Heat dissipation structure, high-voltage distribution box and electric automobile

Abstract

The invention belongs to the technical field of electric vehicles, and discloses a heat dissipation structure, a high-voltage distribution box and an electric vehicle. The heat dissipation structure comprises a heating source and a heat dissipation cover, wherein the heating source is provided with a heat dissipation surface; the VC vapor chamber is attached to the heat dissipation surface; and the heat conduction piece is connected with the heating source. By means of the innovative design, the problems that in the prior art, the heat dissipation effect is poor, the space utilization rate is low, and safety and reliability are insufficient are solved. By means of the design, the heat dissipation performance is improved, space utilization is optimized, safety and reliability are improved, and meanwhile production efficiency and cost control are both considered. Through the comprehensive improvement, the heat dissipation device is particularly suitable for the fields such as new energy automobiles with high requirements for heat dissipation performance and space utilization rate, and has wide application prospects.

Description

Technical Field

[0001] The invention relates to the technical field of electric vehicles, and in particular to a heat dissipation structure, a high-voltage distribution box and an electric vehicle. Background Art

[0002] With the rapid development of new energy vehicle technology, the performance and reliability of high-voltage power distribution systems have attracted more and more attention. There are some patent solutions involving high-voltage distribution boxes in the prior art, such as CN209402918U and CN208209321U. However, these solutions have some limitations:

[0003] 1. Poor heat dissipation. The existing high-voltage distribution box design often ignores the effective heat dissipation of key components (such as high-voltage contactor contacts), which leads to overheating problems in scenarios such as high-power charging, affecting the current carrying capacity and service life of the system.

[0004] 2. Low space utilization. The layout of traditional high-voltage distribution boxes is usually loose, and space optimization is not fully considered, resulting in a large overall volume, which is not conducive to the layout of the entire vehicle. This loose layout is mainly due to two reasons: First, due to the lack of an effective cooling design solution, the dense layout of heat-generating components will lead to heat accumulation, which may cause overheating problems. Therefore, the traditional design solution has a large layout gap to allow natural heat dissipation; secondly, in order to reduce heat generation, designers often increase the cross-sectional area of ​​copper bars or wires to reduce resistance and heat generation. However, both methods will cause the BDU (battery distribution unit) to take up more space. Although this design has certain advantages in heat dissipation and safety, it has become less optimized in modern designs with increasingly tight vehicle space, affecting the overall space utilization efficiency.

[0005] 3. Safety needs to be improved. Some designs do not fully consider safety hazards in extreme situations, such as secondary damage that may be caused by failure of high-voltage contactors. Traditional cooling solutions cannot cool down when power supply is abnormal, which further exacerbates potential safety risks. When a high-voltage system fails, if the cooling system fails due to power outage, it may cause the temperature to rise rapidly, increasing the possibility of fire or other safety accidents. This design limitation not only affects the reliability of the system under abnormal conditions, but also highlights the shortcomings of traditional high-voltage distribution systems in comprehensive safety assurance, which urgently needs to be improved and optimized in future designs.

[0006] 4. Low production efficiency. Components in existing solutions often need to be installed separately, which increases the production and assembly process and complexity.

[0007] 5. Insufficient reliability. The connection method of components in some designs may become loose after long-term use or in a vibration environment, affecting the overall stability and reliability.

[0008] Although CN114360965A proposes some improvement schemes, such as using thermal pads and liquid cooling plates for heat dissipation, and integrating the busbar with the housing, there is still room for further optimization. For example, how to further improve space utilization while ensuring heat dissipation effect, and how to better balance production efficiency, reliability and cost, etc., still need to be explored.

[0009] In the field of new energy power batteries, end consumers have put forward requirements for long driving range and faster charging speed, and the new energy 800V high-voltage platform has come into being; at the same time, in order to improve the integration efficiency of the three-electric system and expand the passenger space, the functions of the distribution box are becoming more and more complete, and the number of corresponding high-voltage components is increasing. The above two factors of battery high voltage and battery integration mean that the heat dissipation and cooling of the high-voltage distribution box has gradually become a key design. The main forms of existing technical solutions are: ① The high-voltage distribution box is cooled separately through a liquid cooling plate or a cooler, or shared with the whole package; ② The high-voltage distribution box is cooled by air supply through a heat dissipation component including a fan, a heat sink, and a heat dissipation cover. However, whether it is liquid cooling or air cooling, it is necessary to provide additional power to the cooling device for cooling and heat exchange. Liquid cooling also needs to transport coolant or refrigerant through a circulating water pump to work, which will cause power loss and affect the stability and constancy of the working temperature. Summary of the invention

[0010] In order to solve or partially solve the problems existing in the related art, the purpose of the present invention is to provide a heat dissipation structure, a high-voltage distribution box and an electric vehicle, which have better heat dissipation performance, higher space utilization, better safety and reliability, while taking into account production efficiency and cost control.

[0011] To achieve the above objectives, in a first aspect, the present invention provides a heat dissipation structure, comprising:

[0012] A heat source, the heat source having a heat dissipation surface;

[0013] VC heat spreader, attached to the heat dissipation surface;

[0014] A heat conducting member is connected to the heat source.

[0015] When the heat dissipation structure is working, the heat generated by the heat source (such as a relay) is first transferred to the VC heat spreader through the heat dissipation surface. The VC heat spreader has excellent thermal conductivity and can quickly and evenly disperse heat. The heat conductor is directly connected to the heat source, providing another transfer path for heat, further enhancing the heat dissipation effect.

[0016] In some embodiments of the present invention, the heat dissipation surface is coated with insulating thermally conductive adhesive.

[0017] When insulating thermal conductive adhesive is applied to the heat dissipation surface, the heat conduction efficiency can be improved while ensuring electrical insulation.

[0018] In some embodiments of the present invention, the VC vapor chamber is coated with a thermally conductive insulating film.

[0019] The VC heat spreader is covered with a thermally conductive insulating film, which not only ensures heat dissipation performance but also improves safety.

[0020] In some embodiments of the present invention, the heat conducting member includes a connecting portion connected to the heat source and a heat conducting portion attached to the VC heat spreader.

[0021] In some embodiments of the present invention, the connecting portion and the heat conducting portion are integrally formed by using a copper plate.

[0022] The heat-conducting parts formed by integrally processing the copper plate not only improve the heat conduction efficiency, but also simplify the production process and improve the production efficiency and reliability.

[0023] In some embodiments of the present invention, the heat-conducting portion is coated with insulating heat-conducting glue.

[0024] The heat conducting part is coated with insulating thermal conductive glue to further optimize the heat conduction effect.

[0025] In some embodiments of the present invention, the heat conductive member includes a first heat conductive member, the connecting portion of the first heat conductive member simultaneously connects two adjacent heat sources, and the heat conductive portion of the first heat conductive member is bent from the surface where the connecting portion of the first heat conductive member is located and fits with the bottom surface of the VC heat spreader.

[0026] In some embodiments of the present invention, the heat conductive member includes a second heat conductive member, the connecting portion of the second heat conductive member is connected to a heat source, and the heat conductive portion of the second heat conductive member is bent from the surface where the connecting portion of the second heat conductive member is located and fits into the bottom surface of the VC heat spreader; the second heat conductive member also includes a vertical portion, and the numerical portion is bent reversely from the surface where the heat conductive portion of the second heat conductive member is located toward the connecting portion of the second heat conductive member.

[0027] The design of the heat conducting member, especially the structure of the first heat conducting member and the second heat conducting member, enables the heat dissipation structure to adapt to different space layouts, thereby improving space utilization.

[0028] In some embodiments of the present invention, a top surface of the VC vapor chamber is provided with heat dissipation fins.

[0029] The heat dissipation fins installed on the top surface of the VC heat spreader increase the heat dissipation area and further improve the heat dissipation performance.

[0030] In a second aspect, the present invention provides a high-voltage distribution box, which includes the heat dissipation structure in the above embodiment.

[0031] In a third aspect, the present invention provides an electric vehicle, which includes the high-voltage distribution box in the above embodiment.

[0032] The beneficial effects of the present invention are:

[0033] 1. Significantly improved heat dissipation performance: The heat dissipation efficiency is greatly improved through VC heat spreader and multi-path heat conduction design.

[0034] 2. High space utilization: The flexible design of heat conduction parts enables the heat dissipation structure to be arranged compactly to adapt to various space restrictions.

[0035] 3. Good safety and reliability: The use of insulating thermal conductive materials and coating design ensures electrical safety; the integrated structure improves overall reliability.

[0036] 4. High production efficiency: Component design simplifies the assembly process and improves production efficiency.

[0037] 5. Excellent cost control: Material selection and structural design take cost factors into consideration while ensuring performance.

[0038] The present invention adopts a VC heat spreader as an efficient heat sink to quickly dissipate heat and cool down the heating components and copper bars in the high-voltage distribution box. In the case of extremely high temperature and no power supply, the high-voltage distribution box can still be continuously dissipated and cooled down.

[0039] The thermal conductivity of copper is 401W / m·k, while the VC heat spreader can reach 20,000~10,000W / m·k, or even higher. Therefore, the VC heat spreader acts as an efficient heat sink to quickly dissipate heat and cool down the heating components and heating copper bars in the high-voltage distribution box. Secondly, the heat dissipation process does not require power to the cooling structure, reducing power and energy loss. In the case of extreme high temperatures and no power, the high-voltage distribution box can still be continuously cooled and cooled, which improves the reliability and service life of the components in the distribution box. At the same time, in terms of manufacturing technology, the VC heat spreader theoretically has no size limit, and the thickness is generally 2.5~4mm, which will not take up too much space in the high-voltage distribution box.

[0040] The heat dissipation structure, high-voltage distribution box and electric vehicle provided by the present invention solve the problems of poor heat dissipation effect, low space utilization, insufficient safety and reliability in the prior art through innovative design. The design not only improves the heat dissipation performance, but also optimizes the space utilization, improves the safety and reliability, and takes into account the production efficiency and cost control. This comprehensive improvement makes the present invention particularly suitable for fields such as new energy vehicles that have high requirements for heat dissipation performance and space utilization, and has broad application prospects. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] In order to more clearly illustrate the technical solutions of the embodiments disclosed in the present invention, the drawings of the embodiments will be briefly introduced below. These drawings are only used for illustrative purposes and are not intended to limit the protection scope of the present invention.

[0042] Figure 1 It is a schematic diagram of the assembly of the heat dissipation structure of the present invention;

[0043] Figure 2 is an exploded schematic diagram of the heat dissipation structure of the present invention;

[0044] Figure 3 It is a schematic diagram of the structure of the VC heat spreader of the present invention. DETAILED DESCRIPTION

[0045] The technical solution of the present invention (including the preferred technical solution) is further described in detail below by means of the accompanying drawings and by listing some optional embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0046] Example 1

[0047] like Figure 1 and Figure 3 As shown, the present invention provides a heat dissipation structure, including a heat source 100, a VC heat spreader 200 and a heat conductor 300. The heat dissipation structure can be applied to a high-voltage distribution box to dissipate heat generated by heating elements such as high-voltage contactors and relays.

[0048] The heat source 100 may be a relay, a high voltage contactor or other components that generate a large amount of heat during operation. The heat source 100 has a heat dissipation surface 110, which is the main heat dissipation part of the heat source 100. In order to improve the heat dissipation efficiency, the heat dissipation surface 110 may be coated with a layer of insulating thermal conductive adhesive 120. The insulating thermal conductive adhesive 120 can both ensure electrical insulation and improve heat conduction efficiency, and is an ideal interface material.

[0049] VC vapor chamber 200 is attached to heat dissipation surface 110. VC vapor chamber 200 is a highly efficient heat dissipation component that transfers heat by utilizing the evaporation and condensation cycle of the working liquid in a vacuum chamber, thereby achieving rapid heat conduction and heat diffusion. Compared with traditional heat pipe technology, VC vapor chamber 200 can diffuse heat on a two-dimensional plane and provide more uniform heat distribution.

[0050] The heat absorbed by the bottom of the VC heat spreader 20 quickly vaporizes the working fluid in the vacuum sealed chamber, and moves to the upper condensation area through the internal capillary structure. After exchanging heat with the outside, it condenses into liquid and refluxes, and the cycle repeats.

[0051] In this embodiment, the VC vapor chamber 200 is covered by a thermally conductive insulating film 210. The thermally conductive insulating film 210 can not only ensure the heat dissipation performance of the VC vapor chamber 200, but also improve the safety of the entire heat dissipation structure and prevent possible electrical failures.

[0052] The heat conducting member 300 is connected to the heat source 100, providing another path for heat transfer. Figure 2 As shown, the heat conducting member 300 includes a connecting portion 310 and a heat conducting portion 320. The connecting portion 310 is directly connected to the heat source 100, and the heat conducting portion 320 is attached to the VC heat spreader 200. This design not only enhances the heat dissipation effect, but also improves the stability of the entire structure.

[0053] In this embodiment, the connection part 310 and the heat conducting part 320 are integrally formed by copper plate. Copper has excellent thermal conductivity, and the integrally formed design simplifies the production process and improves production efficiency and reliability. In addition, the heat conducting part 320 can be coated with insulating thermal conductive glue 120 to further optimize the heat conduction effect.

[0054] Example 2

[0055] Based on Example 1, this example provides an improved heat conducting element design. Figure 2 As shown, the heat conducting member includes a first heat conducting member 400. The connecting portion 410 of the first heat conducting member 400 simultaneously connects two adjacent heat sources 100. The heat conducting portion 420 of the first heat conducting member 400 is bent from the surface where the connecting portion 410 is located and is attached to the bottom surface of the VC heat spreader 200.

[0056] The advantages of this design are:

[0057] 1. One heat conductor can serve two heat sources at the same time, reducing the number of parts and simplifying the structure.

[0058] 2. The bending design increases the length of the heat conduction path, which is conducive to the full diffusion of heat.

[0059] 3. The design of fitting with the bottom surface of the VC heat spreader 200 utilizes the entire surface area of ​​the VC heat spreader 200, thereby improving the heat dissipation efficiency.

[0060] Example 3

[0061] Based on Embodiment 1 or 2, this embodiment provides another design of a heat conducting member. Figure 2As shown, the heat conducting member includes a second heat conducting member 500. The connecting portion 510 of the second heat conducting member 500 is connected to a heat source 100, and the heat conducting portion 520 is bent from the surface where the connecting portion 510 is located and is attached to the bottom surface of the VC heat spreader 200.

[0062] The second heat conducting member 500 further includes a vertical portion 530. The vertical portion 530 is bent in the opposite direction from the heat conducting portion 520 to the connecting portion 510. The advantages of this design include:

[0063] 1. The vertical portion 530 increases the heat dissipation area and further improves the heat dissipation effect.

[0064] 2. The reverse bending design makes the entire heat conductor more compact, which is conducive to achieving the best heat dissipation effect in a limited space.

[0065] 3. This structure also increases the mechanical strength of the entire heat dissipation structure and improves reliability.

[0066] In Examples 2 and 3, in addition to the direct contact heat dissipation method, heat is transferred to the VC heat spreader 200 through the heat conducting portion 320 on the heat conducting member 300 to achieve the purpose of heat dissipation. Therefore, other heat conducting media can be installed inside the high-voltage distribution box or copper busbar to conduct heat to the VC heat spreader 200 to flexibly meet the needs of device layout.

[0067] Example 4

[0068] Based on any of the above embodiments, in this embodiment, a heat dissipation fin 600 is disposed on the top surface of the VC heat spreader 200. Figure 1 and Figure 2 As shown. For areas or contacts with severe heat generation, heat dissipation fins 600 can be installed in a stacked manner to increase the heat dissipation area for efficient heat dissipation, and to dissipate heat more quickly to the surrounding environment. The heat dissipation fins 600 can be made of a material with good thermal conductivity and light weight, such as aluminum alloy, and their shape and density can be optimized according to the specific application scenario.

[0069] Example 5

[0070] Based on the above heat dissipation structure, this embodiment provides a high-voltage distribution box. The high-voltage distribution box includes a housing, and the heat dissipation structure described in any of the above embodiments is arranged in the housing. The relay is installed in the housing as a heat source 100, and the VC heat spreader 200 and the heat conductor 300 are arranged in the manner of the above embodiments.

[0071] In addition, the high-voltage distribution box may also include other functional components, such as circuit breakers, fuses, connectors, etc. The arrangement of these components should take into account the position of the heat dissipation structure to achieve optimal space utilization and heat dissipation effect.

[0072] Example 6

[0073] This embodiment provides an electric vehicle. The electric vehicle includes a body, a power system and an electric control system. The electric control system includes the high-voltage distribution box described in the above embodiment 5.

[0074] In the electric vehicle, the high-voltage distribution box plays the role of connecting the power battery, the motor controller and other high-voltage electrical equipment. The heat dissipation structure of the present invention ensures that the high-voltage distribution box can maintain good heat dissipation performance under various working conditions, thereby improving the reliability and safety of the entire vehicle.

[0075] When the heat dissipation structure of the present invention is working, the heat generated by the heat source 100 (such as a relay) is transferred and dissipated through multiple paths:

[0076] 1. Direct conduction: Heat is directly transferred to the VC heat spreader 200 through the heat dissipation surface 110. The use of insulating thermal conductive glue improves the efficiency of this process.

[0077] 2. Auxiliary conduction: The heat is transferred to the VC heat spreader 200 through the heat conductor 300, providing an additional transfer path for the heat.

[0078] 3. Heat diffusion: The phase change medium inside the VC heat spreader 200 quickly and evenly distributes the heat to the entire board surface.

[0079] 4. Air convection: The heat sink 600 transfers heat to the surrounding air and dissipates the heat into the environment through natural convection or forced convection (if there is a fan).

[0080] This multi-path, multi-level heat dissipation design has the following advantages:

[0081] 1. Efficient heat dissipation: The use of multiple heat transfer paths and VC heat sinks significantly improves heat dissipation efficiency.

[0082] 2. Uniform heat dissipation: VC heat spreader can quickly and evenly disperse heat to avoid local overheating.

[0083] 3. Space optimization: The flexible design of heat conduction parts enables the heat dissipation structure to adapt to various space restrictions and improve space utilization.

[0084] 4. Safe and reliable: Insulation design and the use of thermal conductive materials ensure electrical safety; the integrated structure improves overall reliability.

[0085] 5. Production efficiency: Simplified component design and one-piece molding process improve production efficiency.

[0086] 6. Cost control: While ensuring performance, cost factors are also taken into consideration in material selection and structural design.

[0087] 7. Strong adaptability: The heat dissipation structure can be flexibly adjusted and optimized according to specific application requirements.

[0088] Those skilled in the art will readily appreciate that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, combinations, replacements, improvements, etc. made within the spirit and principles of the present invention are included within the protection scope of the present invention.

Claims

1. A heat dissipation structure, characterized in that: include: A heat source, the heat source having a heat dissipation surface; VC heat spreader, attached to the heat dissipation surface; A heat conducting member is connected to the heat source.

2. The heat dissipation structure according to claim 1, characterized in that: The heat dissipation surface is coated with insulating thermal conductive glue; the VC heat spreader is covered with a thermal conductive insulating film.

3. The heat dissipation structure according to claim 1, characterized in that: The heat conducting member includes a connection portion connected to the heat source and a heat conducting portion attached to the VC heat spreader.

4. The heat dissipation structure according to claim 3, characterized in that: The connecting part and the heat conducting part are integrally formed by copper plates.

5. The heat dissipation structure according to claim 4, characterized in that: The heat-conducting part is coated with insulating heat-conducting glue.

6. The heat dissipation structure according to claim 3, 4 or 5, characterized in that: The heat conducting member includes a first heat conducting member, a connecting portion of the first heat conducting member simultaneously connects two adjacent heat sources, and the heat conducting portion of the first heat conducting member is bent from the surface where the connecting portion of the first heat conducting member is located and then adhered to the bottom surface of the VC heat spreader.

7. The heat dissipation structure according to claim 6, characterized in that: The heat conductor includes a second heat conductor, the connecting portion of the second heat conductor is connected to a heat source, the heat conductor of the second heat conductor is bent from the surface where the connecting portion of the second heat conductor is located and fits with the bottom surface of the VC heat spreader; the second heat conductor also includes a vertical portion, the numerical portion is bent in reverse from the surface where the heat conductor of the second heat conductor is located to the connecting portion of the second heat conductor.

8. The heat dissipation structure according to claim 1 or 2 or 3 or 4 or 5 or 7, characterized in that: The top surface of the VC heat spreader is provided with heat dissipation fins.

9. A high voltage distribution box, characterized in that: The high-voltage distribution box comprises the heat dissipation structure according to any one of claims 1 to 8.

10. An electric vehicle, characterized in that: The electric vehicle comprises the high-voltage distribution box according to claim 9.

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