first cover plate 220 are respectively used to communicate with the two liquid cooling pipes 15 of the cooling assembly 14 (combined with Figure 2 and Figure 6 The first sub-chamber 201 receives the heat exchange medium transmitted by the cooling assembly 14 through the liquid inlet 221, and delivers the received heat exchange medium to the cold plate 300 and the air-to-liquid heat exchanger 400 through the cold plate inlet 211 and the heat exchanger inlet 213, respectively. The heat exchange medium flowing out of the cold plate 300 and the air-to-liquid heat exchanger 400 flows into the second sub-chamber 202 through the cold plate outlet 212 and the heat exchanger outlet 214, respectively, and the heat exchange medium in the second sub-chamber 202 is delivered to the cooling assembly 14 through the liquid outlet 222.

[0127] The connection base 210 further includes a second groove, and the second groove and the first groove are arranged along the first direction X. The outer peripheral surface of the second cover plate 230 is fixedly connected to the groove wall of the second groove, and the second cover plate 230 is spaced apart from the groove bottom of the second groove to form a second cavity 252. The connection base 210 further includes a drainage hole 215, and the drainage hole 215 penetrates the connection base 210 along the first direction X. The projection of the second cover plate 230 along the first direction covers the projection of the drainage hole 215 along the first direction.

[0128] In one embodiment, the projection of the first cover plate 220 along the first direction X does not overlap with the projection of the drainage hole 215 along the first direction X (eg Figure 5 Along the first direction X, the projection of the first cover plate 220 on the connection seat 210 covers part of the connection seat 210, and the drainage hole 215 is provided in the area of ​​the connection seat 210 that is not covered by the projection of the first cover plate 220. The drainage hole 215 only needs to penetrate the connection seat 210 to discharge the heat exchange medium leaked into the second cavity 252 to the outside of the connector 200.

[0129] In one embodiment, the housing 100 includes a top plate 150 and a bottom plate 160, and the top plate 150 and the bottom plate 160 are arranged relative to each other along the third direction Z. Along the third direction Z, the distance between the drain hole 215 and the bottom plate 160 is smaller than the distance between the heat exchanger inlet 213 or the heat exchanger outlet 214 and the bottom plate 160. The drain hole 215 is arranged close to the bottom plate 160, which is conducive to the rapid discharge of the heat exchange medium in the second cavity 252, and is also conducive to draining the heat exchange medium in the second cavity 252 to avoid the heat exchange medium accumulating in the second cavity 252.

[0130] The second cover plate 230 is provided with a first opening 231, a second opening 232, a third opening 233 and a fourth opening 234 (such as Figure 5 and Figure 6 ). Along the second direction Y, the first opening 231 is arranged adjacent to the second opening 232, and the third opening 233 is arranged adjacent to the fourth opening 234. Along the third direction Z, the first opening 231 is arranged adjacent to the third opening 233, and the second opening 232 is arranged adjacent to the fourth opening 234. The power module 10 further includes a cold plate liquid inlet pipe 310, a cold plate liquid outlet pipe 320, a heat exchanger liquid inlet pipe 430, and a heat exchanger liquid outlet pipe 440 (combined with Figure 4 ). The cold plate liquid inlet pipe 310 extends into the second cavity 252 through the first opening 231 and is fixed to the inner wall of the cold plate inlet 211. The cold plate liquid outlet pipe 320 extends into the second cavity 252 through the second opening 232 and is fixed to the inner wall of the cold plate outlet 212. The heat exchanger liquid inlet pipe 410 extends into the second cavity 252 through the third opening 233 and is fixed to the inner wall of the heat exchanger inlet 213. The heat exchanger liquid outlet pipe 440 extends into the second cavity 252 through the fourth opening 234 and is fixed to the inner wall of the heat exchanger outlet 214.

[0131] Along the first direction X, the first opening 231 is arranged opposite to the cold plate inlet 211, and the distance between the first opening 231 and the cold plate inlet 211 is short. When the cold plate liquid inlet pipe 310 is connected to the cold plate inlet 211, the pipe is short and does not need to be bent, which not only saves costs, but also reduces the risk of bending and breaking of the cold plate liquid inlet pipe 310, and improves the reliability of the connection between the cold plate liquid inlet pipe 310 and the cold plate inlet 211. Similarly, along the first direction X, the second opening 232 is arranged opposite to the cold plate outlet 212, the third opening 233 is arranged opposite to the heat exchanger inlet 213, and the fourth opening 234 is arranged opposite to the heat exchanger outlet 214, which can also save costs and improve the reliability of the connection between the cold plate liquid outlet pipe 320, the heat exchanger liquid inlet pipe 410 and the heat exchanger liquid outlet pipe 440 and the connecting seat 210.

[0132] In a possible implementation, the power module 10 includes a liquid inlet connector 223 and a liquid outlet connector 224 (eg, Figure 5 and Figure 6 As shown), the liquid inlet connector 223 and the liquid outlet connector 224 are fixed to the first cover plate 220 and are connected to the liquid inlet hole 221 and the liquid outlet hole 222 respectively. The front plate 110 includes a through hole 111 (as shown Figure 3 ), the through hole 111 penetrates the front plate 110 along the first direction X. Along the first direction X, the projection of the through hole 111 covers the projection of the liquid inlet joint 223 and the projection of the liquid outlet joint 224, and the projection of the first cover plate 220 covers the projection of the through hole 111; along the third direction Z, the length of the liquid inlet joint 223 and the liquid outlet joint 224 is greater than the distance between the first cover plate 220 and the front plate 110.

[0133] Among them, the liquid inlet connector 223 is used to connect the liquid inlet hole 221 and the cooling assembly 14, and the liquid outlet connector 224 is used to connect the liquid outlet hole 222 and the cooling assembly. Along the first direction X, the liquid inlet connector 223 and the liquid outlet connector 224 extend from the inside of the shell 100 to the outside of the shell 100 through the through hole 111. The power module 10 can be connected to the cooling assembly 14 outside the shell 100. Compared with the connection inside the shell 100, the power module 10 is connected to the two liquid cooling pipes 15 of the cooling assembly 14 outside the shell 100 through the liquid inlet connector 223 and the liquid outlet connector 224 respectively. On the one hand, the operating space outside the shell 100 is larger, which is convenient for connecting the two liquid cooling pipes 15 to the liquid inlet connector 223 and the liquid outlet connector 224. On the other hand, the connection between the power module 10 and the liquid cooling pipe 15 is arranged outside the shell 100. If the heat exchange medium leaks due to loose connection between the joint and the pipe during long-term operation of the power module 10, the leaked heat exchange medium is located outside the shell 100 to avoid damage to the devices inside the shell 100.

[0134] In addition, the projection of the first cover plate 220 along the first direction X covers the projection of the through hole 111, and the area of ​​the first cover plate 220 is larger than the area of ​​the through hole 111. The through hole 111 has a smaller area, which facilitates ensuring the sealing of the housing 100.

[0135] In such Figure 5 In the embodiment shown, the liquid inlet connector 223 and the liquid outlet connector 224 are arranged adjacent to each other and spaced apart along the second direction Y. In one embodiment, the liquid inlet connector 223 and the liquid outlet connector 224 can be arranged at diagonal positions of the first cover plate 220 (e.g. Figure 7 As shown in FIG. 1 , the liquid inlet hole 221 and the liquid outlet hole 222 are also arranged at the diagonal of the first cover plate 220. The liquid inlet joint 223 and the liquid outlet joint 224 are far apart, and when the liquid inlet joint 223 and the liquid outlet joint 224 are connected to the liquid cooling pipe 15, there is a large operating space, which is convenient for connecting the liquid cooling pipe 15. The liquid inlet joint 223 and the liquid outlet joint 224 are staggered, and the size of the connector 200 along the second direction Y can be reduced while ensuring that the liquid inlet joint 223 and the liquid outlet joint 224 have a sufficient distance for connecting the liquid cooling pipe 15.

[0136] In one embodiment, a seal is provided between the first cover plate 220 and the front plate 110 along the first direction X, and the seal is arranged around the through hole 111. The seal is used to prevent moisture, air, dust and other substances in the external environment from entering the housing 100 through the through hole 111 and the gap between the first cover plate 220 and the front plate 110, so as to ensure the stable operation of the power module 10. In the present application, the area of ​​the through hole 111 is small, so the corresponding seal can be made small and the reliability of the seal when used for sealing is high, thereby improving the sealing performance of the housing 100 to better protect the components in the housing 100.

[0137] In the present application, since the heat dissipation through the cold plate 300 and the air-to-liquid heat exchanger 400 is carried out inside the shell 100, and the cold plate 300 and the air-to-liquid heat exchanger 400 only receive the heat exchange medium outside the shell 100 through a smaller through hole 111 and discharge the heat exchange medium to the outside of the shell 100, when a seal is set to seal the gap between the side of the through hole 111 and the first cover plate 220, the shell 100 as a whole has strong airtightness and a high protection level, which improves the long-term working reliability of the power module 10, reduces the failure rate of components in the shell 100, and increases the life of the components.

[0138] In one embodiment, the projection of the through hole 111 along the first direction X covers the projection of the drain hole 215 , so that the heat exchange medium in the second cavity 252 is discharged to the outside of the housing 100 through the drain hole 215 and the through hole 111 .

[0139] See also Figure 8 and Fig. 9 , Figure 8 and Fig. 9 This is an exploded view of a connector 200 provided in one embodiment of the present application. In a possible implementation, the connector 200 includes a first sub-cavity 201, a second sub-cavity 202, and a third sub-cavity 203. The first sub-cavity 201 and the third sub-cavity 203 are adjacent and spaced apart along the third direction Z, and the first sub-cavity 201 or the third sub-cavity 203 is adjacent and spaced apart from the second sub-cavity 202 along the second direction Y. The first sub-cavity 201 is used to connect the heat exchanger inlet 213, the second sub-cavity 202 is used to connect the heat exchanger outlet 214 and the cold plate inlet 211, and the third sub-cavity 203 is used to connect the cold plate outlet 212.

[0140] The flow path of the cold plate 300 and the flow path of the air-to-liquid heat exchanger 400 are operated in series. The inlet of the air-to-liquid heat exchanger 400 is connected to the first sub-cavity 201 and receives the heat exchange medium through the first sub-cavity 201. The outlet of the air-to-liquid heat exchanger 400 and the inlet of the cold plate 300 are connected to the second sub-cavity 202. The heat exchange medium discharged from the outlet of the air-to-liquid heat exchanger 400 into the second sub-cavity 202 can be transported to the cold plate 300. The outlet of the cold plate 300 is connected to the third sub-cavity 203, and the heat exchange medium is transported to the cooling assembly 14 through the third sub-cavity 203.

[0141] By setting the first sub-cavity 201, the second sub-cavity 202 and the third sub-cavity 203 to realize the series operation of the cold plate 300 and the air-to-liquid heat exchanger 400, the heat dissipation energy consumption of the power module 10 can be reduced. The two liquid cooling pipes 15 of the cooling assembly 14 are respectively connected to the first sub-cavity 201 and the third sub-cavity 203, so that the cooling assembly 14 can be connected with the cold plate inlet 211, the heat exchanger inlet 213, the cold plate outlet 212 and the heat exchanger outlet 214. On the one hand, the number of pipes between the cooling assembly 14 and the connector 200 is reduced, and on the other hand, the number of joints on the connector 200 for connecting with the liquid cooling pipes 15 of the cooling assembly 14 is reduced, and the volume of the connector 200 is reduced, which is convenient for miniaturization of the power module 10.

[0142] On the other hand, since the cold plate 300 is mainly used to dissipate heat for high-heat devices, and the air-liquid heat exchanger 400 is mainly used to dissipate heat for medium- and low-heat devices, the temperature difference before and after the cold plate 300 is large, and the temperature difference before and after the air-liquid heat exchanger 400 is small. In the present application, by controlling the heat exchange medium to flow through the air-liquid heat exchanger 400 and the cold plate 300 in sequence, the heat dissipation of the heat-generating devices by the two heat dissipation methods can be taken into account, which is conducive to better heat dissipation of various heat-generating devices.

[0143] Generally, when the heat dissipation demand of the power module 10 is large, the power module 10 can use the cold plate 300 and the air-liquid heat exchanger 400 to operate in parallel to dissipate heat for the heat generating device, and the parallel operation can quickly cool down various heat generating devices. When the heat dissipation demand of the power module 10 is small, the power module 10 can use the cold plate 300 and the air-liquid heat exchanger 400 to operate in series to dissipate heat for the heat generating device to save energy consumption.

[0144] In one embodiment, the connector 200 includes a connection base 210, a first cover plate 220 and a partition plate 240. The connection base 210 and the first cover plate 220 are surrounded to form a first cavity 251. The partition plate 240 divides the first cavity 251 into a first sub-cavity 201, a second sub-cavity 202 and a third sub-cavity 203. The connector 200 may include two partition plates 240 connected to each other, such as Fig. 9 The partition 240a and the partition 240b are located between the cold plate inlet 211 and the cold plate outlet 212, and between the heat exchanger outlet 214 and the heat exchanger inlet 213 (combined with Figure 8 ), the partition 240a is used to separate the cold plate inlet 211, the heat exchanger outlet 214 from the cold plate outlet 212, the heat exchanger inlet 213. The partition 240b is located between the cold plate outlet 212 and the heat exchanger inlet 213 and is used to separate the cold plate outlet 212 and the heat exchanger inlet 213.

[0145] The connection base 210 includes a cold plate inlet 211, a cold plate outlet 212, a heat exchanger inlet 213 and a heat exchanger outlet 214. In the third direction Z, the cold plate inlet 211 and the heat exchanger outlet 214 are arranged adjacent to each other, and the cold plate outlet 212 and the heat exchanger inlet 213 are arranged adjacent to each other (e.g., Figure 8 and Fig. 9 shown).

[0146] The first cover plate 220 includes a liquid inlet hole 221 and a liquid outlet hole 222. The liquid inlet hole 221 and the liquid outlet hole 222 respectively penetrate the first cover plate 220 along the first direction X. The liquid inlet hole 221 is connected to the first sub-cavity 201, thereby connecting to the heat exchanger inlet 213. The liquid outlet hole 222 is connected to the third sub-cavity 203, thereby connecting to the cold plate outlet 212. The liquid inlet hole 221 and the liquid outlet hole 222 are arranged along the third direction Z.

[0147] In one embodiment, the connector 200 further includes a second cavity 252 and a drainage hole 215 (eg, Figure 8 and Fig. 9). The second cavity 252 is adjacent to the first sub-cavity 201, the second sub-cavity 202, and the third sub-cavity 203 along the first direction X and arranged at intervals. In one embodiment, the connector 200 further includes a second cover plate 230, and the second cover plate 230 and the connecting seat 210 are arranged along the first direction X away from the first cover plate 220 to form the second cavity 252. The drainage hole 215 penetrates the connecting seat 210 along the first direction X. The second cavity 252 and the drainage hole 215 are used to increase the sealing performance of the connector 200 and reduce the risk of heat exchange medium leaking into the interior of the housing 100.

[0148] It is worth noting that other structural features of the connector 200 when the cold plate 300 and the air-to-liquid heat exchanger 400 operate in series can refer to the structural features of the connector 200 when the cold plate 300 and the air-to-liquid heat exchanger 400 operate in parallel as mentioned above, and will not be repeated here.

[0149] See also Fig.10 , Fig.11 , Fig.12 and Fig.13 . Fig.10 A three-dimensional diagram of a circuit board 600, a cold plate 300, and an air-to-liquid heat exchanger 400 provided in one embodiment of the present application. Fig.11 It is a front view of a circuit board 600, a cold plate 300 and an air-to-liquid heat exchanger 400 provided in one embodiment of the present application. Fig.12 It is a rear view of a circuit board 600, a cold plate 300 and an air-to-liquid heat exchanger 400 provided in one embodiment of the present application. Fig.13 A top view of a circuit board 600, a cold plate 300, and an air-to-liquid heat exchanger 400 provided in accordance with an embodiment of the present application.

[0150] In a possible implementation, the power module 10 further includes a circuit board 600 and a plurality of power tubes 700, and the housing 100 includes a top plate 150 and a bottom plate 160 (see Figure 3 and Figure 4 ), along the third direction Z, the top plate 150 and the bottom plate 160 are arranged relatively to each other, the circuit board 600 is arranged between the top plate 150 and the bottom plate 160 at intervals, a plurality of power tubes 700 and a cold plate 300 are arranged on a side of the circuit board 600 facing the bottom plate 160, and along the first direction X, the cold plate 300 is in contact with at least one power tube 700.

[0151] The power tube 700 may be an IGBT tube, a MOSFET or other types of power tubes 700. A plurality of power tubes 700 are connected to the circuit board 600 along the third direction Z. The power tube 700 and the circuit board 600 are used together to achieve power change. At least one power tube 700 is stacked and arranged with the cold plate 300 along the first direction X (e.g., Fig.12 and Fig.13As shown in FIG. 1 , at least one side of the power tube 700 along the first direction X contacts the cold plate 300 . Both sides of the cold plate 300 that are oppositely disposed along the first direction X can be used to contact the power tube 700 .

[0152] In one embodiment, the plurality of power tubes 700 are in contact with the cold plate 300 along the first direction X.

[0153] In the power module 10 provided in the present application, the power tube 700 is a high heat generating device, and the cold plate 300 is used to dissipate heat from the power tube 700 to improve the cooling efficiency of the power tube 700. The first direction X is a direction parallel to the circuit board 600, and the cold plate 300 and the power tube 700 are attached along the first direction X, which can reduce the size of the power module 10 along the third direction X.

[0154] In one embodiment, the length of the cold plate 300 along the first direction X is less than the length of the cold plate 300 along the third direction Z. The two side surfaces of the cold plate 300 that are oppositely disposed along the first direction X are side surfaces with larger areas. The side surface with larger area of ​​the cold plate 300 contacts the power tube 700, and can better cool the power tube 700.

[0155] In one embodiment, the length of the power tube 700 along the first direction X is less than the length of the power tube 700 along the second direction Y. The two side surfaces of the power tube 700 that are oppositely arranged along the first direction X are side surfaces with larger areas, and the side surface with larger area of ​​the power tube 700 contacts the cold plate 300, thereby increasing the contact area between the power tube 700 and the cold plate 300, and facilitating rapid cooling of the power tube 700.

[0156] In one embodiment, along the first direction X, the projection of the cold plate 300 covers the projection of the power tube 700. The power tube 700 and the cold plate 300 have a large contact area, which is conducive to rapid cooling of the power tube 700.

[0157] In one embodiment, at least one of silicone grease and ceramic sheet is further included between the power tube 700 and the cold plate 300. The power tube 700 is attached to the cold plate 300 through the silicone grease and / or the ceramic sheet. The silicone grease and the ceramic sheet have good thermal conductivity and insulation properties, and can insulate the power tube 700 from the cold plate 300 without affecting the rapid heat dissipation of the power tube 700.

[0158] In a possible implementation, the power module 10 includes a plurality of cold plates 300 connected to each other, the plurality of cold plates 300 are arranged at intervals along a first direction X, and the plurality of power tubes 700 include a plurality of columns of power tubes 700 (such as Figure 4 and Fig.13 As shown in FIG. 3 , each column of power tubes 700 includes a plurality of power tubes 700 sequentially arranged along the second direction Y, and the plurality of power tubes 700 in each column of power tubes 700 are in contact with the same cold plate 300 .

[0159] The cold plate 300 extends along the second direction Y. The length of the cold plate 300 along the second direction Y is greater than or equal to the length of each column of power tubes 700 along the second direction Y. The multiple power tubes 700 in each column of power tubes 700 are in contact with the same side of the cold plate 300 along the first direction X on the same side of the first direction X. Fig.13 In the illustrated embodiment, the power module 10 includes 6 columns of power tubes 700 , and each column of power tubes 700 includes 16 power tubes.

[0160] In the power module 10 provided in the present application, one cold plate 300 can be used to cool at least one column of power tubes 700, thereby improving the utilization rate of the cold plate 300. In addition, in the present application, by providing multiple cold plates 300 to cool multiple columns of power tubes 700, the multiple columns of power tubes 700 in the power module 10 can be better dissipated, thereby improving the reliability of the power module 10.

[0161] In one embodiment, the power module 10 further includes at least one cold plate communicating pipe 330 (eg Fig.13 As shown in FIG. 1 , at least one cold plate connecting pipe 330 and a plurality of cold plates 300 are alternately arranged along a first direction X, and the cold plate connecting pipe 330 is used to connect two adjacent cold plates 300. The cold plate connecting pipe 330 can be used to realize the series connection between the plurality of cold plates 300. In one embodiment, the at least one cold plate connecting pipe 330 and the plurality of cold plates 300 are an integrated structure, which not only improves the overall structural strength of the at least one cold plate connecting pipe 330 and the plurality of cold plates 300, but also reduces the welding points between the cold plate connecting pipe 330 and the cold plate 300, so as to reduce the risk of leakage of the heat exchange medium.

[0162] In one embodiment, the power module 10 further includes a cold plate liquid inlet pipe 310 and a cold plate liquid outlet pipe 320 (eg, Fig.13 ). One end of the cold plate liquid inlet pipe 310 is used for the cold plate inlet 211 of the connector 200, and one end of the cold plate liquid inlet pipe 310 is used to connect the inlet of the first cold plate 300 among the multiple cold plates 300. One end of the cold plate liquid outlet pipe 320 is used to connect the cold plate outlet 212 of the connector 200, and one end of the cold plate liquid outlet pipe 320 is used to connect the outlet of the last cold plate 300 among the multiple cold plates 300. The first cold plate 300 and the last cold plate 300 are respectively the first and last cold plates 300 along the first direction among the multiple cold plates 300.

[0163] In one embodiment, the cold plate liquid inlet pipe 310, multiple cold plates 300, at least one cold plate connecting pipe 330 and the cold plate liquid outlet pipe 320 are an integrated structure, which not only improves the overall structural strength of the cold plate liquid inlet pipe 310, multiple cold plates 300, at least one cold plate connecting pipe 330 and the cold plate liquid outlet pipe 320, but also reduces the welding points between the cold plate connecting pipe 330 and multiple cold plates 300, the welding points between the cold plate liquid inlet pipe 310 and the cold plate 300, and the welding points between the cold plate liquid outlet pipe 320 and the cold plate 300, so as to reduce the risk of leakage of the heat exchange medium.

[0164] In one embodiment, the cold plate liquid inlet pipe 310, the plurality of cold plates 300, at least one cold plate connecting pipe 330 and the cold plate liquid outlet pipe 320 are connected to form a cooling pipe, which is formed by bending a flat pipe multiple times. The cooling pipe is integrally formed, which reduces the risk of heat exchange medium leakage.

[0165] In a possible implementation, at least one cold plate 300 is arranged between two adjacent rows of power tubes 700 (eg Fig.13 As shown in FIG. 1 , at least one cold plate 300 includes two sides along the first direction X, one side of the at least one cold plate 300 is respectively in contact with a plurality of power tubes 700 in one column of power tubes 700, and the other side of the at least one cold plate 300 is respectively in contact with a plurality of power tubes 700 in another column of power tubes 700. Both sides of the cold plate 300 along the first direction X are used to cool the power tubes 700, and one cold plate 300 can cool two columns of power tubes 700, thereby improving the utilization rate of the cold plate 300.

[0166] In one embodiment, along the first direction X, the distance between two adjacent cold plates 300 is greater than twice the thickness of the power tube 700. Along the first direction X, two rows of power tubes 700 are arranged between two adjacent cold plates 300, and the two rows of power tubes 700 are in contact with different cold plates 300 respectively.

[0167] In one embodiment, along the first direction X, the distance between two adjacent cold plates 300 is equal to the thickness of the power tube 700. Along the first direction X, a row of power tubes 700 is arranged between two adjacent cold plates 300, and the two sides of the row of power tubes 700 in the first direction X are respectively in contact with the two cold plates 300, thereby improving the cooling efficiency of the power tubes 700.

[0168] In one embodiment, along the third direction Z, the projections of the plurality of cold plates 300 and the projection of the air-to-liquid heat exchanger 400 do not overlap (eg Figure 4 and Fig.13As shown). The cold plate 300 and the air-liquid heat exchanger 400 are staggered along the first direction X to prevent the power tube 700 from contacting the air-liquid heat exchanger 400 and damaging the power tube 700. Since the multiple cold plates 300 and the air-liquid heat exchanger 400 are staggered, a gap is left between the cold plate 300 and the bottom plate 160. At this time, a fixing member can be set between the circuit board 600 and the bottom plate 160. The fixing member is used to clamp the power tube 700 and the cold plate 300 to ensure the heat dissipation effect of the power tube 700, and the fixing member can also play a role in supporting the power tube 700 and the cold plate 300.

[0169] In a possible implementation, along the third direction Z, the distance between the air-to-liquid heat exchanger 400 and the top plate 150 is greater than the distance between the cold plate 300 and the top plate 150 (combined with Figure 3 , Figure 4 and Fig.11 ). The distance between at least one of the cold plate inlet 211 or the cold plate outlet 212 and the top plate 150 is smaller than the distance between the air-to-liquid heat exchanger 400 and the top plate 150, and the distance between at least one of the heat exchanger inlet 213 or the heat exchanger outlet 214 and the bottom plate 160 is smaller than the distance between the cold plate 300 and the bottom plate 160. Among them, the air-to-liquid heat exchanger 400 and the cold plate 300 are staggered along the third direction Z, and the cold plate inlet 211, the cold plate outlet 212, the heat exchanger inlet 213, and the heat exchanger outlet 214 are arranged relatively concentratedly, so as to reduce the size of the connector 200.

[0170] In one embodiment, along the third direction Z, the distance between the cold plate inlet 211 or the cold plate outlet 212 and the heat exchanger inlet 213 or the heat exchanger outlet 214 is less than or equal to the distance between the air-to-liquid heat exchanger 400 and the cold plate 300, and the size of the connector 200 along the third direction Z is small, which facilitates the miniaturization of the connector 200.

[0171] See also Figure 4 , Fig.13 and Fig.14 In a possible implementation, the air-to-liquid heat exchanger 400 includes a plurality of heat exchange plates 410 that are connected to each other. The air-to-liquid heat exchanger 400 is located between the connector 200 and the circuit board 600 along the first direction X, and the air-to-liquid heat exchanger 400 is arranged between the top plate 150 and the bottom plate 160 along the third direction Z. The plurality of heat exchange plates 410 are arranged at intervals along the first direction X. In the third direction Z, the projection of the air-to-liquid heat exchanger 400 does not overlap with the projection of the circuit board 600. The air-to-liquid heat exchanger 400 and the circuit board 600 are staggered, and the air-to-liquid heat exchanger 400 will not hinder the circuit board 600 from carrying components. The circuit board 600 has high space utilization, which is beneficial to improving the performance of the power module 10.

[0172] Generally, in order to carry more onboard components, the volume of the circuit board 600 is relatively large. And because the inductor 500 is located on the side of the circuit board 600 close to the rear plate 120 along the first direction X, the distance between the air-liquid heat exchanger 400 and the front plate 110 is relatively small, and generally no components are placed between the air-liquid heat exchanger 400 and the front plate 110. At this time, the multiple heat exchange plates 410 of the air-liquid heat exchanger 400 are arranged at intervals along the first direction X, and the air-liquid heat exchanger 400 is ventilated along the third direction Z. The air in the housing 100 passes through the gap between two adjacent heat exchange plates 410 along the third direction Z, and exchanges heat with the heat exchange plates 410, thereby cooling the air in the housing 100. Arranging multiple heat exchange plates 410 along the first direction X is more conducive to heat dissipation of the power module 10.

[0173] In one embodiment, the power module 10 further includes a fan 800 (eg Fig.14 The fan 800 is used to drive the air in the housing 100 to flow toward the air-to-liquid heat exchanger 400. The fan 800 accelerates the air flow rate in the housing 100, which is more conducive to the rapid heat dissipation of the heating components in the housing 100.

[0174] In one embodiment, if Fig.14 As shown by the arrow in , the fan 800 drives the air to pass through the gap between the circuit board 600 and the bottom plate 160 along the first direction X to take away the heat of the heating components between the circuit board 600 and the bottom plate 160. Then the air passes through the gap between the circuit board 600 and the back plate 120 along the third direction Z and enters the gap between the circuit board 600 and the top plate 150. The air flows through the gap between the circuit board 600 and the top plate 150 along the first direction X to cool the side of the circuit board 600 facing the top plate 150. Thereafter, the air flows along the third direction Z to the gap between the circuit board 600 and the front plate 110 and passes through the air-to-liquid heat exchanger 400. The air is converted into air with a lower temperature after heat exchange with the air-to-liquid heat exchanger 400. The air with a lower temperature enters the gap between the circuit board 600 and the bottom plate 160. This cycle is repeated to cool various heating components in the housing 100. The air flows below and above the circuit board 600, which is conducive to sufficient heat dissipation of the circuit board and other heating components.

[0175] In one embodiment, the flow direction of the air in the shell 100 can also be: the air passes through the gap between the circuit board 600 and the bottom plate 160, the gap between the circuit board 600 and the front plate 110, and passes through the air-to-liquid heat exchanger 400, the gap between the circuit board 600 and the top plate 150, and the gap between the circuit board 600 and the rear plate 120 in sequence.

[0176] In one embodiment, the length of the heat exchange plate 410 along the first direction X is less than the length of the heat exchange plate 410 along the third direction Z. The heat exchange plate 410 extends along the second direction, and the two side surfaces of the heat exchange plate 410 that are arranged opposite to each other along the first direction X are the side surfaces of the heat exchange plate 410 with a larger area. A plurality of heat exchange plates 410 are arranged along the first direction X, and the volume of the air-to-liquid heat exchanger 400 formed is relatively small, which is conducive to reducing the volume of the power module 10. In addition, after the air enters the air-to-liquid heat exchanger 400, it contacts the surface of the heat exchange plate 410 with a larger area. The heat exchange area between the air and the heat exchange plate 410 is relatively large, which facilitates the air-to-liquid heat exchanger 400 to quickly cool the air.

[0177] In one embodiment, the distance between two adjacent heat exchange plates 410 along the first direction X is smaller than the distance between two adjacent cold plates 300. The smaller distance between two adjacent heat exchange plates 410 is conducive to adding heat exchange plates 410 to enhance the heat dissipation effect of the air-to-liquid heat exchanger 400 or reduce the volume of the air-to-liquid heat exchanger 400.

[0178] In one embodiment, along the first direction X, the length of the heat exchange plate 410 is less than the length of the cold plate 300. The heat exchange plate 410 is thinner along the first direction X, which is more conducive to improving the heat exchange efficiency between the heat exchange plate 410 and the air.

[0179] In one embodiment, the length of the heat exchange plate 410 is greater than the length of the cold plate 300 along the third direction Z. The heat exchange plate 410 is longer along the third direction Z, which increases the heat exchange area between the air and the heat exchange plate 410, and is more conducive to the air-to-liquid heat exchanger 400 to quickly cool the air.

[0180] In one embodiment, the power module 10 further includes at least one heat exchange plate communicating pipe 420 (eg Fig.10 As shown). At least one heat exchange plate connecting pipe 420 and multiple heat exchange plates 410 are alternately arranged along the first direction X, and the heat exchange plate connecting pipe 420 is used to connect two adjacent heat exchange plates 410. The heat exchange plate connecting pipe 420 can be used to achieve a series connection between multiple heat exchange plates 410. In one embodiment, at least one heat exchange plate connecting pipe 420 and multiple heat exchange plates 410 are an integrated structure, which not only improves the overall structural strength of at least one heat exchange plate connecting pipe 420 and multiple heat exchange plates 410, but also reduces the welding points between the heat exchange plate connecting pipe 420 and the heat exchange plates 410, so as to reduce the risk of leakage of the heat exchange medium.

[0181] In one embodiment, the power module 10 further includes a heat exchanger liquid inlet pipe 430 and a heat exchanger liquid outlet pipe 440 (eg, Fig.13). One end of the heat exchanger liquid inlet pipe 430 is used for the heat exchanger inlet 213 of the connector 200, and one end of the heat exchanger liquid inlet pipe 430 is used to connect to the inlet of the first heat exchange plate 410 among the multiple heat exchange plates 410. One end of the heat exchanger liquid outlet pipe 440 is used to connect to the heat exchanger outlet 214 of the connector 200, and one end of the heat exchanger liquid outlet pipe 440 is used to connect to the outlet of the last heat exchange plate 410 among the multiple heat exchange plates 410. The first heat exchange plate 410 and the last heat exchange plate 410 are respectively the first and last heat exchange plates 410 in the first direction among the multiple heat exchange plates 410.

[0182] In one embodiment, the heat exchanger liquid inlet pipe 430, multiple heat exchange plates 410, at least one heat exchange plate connecting pipe 420 and the heat exchanger liquid outlet pipe 440 are an integrated structure, which not only improves the overall structural strength of the heat exchanger liquid inlet pipe 430, multiple heat exchange plates 410, at least one heat exchange plate connecting pipe 420 and the heat exchanger liquid outlet pipe 440, but also reduces the welding points between the heat exchange plate connecting pipe 420 and the multiple heat exchange plates 410, the welding points between the heat exchanger liquid inlet pipe 430 and the heat exchange plate 410, and the welding points between the heat exchanger liquid outlet pipe 440 and the heat exchange plate 410, so as to reduce the risk of leakage of the heat exchange medium.

[0183] In one embodiment, the heat exchanger liquid inlet pipe 430, the plurality of heat exchange plates 410, at least one heat exchange plate connecting pipe 420 and the heat exchanger liquid outlet pipe 440 are connected to form a heat exchange pipe, which is formed by bending a flat pipe multiple times. The cooling pipe is integrally formed, which reduces the risk of heat exchange medium leakage.

[0184] In one embodiment, the heat exchange pipe and the cooling pipe are both integrated structures. The heat exchange pipe and the cooling pipe are both welded to the connector 200. Except for the welding points at the welding parts with the connector 200, the heat exchange pipe and the cooling pipe have no welds, which reduces the risk of heat exchange medium leakage. In addition, the design of welding the heat exchange pipe and the cooling pipe with the connector 200 as one body makes the structure of the heat exchange pipe and the cooling pipe more compact, and improves the reliability of the power module 10.

[0185] See also Fig.15 , Fig.16 and Fig.17 . Fig.15 A schematic diagram of a power module 10 provided in accordance with an embodiment of the present application. Fig.16 It is a front view of a circuit board 600, a cold plate 300 and an air-to-liquid heat exchanger 400 provided in one embodiment of the present application. Fig.17 A top view of a circuit board 600, a cold plate 300, and an air-to-liquid heat exchanger 400 provided in accordance with an embodiment of the present application.

[0186] In a possible implementation, the projection of the air-liquid heat exchanger 400 along the third direction Z coincides with the projection of the circuit board 600 along the third direction Z, and the projection of the air-liquid heat exchanger 400 along the third direction Z is staggered with the projection of the cold plate 300 along the third direction Z, and a plurality of heat exchange plates 410 are arranged at intervals along the third direction Z. The air-liquid heat exchanger 400 and the circuit board 600 are arranged overlappingly along the third direction Z, and on-board components are arranged on both the front and rear sides of the air-liquid heat exchanger 400 along the first direction X. At this time, a plurality of heat exchange plates 410 are arranged along the third direction Z, and the air-liquid heat exchanger 400 is ventilated along the first direction X, which can take into account the heat dissipation of the on-board components before and after the circuit board 600 along the first direction X.

[0187] See also Fig.15 In one embodiment, the air flow direction in the housing 100 can be: the air passes through the gap between the circuit board 600 and the bottom plate 160 along the first direction X, and passes through the air-to-liquid heat exchanger 400, and the air flow takes away the heat of the heating components between the circuit board 600 and the bottom plate 160. The air is converted into air with a lower temperature after passing through the air-to-liquid heat exchanger 400. Then the air passes through the gap between the circuit board 600 and the back plate 120 along the third direction Z and enters the gap between the circuit board 600 and the top plate 150. The air flows through the gap between the circuit board 600 and the top plate 150 along the first direction X to cool the side of the circuit board 600 facing the top plate 150. Thereafter, the air flows through the gap between the circuit board 600 and the front plate 110 along the third direction Z, and flows through the gap between the circuit board 600 and the bottom plate 160 along the first direction X. This cycle is repeated to cool various heating components in the housing 100. The air flows below and above the circuit board 600, which is conducive to sufficient heat dissipation of the circuit board and other heating components. In one embodiment, the air flow direction may be opposite to the above-mentioned flow direction.

[0188] See also Fig.18 In one embodiment, the air flow direction in the housing 100 may also be: the air flows from the front plate 110 toward the rear plate 120 along the first direction X and flows through the air-to-liquid heat exchanger 400. The air changes its flow direction at the rear plate 120 and flows from the rear plate 120 toward the front plate 110 along the first direction X. This cycle is performed to cool the components in the housing 100. The air may first flow through the area between the circuit board 600 and the top plate 150 and the bottom plate 160, and then return air in the opposite direction from the gap between the circuit board 600 and the first side plate 130 and the second side plate 140. In one embodiment, the air flow direction may also be opposite to the above-mentioned flow direction.

[0189] It is worth mentioning that the above two different air flow methods can be used in combination.

[0190] In one embodiment, the air-to-liquid heat exchanger 400 further includes fins 450 (eg Fig.16As shown in FIG. 4 , the fin 450 is located between two adjacent heat exchange plates 410. The fin 450 has good thermal conductivity. The air in the housing 100 transfers heat to the heat exchange medium in the heat exchange plate 410 through the fin 450. The provision of the fin 450 improves the heat exchange rate between the air-to-liquid heat exchanger 400 and the air in the housing 100.

[0191] In one embodiment, a plurality of microchannels are disposed in the cold plate 300 and the heat exchange plate 410 , and the microchannels can improve the heat exchange efficiency of the cold plate 300 and the heat exchange plate 410 .

[0192] In a possible implementation, the power module 10 includes a plurality of inductors 500 and a plurality of fans 800 (eg, Figure 4 and Fig.18 As shown in FIG. 4 , a plurality of inductors 500 are arranged at intervals along the second direction Y, and a plurality of fans 800 are arranged at intervals along the second direction Y; along the first direction X, the fan 800 is located between the inductor 500 and the circuit board 600. The fan 800 plays a role of turbulence, and the fan 800 can provide power for the air to flow toward the air-to-liquid heat exchanger 400 to improve the heat dissipation effect of the air-to-liquid heat exchanger 400. The fan 800 is located between the inductor 500 and the circuit board 600, which not only does not hinder the installation of various components, but also can achieve a better heat dissipation effect.

[0193] See also Fig.19 In a possible implementation, the power module 10 further includes a first baffle 910, a second baffle 920 and a third baffle 930, the first baffle 910 and the second baffle 920 are respectively located on both sides of the circuit board 600 along the second direction Y, and the third baffle 930 is located between the top plate 150 and the fan 800 along the third direction Z; the first baffle 910 is respectively connected to the circuit board 600 and the first side plate 130 on both sides along the second direction Y, and the second baffle 920 is respectively connected to the circuit board 600 and the second side plate 140 on both sides along the second direction Y. When the third baffle is respectively connected to the circuit board and the inductor on both sides along the first direction, the air-liquid heat exchanger 400 is located between the connector 200 and the circuit board 600 along the first direction X, or the projection of the air-liquid heat exchanger 400 along the third direction Z coincides with the projection of the circuit board 600 along the third direction Z.

[0194] The first baffle 910, the second baffle 920, and the third baffle 930 can guide the air to circulate through the bottom and top of the circuit board 600. Exemplarily, the first baffle 910, the second baffle 920, and the third baffle 930 can guide the air to flow along the gap between the circuit board 600 and the bottom plate 160, the gap between the circuit board 600 and the rear plate 120, the gap between the circuit board 600 and the top plate 150, and the gap between the circuit board 600 and the front plate 110 in sequence (combined with the airflow path). Fig.19 , Figure 4 and Fig.14 ).

[0195] The third baffle 930 is used to cover the gap between the inductor 500 and the circuit board 600 to prevent the air from flowing in the gap between the circuit board 600 and the bottom plate 160 along the first direction X and then being blocked by the inductor 500 and turning to flow toward the top plate 150 along the third direction Z without passing through the inductor 500, resulting in poor heat dissipation effect of the inductor 500. After the third baffle 930 is set, the third baffle 930 blocks the air from flowing from the gap between the inductor 500 and the circuit board 600 to the top plate 150. At this time, the air first passes through the inductor 500 and flows to the rear plate 120 along the first direction X, and then flows toward the top plate 150 along the third direction Z, which is conducive to improving the heat dissipation effect of the inductor 500.

[0196] The first baffle 910 and the second baffle 920 are respectively used to cover the gaps between the circuit board 600 and the first side plate 130 and the second side plate 140, so as to prevent the air flowing in the gap between the circuit board 600 and the top plate 150 along the first direction X from directly passing through the gaps between the circuit board 600 and the first side plate 130 and the gaps between the circuit board 600 and the second side plate 140 to flow to the gap between the circuit board 600 and the bottom plate 160, and the air does not pass through the front end of the circuit board 600 close to the front plate 110 along the first direction X, resulting in poor heat dissipation effect of the front heating device. In the present application, by setting the first baffle 910 and the second baffle 920, the air flowing above the circuit board 600 needs to flow to the bottom of the circuit board 600 through the gap between the circuit board 600 and the front plate 110, and the air flows within the entire range of the housing 100, which is more conducive to the heat dissipation of various heating devices by the air-to-liquid heat exchanger 400.

[0197] The flow pattern of air circulation passing through the bottom and top of the circuit board 600 can be applied to two different placement positions of the air-to-liquid heat exchanger 400. That is, when the air-to-liquid heat exchanger 400 is located between the connector 200 and the circuit board 600 along the first direction X or when the projection of the air-to-liquid heat exchanger 400 coincides with the projection of the circuit board 600 along the third direction Z, the air circulation passing through the bottom and top of the circuit board 600 can be used to dissipate heat. Among them, when the air-to-liquid heat exchanger 400 is located between the connector 200 and the circuit board 600 along the first direction X, the multiple heat exchange plates 410 are arranged at intervals along the first direction X. When the projection of the air-to-liquid heat exchanger 400 along the third direction Z coincides with the projection of the circuit board 600, the multiple heat exchange plates 410 are arranged at intervals along the third direction Z.

[0198] See also Fig. 20 In a possible implementation, when the third baffle 930 is connected to the circuit board 600 and the rear plate 120 on both sides along the first direction X, the projection of the air-to-liquid heat exchanger 400 along the third direction Z coincides with the projection of the circuit board 600 along the third direction Z.

[0199] When the projection of the air-to-liquid heat exchanger 400 along the third direction Z coincides with the projection of the circuit board 600 along the third direction Z, the air inside the housing 100 may also adopt a flow pattern in which the air circulates through the circuit board 600 and both sides of the circuit board 600 (combined with Fig. 20 and Fig.18 That is, the first baffle plate 910, the second baffle plate 920 and the third baffle plate 930 can guide the air to flow in the gap between the circuit board 600 and the bottom plate 160 along the first direction X from the front plate 110 toward the rear plate 120, and then flow in the gap between the circuit board 600 and the first side plate 130 and the gap between the circuit board 600 and the second side plate 140 along the first direction X from the rear plate 120 toward the front plate 110.

[0200] The third baffle 930 is used to cover the gap between the rear plate 120 and the circuit board 600 to prevent the air from flowing directly toward the top plate 150 and entering the gap between the circuit board 600 and the top plate 150 when flowing in the gap between the circuit board 600 and the bottom plate 160 along the first direction X, resulting in poor heat dissipation effect of the inductor 500 and the components below the circuit board 600. After the third baffle 930 is set, the third baffle 930 limits the air from flowing under the circuit board 600. At this time, the air first passes through the inductor 500 and flows toward the rear plate 120 along the first direction X, and then flows toward the first side plate 130 and the second side plate 140, which is conducive to improving the heat dissipation effect of the inductor 500 and ensuring the heat dissipation effect of other heat-generating components.

[0201] The first baffle 910 and the second baffle 920 are respectively used to cover the gap between the circuit board 600 and the first side plate 130 and the second side plate 140, so as to prevent the air flowing in the gap between the circuit board 600 and the bottom plate 160 along the first direction X from directly passing through the gap between the circuit board 600 and the first side plate 130 and the gap between the circuit board 600 and the second side plate 140 to flow to the gap between the circuit board 600 and the top plate 150, and the air circulation path is short, resulting in poor heat dissipation effect of the heating device. In the present application, by setting the first baffle 910 and the second baffle 920, the air flows under the circuit board 600 and circulates through the circuit board 600 and the two sides of the circuit board 600 along the second direction Y, which is conducive to the heat dissipation of various heating devices by the air-to-liquid heat exchanger 400. In this heat dissipation mode. Since the air mainly flows along the first direction X, the ventilation direction of the air-to-liquid heat exchanger 400 is set in the first direction X, that is, the multiple heat exchange plates 410 are arranged at intervals along the third direction Z, which is conducive to the air-to-liquid heat exchanger 400 to achieve a better heat dissipation effect.

[0202] See also Figure 1The present application also provides an energy storage system, which includes an energy storage cabinet 1, a battery pack 11 and the power module 10 as described above, the battery pack 11 is connected to the power module 10 and supplies power to the load 2 through the power module 10, the energy storage cabinet 1 also includes a cabinet 12, a cabinet door 13 and a cooling assembly 14, the cabinet door 13 is used to close the cabinet 12, the power module 10 and the battery pack 11 are stacked and arranged inside the cabinet 12, the front plate 110 of the shell 100 of the power module 10 faces the cabinet door 13, and the cooling assembly 14 is connected to the cold plate inlet 211, the heat exchanger inlet 213, the cold plate outlet 212 and the heat exchanger outlet 214 of the connector 200 through two liquid cooling pipes 15.

[0203] The power module and energy storage system provided in the embodiments of the present application are introduced in detail above. Specific examples are used in this article to illustrate the principles and embodiments of the present application. The description of the above embodiments is only used to help understand the method of the present application and its core idea; at the same time, for general technical personnel in this field, according to the idea of ​​the present application, there will be changes in the specific embodiments and application scope. In summary, the content of this specification should not be understood as a limitation on the present application.

Claims

1. A power module, characterized in that: The power module includes a shell and a connector, an inductor, a cold plate and an air-liquid heat exchanger. The connector, the air-liquid heat exchanger, the cold plate and the inductor are sequentially arranged inside the shell along a first direction. The shell includes a front plate and a rear plate. The front plate and the rear plate are arranged relative to each other along the first direction. The connector is arranged between the air-liquid heat exchanger and the front plate along the first direction. The connector includes a cold plate inlet, a heat exchanger inlet, a cold plate outlet and a heat exchanger outlet, wherein: Along a second direction, the cold plate inlet is arranged adjacent to the cold plate outlet, the heat exchanger inlet is arranged adjacent to the heat exchanger outlet, and the second direction is perpendicular to the first direction; Along a third direction, one of the cold plate inlet and the cold plate outlet is arranged adjacent to the heat exchanger inlet, and the other of the cold plate inlet and the cold plate outlet is arranged adjacent to the heat exchanger outlet, and the third direction is perpendicular to the second direction and the first direction.

2. The power module according to claim 1, characterized in that: The housing includes a first side plate and a second side plate, the first side plate and the second side plate are arranged opposite to each other along the second direction, the connector, the air-to-liquid heat exchanger, the cold plate, and the inductor are arranged between the first side plate and the second side plate, wherein: Along the second direction, the distance between the connector and the first side panel is smaller than the distance between the connector and the second side panel, the distance between the connector and the first side panel is smaller than the distance between the air-liquid heat exchanger and the first side panel, the distance between the connector and the second side panel is larger than the distance between the air-liquid heat exchanger and the second side panel, and at least one of the distance between the cold plate inlet and the cold plate outlet or the distance between the heat exchanger inlet and the heat exchanger outlet is smaller than the distance between the air-liquid heat exchanger and the first side panel.

3. The power module according to claim 1, characterized in that: The connector includes a first sub-cavity and a second sub-cavity, wherein the first sub-cavity is adjacent to the second sub-cavity and arranged at an interval along the second direction, the first sub-cavity is used to connect the cold plate inlet and the heat exchanger inlet, and the second sub-cavity is used to connect the cold plate outlet and the heat exchanger outlet.

4. The power module according to claim 1, characterized in that: The connector includes a first sub-cavity, a second sub-cavity and a third sub-cavity. The first sub-cavity and the third sub-cavity are adjacent to each other and arranged at intervals along the third direction. The first sub-cavity or the third sub-cavity is adjacent to the second sub-cavity and arranged at intervals along the second direction. The first sub-cavity is used to connect the heat exchanger inlet, the second sub-cavity is used to connect the heat exchanger outlet and the cold plate inlet, and the third sub-cavity is used to connect the cold plate outlet.

5. The power module according to claim 3, characterized in that: The connector further includes a second cavity and a drainage hole. The second cavity is adjacent to the first sub-cavity or the second sub-cavity and arranged at intervals along the first direction. The drainage hole is connected to the second cavity.

6. The power module according to claim 5, characterized in that: The connector includes a first cover plate, a connection seat, a second cover plate and a partition plate. The first cover plate and the second cover plate are respectively arranged on both sides of the connection seat along the first direction, and are respectively surrounded by both sides of the connection seat to form a first cavity and a second cavity. The partition plate is located in the first cavity and is used to separate the first cavity into the first sub-cavity and the second sub-cavity. The connection seat includes the cold plate inlet, the cold plate outlet, the heat exchanger inlet and the heat exchanger outlet. The cold plate inlet, the cold plate outlet, the heat exchanger inlet and the heat exchanger outlet penetrate the connection seat along the first direction; wherein: The first cover plate comprises a liquid inlet hole and a liquid outlet hole, the liquid inlet hole and the liquid outlet hole respectively penetrate the first cover plate along the first direction, the liquid inlet hole is used to connect to at least one of the cold plate inlet or the heat exchanger inlet, and the liquid outlet hole is used to connect to at least one of the cold plate outlet or the heat exchanger outlet; The second cover plate includes a first opening, a second opening, a third opening and a fourth opening, and the first opening, the second opening, the third opening and the fourth opening respectively penetrate the second cover plate along the first direction, and along the first direction, the first opening, the second opening, the third opening and the fourth opening are respectively arranged opposite to the cold plate inlet, the cold plate outlet, the heat exchanger inlet and the heat exchanger outlet.

7. The power module according to claim 6, characterized in that: The power module includes a liquid inlet connector and a liquid outlet connector, the liquid inlet connector and the liquid outlet connector are fixed to the first cover plate and are connected to the liquid inlet hole and the liquid outlet hole respectively, the front plate includes a through hole, and the through hole passes through the front plate along the first direction, wherein: Along the first direction, the projection of the through hole covers the projection of the liquid inlet joint and the projection of the liquid outlet joint, and the projection of the first cover plate covers the projection of the through hole; Along the third direction, the length of the liquid inlet joint and the liquid outlet joint is greater than the distance between the first cover plate and the front plate.

8. The power module according to claim 1, characterized in that: The power module also includes a circuit board and a plurality of power tubes. The shell includes a top plate and a bottom plate. The top plate and the bottom plate are arranged relative to each other along the third direction. The circuit board is arranged between the top plate and the bottom plate at intervals. The plurality of power tubes and the cold plate are arranged on a side of the circuit board facing the bottom plate. The cold plate is in contact with at least one of the power tubes along the first direction.

9. The power module according to claim 8, characterized in that: The power module includes a plurality of connected cold plates, the plurality of cold plates are arranged at intervals along the first direction, the plurality of power tubes include a plurality of columns of power tubes arranged at intervals along the first direction, each column of power tubes includes a plurality of power tubes arranged in sequence along the second direction, and the plurality of power tubes in each column of power tubes are in contact with the same cold plate.

10. The power module according to claim 9, characterized in that: At least one of the cold plates is arranged between two adjacent columns of the power tubes. The at least one cold plate includes two sides along the first direction. One side of the at least one cold plate is in contact with the multiple power tubes in one column of the power tubes, and the other side of the at least one cold plate is in contact with the multiple power tubes in another column of the power tubes.

11. The power module according to claim 8, characterized in that: Along the third direction, the distance between the air-to-liquid heat exchanger and the top plate is greater than the distance between the cold plate and the top plate, the distance between at least one of the cold plate inlet or the cold plate outlet and the top plate is smaller than the distance between the air-to-liquid heat exchanger and the top plate, and the distance between at least one of the heat exchanger inlet or the heat exchanger outlet and the bottom plate is smaller than the distance between the cold plate and the bottom plate.

12. The power module according to claim 8, characterized in that: The air-liquid heat exchanger includes a plurality of interconnected heat exchange plates. When the air-liquid heat exchanger is located between the connector and the circuit board along the first direction, and the air-liquid heat exchanger is arranged between the top plate and the bottom plate at intervals along the third direction, the plurality of heat exchange plates are arranged at intervals along the first direction; when the projection of the air-liquid heat exchanger along the third direction coincides with the projection of the circuit board along the third direction, and the projection of the air-liquid heat exchanger along the third direction is staggered with the projection of the cold plate along the third direction, the plurality of heat exchange plates are arranged at intervals along the third direction.

13. The power module according to claim 8, characterized in that: The power module includes a plurality of the inductors and a plurality of fans, wherein the plurality of inductors are arranged at intervals along the second direction, and the plurality of fans are arranged at intervals along the second direction; along the first direction, the fans are located between the inductors and the circuit board.

14. The power module according to claim 13, characterized in that: The power module also includes a first baffle, a second baffle and a third baffle, the first baffle and the second baffle are respectively located on both sides of the circuit board along the second direction, and the third baffle is located between the top plate and the fan along the third direction; the first baffle is respectively connected to the circuit board and the first side plate on both sides along the second direction, and the second baffle is respectively connected to the circuit board and the second side plate on both sides along the second direction; when the third baffle is respectively connected to the circuit board and the inductor on both sides along the first direction, the air-liquid heat exchanger is located between the connector and the circuit board along the first direction or the projection of the air-liquid heat exchanger along the third direction coincides with the projection of the circuit board along the third direction; when the third baffle is respectively connected to the circuit board and the back plate on both sides along the first direction, the projection of the air-liquid heat exchanger along the third direction coincides with the projection of the circuit board along the third direction.

15. An energy storage system, characterized in that: The energy storage system includes a cooling component, a battery pack and a power module as described in any one of claims 1 to 14, the battery pack is connected to the power module and supplies power to the load through the power module, and the cooling component is connected to the cold plate inlet, the heat exchanger inlet, the cold plate outlet and the heat exchanger outlet through a liquid cooling pipe.

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