High-power-density new energy automobile charger with efficient heat dissipation

Abstract

The invention relates to the technical field of new energy automobile charging equipment, in particular to a high-power-density new energy automobile charger with efficient heat dissipation. The invention relates to a filter module which comprises a shell assembly, a circuit mainboard, a plurality of aluminum substrate assemblies and a filter plate assembly, the shell assembly comprises a shell side wall and a bottom plate, a plurality of cavities are defined, the aluminum substrate assemblies and the circuit mainboard are electrically connected and arranged on the shell side wall, and the filter plate assembly is arranged in the cavities and is separated from the aluminum substrate assemblies through the shell side wall. By optimizing the heat dissipation design and the structural layout, the heat dissipation efficiency and the power density of the charger are improved, and the stability and the reliability of the charger under a high load are ensured.

Description

Technical Field

[0001] The present application relates to the technical field of new energy vehicle charging equipment, and in particular to a high-power density new energy vehicle charger with efficient heat dissipation. Background Art

[0002] With the rapid development of the new energy vehicle industry, charging safety and technological progress have become particularly important. As one of the core components of new energy vehicles, the on-board charger is responsible for safely and quickly converting the AC power on the charging pile into the high-voltage DC power required by the vehicle battery, which is crucial to ensuring the normal operation of the vehicle. In recent years, with the rapid growth of the electric vehicle market, the demand for on-board chargers has also increased, promoting technological innovation and development in this field.

[0003] In the existing technology, in order to cope with the challenges faced by on-board chargers, the following measures are usually taken to improve their performance and reliability. First, by optimizing the circuit design, reducing the number and complexity of circuit components, thereby reducing the volume and weight of the charger; second, using high-performance heat dissipation materials and structures, such as heat sinks, cooling fans, etc., to enhance the heat dissipation effect; third, introducing advanced electromagnetic compatibility design to reduce interference between various electronic components and ensure the stability and safety of the system. In addition, some manufacturers have further improved the efficiency and durability of chargers by improving manufacturing processes and material selection.

[0004] However, although the above method has improved the performance of the on-board charger to a certain extent, there are still obvious shortcomings. The first is the problem of volume and weight. The existing chargers have a large number of circuit components integrated inside, resulting in a large overall volume, which makes it difficult to meet the requirements of lightweight and miniaturization. Secondly, the heat dissipation capacity is insufficient. Especially in high-power density application scenarios, a large amount of heat will be generated when the power devices are powered on. If it cannot be dissipated in a timely and effective manner, the charger will be derated or even shut down. Finally, there is the problem of electromagnetic interference. The signal interference between the electronic components will affect the stability and reliability of the charger, which is not conducive to its long-term use. Therefore, there is an urgent need for a new energy vehicle charger that can achieve miniaturization, high integration and good electromagnetic compatibility while maintaining efficient heat dissipation. Summary of the invention

[0005] The purpose of this application is to provide a high-power density new energy vehicle charger with efficient heat dissipation.

[0006] The above technical objectives of the present application are achieved through the following technical solutions: a high-power density new energy vehicle charger with efficient heat dissipation, comprising: A shell assembly, the shell assembly comprising a shell side wall and a bottom plate, the shell side wall and the bottom plate together form a plurality of cavities; A circuit mainboard is arranged on the housing assembly, and a power device is electrically connected to the circuit mainboard; A plurality of aluminum substrate assemblies are arranged on the side wall of the housing; the aluminum substrate assemblies are electrically connected to the circuit main board; A filter board assembly is arranged in the cavity to form a filter cavity. The filter board assembly is electrically connected to the circuit main board. The filter board assembly is separated from the aluminum substrate assembly by the shell side wall.

[0007] By adopting the above technical solution, multiple cavities are formed through the design of the side wall and bottom plate of the shell, and each aluminum substrate assembly and the circuit main board are closely connected to ensure that the heat can be quickly transferred to the shell and taken away by the liquid cooling plate, which significantly improves the heat dissipation capacity of the charger. A highly integrated circuit board design is adopted to reasonably distribute the power devices, aluminum substrate assemblies and filter board assemblies inside the shell, making full use of the limited space, improving the power density of the charger, and reducing the volume for easy assembly and maintenance. By placing the filter board assembly in an independent cavity and separating it from the aluminum substrate assembly, signal interference between components is effectively avoided, the electromagnetic shielding effect is improved, and the stability and reliability of the charger are guaranteed. The charger shell is made of a material with high thermal conductivity, has high vibration and impact resistance, is suitable for a variety of new energy vehicles, and meets the needs of platform development.

[0008] Optionally, the power device includes a main transformer, a sub-transformer and an electrolytic capacitor.

[0009] By adopting the above technical solution, the main transformer, auxiliary transformer and electrolytic capacitor are the main power devices, which are centrally arranged on the circuit board. The heat is efficiently transferred to the shell through the heat-conducting medium injected into the cavity, thereby significantly improving the heat dissipation capacity and power density of the charger. At the same time, this layout reduces the internal space occupied, improves the overall compactness and integration, and helps to achieve the miniaturization and lightweight of the charger.

[0010] Optionally, the plurality of aluminum substrate assemblies include a first aluminum substrate assembly, a second aluminum substrate assembly and a third aluminum substrate assembly; the first aluminum substrate assembly includes a control board, a connector and a heat dissipation aluminum substrate, the connector is fixedly connected to the control board, connected to the circuit main board through the connector, and the heat dissipation aluminum substrate is connected to the control board through a pin or the connector to form a current path.

[0011] By adopting the above technical solution, the combined design of the control board, connector and heat dissipation aluminum substrate of the first aluminum substrate assembly realizes the effective transmission of power and signals, while enhancing the heat dissipation performance. The control board is connected to the circuit main board through a connector to ensure the stable transmission of electrical signals. The heat dissipation aluminum substrate is connected to the control board through a pin or connector to form a reliable current path, effectively reducing resistance, reducing energy loss, and improving the working efficiency of the charger. In addition, the design of the heat dissipation aluminum substrate can also quickly conduct the heat generated by the MOS switch tube to the side wall of the shell, further improving the heat dissipation effect and extending the service life of the charger.

[0012] Optionally, the first aluminum substrate assembly further includes a plurality of rows of MOS switch tubes electrically connected to the circuit main board, and the plurality of rows of MOS switch tubes are arranged on the heat dissipating aluminum substrate.

[0013] By adopting the above technical solution, multiple rows of MOS switch tubes are added to the first aluminum substrate assembly. These MOS switch tubes are arranged on the heat dissipation aluminum substrate. Through the high thermal conductivity of the heat dissipation aluminum substrate, the large amount of heat energy generated by the MOS switch tube when working is effectively and quickly conducted to the side wall of the shell, and finally taken away through the liquid cooling plate, which significantly improves the heat dissipation capacity of the charger. At the same time, the design of multiple rows of MOS switch tubes makes power transmission more stable, reduces electromagnetic interference, and improves the overall performance and reliability of the charger.

[0014] Optionally, a plurality of copper columns are provided on the heat dissipating aluminum substrate.

[0015] By adopting the above technical solution, a number of copper pillars are provided on the heat dissipation aluminum substrate, which can not only effectively reduce the current transmission impedance between the aluminum substrate and the circuit main board, improve the electrical performance, but also significantly improve the heat dissipation efficiency. As part of the heat conduction path, the copper pillar can quickly transfer the heat generated by the MOS switch tube to the heat dissipation aluminum substrate, and then transfer it to the side wall and bottom plate of the shell through the heat conduction medium, and finally be taken away by the liquid cooling plate, thereby ensuring the stability and reliability of the charger when running at high power.

[0016] Optionally, a heat-conducting medium is filled between the heat-dissipating aluminum substrate and the side wall of the shell.

[0017] By adopting the above technical solution, the contact thermal resistance between the two can be significantly reduced, the heat conduction efficiency can be improved, and the heat dissipation performance of the charger can be effectively enhanced, ensuring the stability and reliability of the internal electronic components in a high temperature environment. At the same time, the application of heat conducting medium also helps to extend the service life of the charger.

[0018] Optionally, the filter plate assembly includes a first filter plate and a second filter plate.

[0019] By adopting the above technical solution, the filter plate assembly includes a first filter plate and a second filter plate, which are respectively arranged in independent cavities inside the shell to form a filter cavity. This design effectively separates the filter plate assembly from the aluminum substrate assembly, avoids signal interference between components, and significantly improves the electromagnetic shielding effect. At the same time, a heat-conducting medium is poured into the filter cavity, and the heat loss of the filter device is quickly transferred to the bottom plate of the shell through the heat-conducting medium, which greatly improves the heat dissipation capacity of the filter plate assembly and enhances the reliability of the electronic components in the charger.

[0020] Optionally, a transformer, a first inductor and a second inductor are further provided in the cavity, and the transformer, the first inductor and the second inductor are provided on the circuit main board and the filter board assembly.

[0021] By adopting the above technical solution, the transformer, the first inductor and the second inductor are arranged in the cavity, and are centrally placed in the cavity filled with a heat-conducting medium, which can quickly conduct heat to the side wall and the bottom plate of the shell, and the liquid cooling plate in contact with the bottom plate quickly completes the heat exchange, thereby significantly improving the heat dissipation capacity and thermal management efficiency of the charger. At the same time, the design of the cavity effectively isolates these magnetic devices from other electronic components, reduces electromagnetic interference, and improves the stability and reliability of the charger.

[0022] Optionally, at least one circuit sub-board is provided on a side of the circuit main board close to the cavity, and the circuit sub-board is electrically connected to the circuit main board.

[0023] By adopting the above technical solution, at least one circuit sub-board is provided on the side of the circuit main board close to the cavity, and the circuit sub-board is electrically connected to the circuit main board. This design makes the circuit layout more compact, effectively utilizes the space in the shell, and improves the power density of the charger. At the same time, through the reasonable distribution of the circuit sub-boards, the length of the signal line is reduced, the signal interference is reduced, and the stability and reliability of the charger are enhanced.

[0024] In summary, this application has at least the following beneficial effects: 1. Through the design of the housing assembly, circuit board, aluminum substrate assembly and filter board assembly, especially the heat-conducting medium between the aluminum substrate assembly and the housing side wall, the heat dissipation capacity of the charger is significantly enhanced, effectively solving the heat dissipation problem in high power density application scenarios; 2. The highly integrated circuit board design and the shell structure with independent cavity avoid signal interference between components, and the isolation and shielding effects are obvious, which improves the electromagnetic compatibility and system stability of the charger; 3. The rationally distributed multiple circuit board components make full use of the limited space inside the shell, improve the power density of the charger, and achieve the goal of small size and light weight. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is an assembly diagram of a high-power density new energy vehicle charger with efficient heat dissipation; Figure 2 It is a decomposed schematic diagram of a high-power density new energy vehicle charger with efficient heat dissipation; Figure 3 is a schematic diagram of the structure of the housing assembly; Figure 4 It is a schematic diagram of the structure of the circuit main board; Figure 5 It is an assembly diagram of the aluminum substrate assembly and the filter board assembly installed on the housing; Figure 6 is a schematic diagram of the exploded structure of the first aluminum substrate assembly; Figure 7 It is a schematic diagram of the structure of the heat dissipation aluminum substrate; Figure 8 It is a cross-sectional view of a high-power density new energy vehicle charger with efficient heat dissipation.

[0026] Reference numerals 1. Shell assembly; 101. Shell side wall; 102. Bottom plate; 2. Cavity; 3. Circuit board; 4. Aluminum substrate assembly; 41. First aluminum substrate assembly; 411. Control board; 412. Connector; 413. Heat dissipation aluminum substrate; 414. Pin; 415. MOS switch tube; 416. Copper column; 42. Second aluminum substrate assembly; 43. Third aluminum substrate assembly; 5. Filter board assembly; 51. First filter board; 52. Second filter board; 6. Main transformer; 7. Sub-transformer; 8. Electrolytic capacitor; 9. First inductor; 10. Second inductor. DETAILED DESCRIPTION

[0027] The present application is further described in detail below in conjunction with the accompanying drawings.

[0028] Example 1 In this embodiment, refer to Figure 1-5 , a high-power density new energy vehicle charger with efficient heat dissipation, including a shell assembly 1, a circuit main board 3, a plurality of aluminum substrate assemblies 4 and a filter board assembly 5. The shell assembly 1 includes a shell side wall 101 and a bottom plate 102, and the shell side wall 101 and the bottom plate 102 are surrounded to form a plurality of cavities 2. The circuit main board 3 is arranged on the shell assembly 1, and a power device is electrically connected to the circuit main board 3. A plurality of aluminum substrate assemblies 4 are arranged on the shell side wall 101, and the aluminum substrate assembly 4 and the circuit main board 3 are electrically connected. The filter board assembly 5 is arranged in the cavity 2 to form a filter cavity 2, and the filter board assembly 5 is separated from the aluminum substrate assembly 4 by the shell side wall 101.

[0029] Specifically, refer to Figure 3The shell assembly 1 includes a shell side wall 101 and a bottom plate 102. The shell side wall 101 and the bottom plate 102 together form a plurality of cavities 2. The bottom plate 102 is generally fixed on a liquid cooling plate with a coolant flow channel, and the bottom plate 102 quickly takes away the heat through the liquid cooling plate. The shell can be made of aluminum or aluminum alloy material with high thermal conductivity, and the bottom plate 102 and side walls of the shell are integrated by die-casting. This design not only has high vibration and impact resistance, but also can effectively protect internal electronic components to avoid damage or falling off due to external forces. The shell side wall 101 and the bottom plate 102 can be connected by welding or bolting to ensure the stability and sealing of the structure.

[0030] Reference Figure 4 , the circuit main board 3 is arranged on the shell assembly 1, and the circuit main board 3 is electrically connected to the power devices. Specifically, the circuit main board 3 is electrically connected to power devices such as the main transformer 6, the auxiliary transformer 7 and the electrolytic capacitor 8. These power devices are fixed to the circuit main board 3 by welding or other reliable connection methods to ensure the reliability and stability of the electrical connection. The circuit main board 3 transfers the heat to the bottom plate 102 through the heat-conducting medium, and then transfers it to the liquid cooling plate by the bottom plate 102 to achieve rapid heat dissipation. For example, thermal conductive silicone grease can be filled in the cavity 2 between the circuit main board 3 and the shell side wall 101 to reduce the contact thermal resistance and further enhance the heat dissipation effect.

[0031] Reference Figure 5-7 , several aluminum substrate assemblies 4 are arranged on the side wall 101 of the shell, and the aluminum substrate assemblies 4 are electrically connected to the circuit main board 3. Specifically, the several aluminum substrate assemblies 4 include a first aluminum substrate assembly 41, a second aluminum substrate assembly 42 and a third aluminum substrate assembly 43. The first aluminum substrate assembly 41 includes a control board 411, a connector 412 and a heat dissipation aluminum substrate 413. The connector 412 is fixedly connected to the control board 411, and the circuit main board 3 is connected through the connector 412. The heat dissipation aluminum substrate 413 is connected to the control board 411 through the pin 414 or the connector 412 to form a current path. The heat dissipation aluminum substrate 413 is provided with a plurality of rows of MOS switch tubes 415 electrically connected to the circuit main board 3. The MOS switch tubes 415 are welded or bonded to the heat dissipation aluminum substrate 413. The heat dissipation aluminum substrate 413 is connected to the control board 411 through the pin 414 or the connector 412, and the power and signal are transmitted to the circuit main board 3 by welding the copper column 416 or the pin 414 or the connector 412 of the control board 411.

[0032] Reference Figure 7, a plurality of copper pillars 416 are provided on the heat dissipation aluminum substrate 413, and the provision of the copper pillars 416 helps to further improve the heat dissipation effect. The diameter and length of the copper pillars 416 can be adjusted according to actual needs to achieve the best heat dissipation effect. A heat conducting medium is filled between the heat dissipation aluminum substrate 413 and the shell side wall 101, and the heat conducting medium can be thermal conductive silicone grease or other materials with high thermal conductivity. By filling the heat conducting medium, the contact thermal resistance between the heat dissipation aluminum substrate 413 and the shell side wall 101 can be reduced, and the heat dissipation effect can be further enhanced.

[0033] Reference Figure 5 , the filter board assembly 5 is arranged in the cavity 2 to form a filter cavity, and the filter board assembly 5 is separated from the aluminum substrate assembly 4 by the shell side wall 101. The filter board assembly 5 includes a first filter board 51 and a second filter board 52. The first filter board 51 and the second filter board 52 are composed of filter components welded on a PCB board, and the current is introduced into the circuit main board 3 through the provided conductive member (such as a copper column 416). The filter board assembly 5 is fixed at the corresponding cavity 2 inside the shell, and the heat dissipation of the filter component is introduced into the shell bottom plate 102 by encapsulating a heat-conducting medium in the cavity 2, which greatly improves the heat dissipation capacity of the filter board assembly 5 and greatly increases the reliability of the electronic components in the charger.

[0034] Reference Figure 8 , a transformer, a first inductor 9 and a second inductor 10 are also provided in the cavity 2, and the transformer, the first inductor 9 and the second inductor 10 are provided on the circuit main board 3 and the filter board assembly 5. The characteristics of these magnetic devices are large size and large heat generation during operation. The present application places the magnetic parts in a cavity 2 filled with a heat-conducting medium, which can quickly conduct heat to the side wall 101 of the shell and the bottom plate 102, and the liquid cooling plate in contact with the bottom plate 102 quickly completes the heat exchange. For example, a thermally conductive potting glue can be filled in the cavity 2 to ensure effective heat conduction and heat dissipation.

[0035] At least one circuit sub-board is provided on the side of the circuit main board 3 close to the cavity 2, and the circuit sub-board is electrically connected to the circuit main board 3. The circuit sub-board can be placed horizontally with the circuit main board 3 or vertically with the circuit main board 3 in the corresponding cavity 2 in the shell. The design of the circuit sub-board can further improve the power density of the charger, and it is reasonably distributed in the cavity 2 or the side wall or the top of the shell, making full use of the limited space, greatly improving the power density of the charger, and has the advantages of small size, easy assembly, and light weight.

[0036] Example 2 The embodiment of the present application provides a high-power density new energy vehicle charger with efficient heat dissipation, which further optimizes the design of the heat dissipation aluminum substrate 413 component 4 and introduces more heat dissipation paths and optimization measures to improve the overall heat dissipation effect.

[0037] Specifically, the heat dissipation aluminum substrate 413 assembly 4 includes a control board 411, a connector 412, a heat dissipation aluminum substrate 413 and additional heat dissipation fins. The heat dissipation fins are fixed to the outside of the heat dissipation aluminum substrate 413, increasing the surface area and further improving the heat dissipation effect. The shape of the heat dissipation fins can be rectangular, circular or other suitable geometric shapes, which can be selected according to actual needs. The thickness and spacing of the heat dissipation fins can also be adjusted to achieve the best heat dissipation effect.

[0038] In addition, a thermally conductive pad is added between the heat dissipating aluminum substrate 413 and the housing side wall 101 to further reduce the contact thermal resistance. The material of the thermally conductive pad can be selected from materials with high thermal conductivity such as graphene and carbon fiber to improve thermal conductivity. The thickness and shape of the thermally conductive pad can be adjusted according to actual needs to ensure the best thermal conductivity effect.

[0039] Example 3 The embodiment of the present application provides a high-power density new energy vehicle charger with efficient heat dissipation, which further optimizes the design of the circuit main board 3 and introduces more circuit optimization measures to improve the overall performance.

[0040] Specifically, the circuit main board 3 includes a main transformer 6, a sub-transformer 7, an electrolytic capacitor 8, a plurality of filter capacitors and a plurality of filter inductors. The main transformer 6 and the sub-transformer 7 are fixed to the circuit main board 3 by welding or other reliable connection methods to ensure the reliability and stability of the electrical connection. A plurality of filter capacitors and filter inductors are arranged in the edge area of ​​the circuit main board 3 and connected by a heat-conducting medium to ensure effective conduction of heat. The parameters of the filter capacitors and filter inductors can be adjusted according to actual needs to achieve the best filtering effect.

[0041] In addition, multiple temperature sensors are arranged on the circuit board 3, and the temperature sensors are fixed at key locations, such as near the main transformer 6, the auxiliary transformer 7 and the electrolytic capacitor 8, to monitor the temperature changes of these key locations in real time. The signal of the temperature sensor is transmitted to the controller through the wire, and the controller dynamically adjusts the operating state of the charger according to the temperature changes to prevent overheating.

[0042] The embodiments of this specific implementation method are all preferred embodiments of the present application, and are not intended to limit the protection scope of the present application. Therefore, all equivalent changes made based on the structure, shape, and principle of the present application should be included in the protection scope of the present application.

Claims

1. A high-power density new energy vehicle charger with efficient heat dissipation, characterized in that: include: A housing assembly (1), the housing assembly (1) comprising a housing side wall (101) and a bottom plate (102), the housing side wall (101) and the bottom plate (102) together forming a plurality of cavities (2); A circuit main board (3) is arranged on the housing assembly (1), and a power device is electrically connected to the circuit main board (3); A plurality of aluminum substrate assemblies (4) are arranged on the housing side wall (101); the aluminum substrate assemblies (4) are electrically connected to the circuit main board (3); A filter board assembly (5) is arranged in the cavity (2) to form a filter cavity (2); the filter board assembly (5) is electrically connected to the circuit main board (3); and the filter board assembly (5) is separated from the aluminum substrate assembly (4) by the shell side wall (101).

2. According to claim 1, a high-power density new energy vehicle charger with high heat dissipation efficiency is characterized in that: The power device comprises a main transformer (6), a sub-transformer (7) and an electrolytic capacitor (8).

3. According to claim 1, a high-power density new energy vehicle charger with high heat dissipation efficiency is characterized in that: The plurality of aluminum substrate assemblies (4) include a first aluminum substrate assembly (41), a second aluminum substrate assembly (42) and a third aluminum substrate assembly (43); the first aluminum substrate assembly (41) includes a control board (411), a connector (412) and a heat dissipation aluminum substrate (413); the connector (412) is fixedly connected to the control board (411) and connected to the circuit main board (3) via the connector (412); the heat dissipation aluminum substrate (413) is connected to the control board (411) via a pin (414) or the connector (412) to form a current path.

4. According to claim 3, a high-power density new energy vehicle charger with high heat dissipation efficiency is characterized in that: The first aluminum substrate assembly (41) further comprises a plurality of rows of MOS switch tubes (415) electrically connected to the circuit main board (3); the plurality of rows of MOS switch tubes (415) are arranged on the heat dissipating aluminum substrate (413).

5. According to claim 4, a high-power density new energy vehicle charger with high heat dissipation efficiency is characterized in that: A plurality of copper pillars (416) are provided on the heat dissipating aluminum substrate (413).

6. The high-power density new energy vehicle charger with high heat dissipation efficiency according to claim 3 is characterized in that: A heat-conducting medium is filled between the heat-dissipating aluminum substrate (413) and the shell side wall (101).

7. The high-power density new energy vehicle charger with high heat dissipation efficiency according to claim 1 is characterized in that: The filter plate assembly (5) comprises a first filter plate (51) and a second filter plate (52).

8. The high-power density new energy vehicle charger with high heat dissipation efficiency according to claim 1 is characterized in that: A transformer, a first inductor (9) and a second inductor (10) are also provided in the cavity (2); the transformer, the first inductor (9) and the second inductor (10) are provided on the circuit main board (3) and the filter board assembly (5).

9. The high-power density new energy vehicle charger with high heat dissipation efficiency according to claim 1 is characterized in that: At least one circuit sub-board is provided on a side of the circuit main board (3) close to the cavity (2), and the circuit sub-board is electrically connected to the circuit main board (3).

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