Direct-current charger with centralized heat dissipation structure

Abstract

The invention provides a direct-current charger with a centralized heat dissipation structure, and belongs to the technical field of direct-current chargers, the direct-current charger comprises a charger host, an input power wire harness is arranged on the left side of the charger host, a charging gun wire harness is arranged on the right side of the charger host, and the charger host comprises an injection molding upper shell and an injection molding lower shell. The injection molding upper shell and the injection molding lower shell are matched through a step shape, and a silica gel button is arranged in the middle of the injection molding upper shell; an inductor, a transformer, a diode, a triode, a rectifier bridge and other heating elements in the charger are intensively installed on one side of a main circuit board and an adapter plate on the same side and are intensively installed at a U-shaped heat conduction device, and heat is conducted to an air channel where a cooling fan directly blows through a heat dissipation structure on an aluminum alloy structural part, so that when the cooling fan works, the heat dissipation effect of the cooling fan is greatly improved. Heat can be rapidly discharged to the outside, the situation that the use function is affected by high heat in the charger is avoided, power reduction caused by too high temperature is avoided, and the reliability and safety during use are improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of DC chargers, and in particular relates to a DC charger with a centralized heat dissipation structure. Background Art

[0002] Electric buses, electric coaches, and electric coaches are currently relatively energy-efficient and environmentally friendly green transportation vehicles. Unlike gasoline-powered vehicles, these vehicles are equipped with power batteries. These batteries can be charged at both the starting and ending points. As operating mileage increases, electric vehicles may need to be recharged mid-trip. Portable chargers are essential for charging electric vehicles.

[0003] A charger is a power conversion device with a specific function used to charge power batteries. Chargers can be operated in two modes: DC and AC. The DC mode uses the controllable DC power output of the charger to directly charge the power battery assembly. The DC charger, on the other hand, uses the DC mode to charge the power batteries of electric vehicles.

[0004] Existing DC chargers have a complex internal structure, with many heat-generating components that are dispersed. This results in a large number of heat sources inside the charger. When the charger is working, heat is generated in multiple locations inside the charger. However, existing chargers generally have a cooling fan installed on one side, and the cooling fan is fixed in position. The charger has a large number of internal structures and is relatively complex. When the cooling fan is working, it cannot quickly concentrate and discharge the heat from various locations inside the charger. In addition, due to the complex structure, airflow cannot flow through some areas, resulting in heat from some areas not being quickly discharged. This causes the local temperature of the charger to become increasingly high, affecting the working efficiency of the charger. If the heat is not dissipated in time, it may even be dangerous.

[0005] Therefore, we propose a DC charger with a centralized heat dissipation structure to solve the above problems. Summary of the Invention

[0006] The purpose of the present invention is to solve the problem that the existing DC charger has a complex internal structure, a large number of heating elements, and a relatively scattered distribution, resulting in a large number of heat sources inside the charger. When the charger is working, heat is generated in multiple places inside the charger main body. However, the existing charger generally has a cooling fan installed on one side, and the cooling fan is fixed in position. The internal structure of the charger is large and relatively complex. When the cooling fan is working, it is not possible to quickly concentrate and quickly discharge the heat from various parts of the charger. In addition, due to the complex structure, airflow cannot flow through some areas, resulting in the inability to quickly discharge heat from some areas, causing the local temperature of the charger to become increasingly high, affecting the working efficiency of the charger. If the heat is not dissipated in time, it may even be dangerous. Therefore, a DC charger with a centralized heat dissipation structure is proposed.

[0007] The objectives of the present invention can be achieved through the following technical solutions: it includes a charger host, an input power harness is provided on the left side of the charger host, a charging gun harness is provided on the right side of the charger host, the external structure of the charger host includes an injection-molded upper shell and an injection-molded lower shell, and the injection-molded upper shell and the injection-molded lower shell are matched through a step shape, a silicone button is provided in the middle of the injection-molded upper shell, an LED light board is provided below the silicone button, a main circuit board is provided below the LED light board, stainless steel studs are fixedly connected to the four corners of the main circuit board by bolts, the stainless steel studs are fixed to the aluminum alloy structural member, the aluminum alloy structural member is fixedly installed on the inside of the injection-molded lower shell by bolts, a heat sink is provided on the rear wall of the aluminum alloy structural member, and air inlet and air outlet are respectively provided on the left and right sides of the injection-molded lower shell, a cooling fan is provided inside the right side of the injection-molded lower shell, and the cooling fan is provided on the inner side of the air inlet.

[0008] As a preferred embodiment of the present invention, the right end of the input power harness and the left end of the charging gun harness are both provided with harness structural parts, and sealing rings are installed on the surfaces of the two harness structural parts. The upper and lower ends of the injection-molded upper shell and the injection-molded lower shell are both provided with power harness installation ports and charging gun harness installation ports that match the harness structural parts.

[0009] As a preferred embodiment of the present invention, the side walls of the two wiring harness structural components are provided with alternating concave and convex card slots, and the interiors of the power harness installation port and the charging gun harness installation port are both provided with connecting slots matching the card slots.

[0010] In a preferred embodiment of the present invention, a 12V external power supply circuit board is installed at the lower end of the main circuit board. A control board is plugged into the right side of the main circuit board, with the side of the control board closest to the aluminum alloy structure maintaining a safety distance of 5mm from the aluminum alloy structure. An insulation detection board is installed at the upper end of the lower surface of the main circuit board.

[0011] As a preferred embodiment of the present invention, an adapter plate is provided in the middle of the lower surface of the main circuit board, and a U-shaped heat conductor is provided below the adapter plate. Diodes, transistors, and a rectifier bridge are installed on the main circuit board, and a transformer and an inductor are installed on the adapter plate. The diodes, transistors, rectifier bridge, transformer and inductor are all installed on the U-shaped heat conductor. The inductor and transformer are both at a safety distance of 4-5mm from the aluminum alloy structural parts. After the inductor and transformer are installed with the U-shaped heat conductor, the two ends of the U-shaped heat conductor are sealed, and then thermal conductive glue is poured into it to transfer the heat of the inductor and transformer to the U-shaped heat conductor through the thermal conductive glue.

[0012] As a preferred embodiment of the present invention, a nameplate label is provided in the middle of the injection-molded lower shell, and an injection-molded integrated handle is provided at the upper end of the injection-molded lower shell.

[0013] Compared with the prior art, the present invention has the following beneficial effects:

[0014] (1) The heating elements such as the inductor, transformer, diode, transistor, rectifier bridge, etc. inside the charger are centrally mounted on one side of the main circuit board and the adapter board on the same side, and then centrally mounted on the U-shaped heat conductor. Then, the heat is transferred to the air duct where the cooling fan blows directly through the aluminum alloy structural parts and the heat sink. When the cooling fan is working, the heat can be quickly discharged to the outside, thus avoiding the high heat inside the charger affecting the efficiency of use and the damage caused by excessive temperature, thereby improving the safety during use.

[0015] (2) The slot structure on the wiring harness structure can stably install the input power harness and the charging gun harness on the charger structure, preventing the input power harness and the charging gun harness from loosening or even falling off, which affects the use of the charger;

[0016] (3) The silicone button and LED light panel are provided to facilitate the operation of the charger and the observation of its working condition. The insulation detection panel is provided to detect the insulation status between the internal circuit and the outer shell of the charger, so that when an insulation abnormality occurs in the charger, it can be quickly discovered and handled, thus ensuring the efficiency and safety of the charger during use. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] To facilitate understanding by those skilled in the art, the present invention is further described below with reference to the accompanying drawings.

[0018] Figure 1 It is a schematic diagram of the three-dimensional structure of the present invention;

[0019] Figure 2 A rear perspective view of the charger host of the present invention;

[0020] Figure 3 It is a schematic diagram of the three-dimensional structure of the main circuit board of the present invention;

[0021] Figure 4 This is a schematic diagram of a first three-dimensional structure of the lower surface of the main circuit board of the present invention;

[0022] Figure 5 A schematic diagram of a second three-dimensional structure of the lower surface of the main circuit board of the present invention;

[0023] Figure 6 Schematic diagram of the three-dimensional structure of the lower surface of the aluminum alloy structural member of the present invention;

[0024] Figure 7 It is a partial three-dimensional structural diagram of the input power harness protective coil structure of the present invention;

[0025] Figure 8 This is a partial three-dimensional structural diagram of the charging gun wire harness coil structure of the present invention;

[0026] Figure 9 Schematic diagram of the three-dimensional structure of the injection-molded upper shell of the present invention;

[0027] Figure 10 It is a schematic diagram of the three-dimensional structure of the injection-molded lower shell of the present invention.

[0028] In the figure: 1. Charger host; 2. Input power wiring harness; 3. Charging gun wiring harness; 4. Wiring harness coil structure; 5. Sealing ring; 6. Injection molded upper shell; 7. Injection molded lower shell; 8. Power wiring harness installation port; 9. Charging gun wiring harness installation port; 10. LED light board; 11. Silicone button; 13. Nameplate label; 14. Handle; 15. Air inlet; 16. Air outlet; 17. Cooling fan; 18. Aluminum alloy structure; 19. Heat sink; 20. Main circuit board; 21. 12V external power supply circuit board; 22. Control board; 23. Insulation detection board; 24. U-shaped heat conductor; 25. Inductor; 26. Capacitor; 27. Card slot structure; 28. Plug slot; 29. Diode; 30. Rectifier bridge; 31. Transistor; 32. Transformer; 33. Adapter board. DETAILED DESCRIPTION

[0029] The technical solutions of the present invention will be clearly and completely described below in conjunction with the embodiments. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0030] Example

[0031] See also Figure 1 - Figure 10As shown, a DC charger with a centralized heat dissipation structure includes a charger host 1, an input power harness 2 is provided on the left side of the charger host 1, and a charging gun harness 3 is provided on the right side of the charger host 1. The external structure of the charger host 1 includes an injection molded upper shell 6 and an injection molded lower shell 7, and the injection molded upper shell 6 and the injection molded lower shell 7 are matched through a step shape, wherein a sealing ring is further provided at the connection between the injection molded upper shell 6 and the aluminum alloy structure 18 to ensure the sealing effect between the injection molded upper shell 6 and the aluminum alloy structure 18, to prevent external dust, water vapor and other debris from entering the host and contaminating the internal electronic components, and the protection level Reaching IP66, the lower surface of the injection-molded lower shell 7 is provided with four rubber feet. The setting of the rubber feet can stably place the charger host 1, making the charger more stable and preventing the charger from moving or wearing out the shell, so that charging can proceed smoothly. The middle part of the injection-molded lower shell 7 is provided with a nameplate label 13. The setting of the nameplate label 13 makes it easy for users to understand the model, parameters and other information of this charger through the nameplate label 13. The upper end of the injection-molded lower shell 7 is provided with an injection-molded integrated handle 14. The setting of the injection-molded integrated handle 14 makes it easy for users to carry the charger by the handle 14;

[0032] A silicone button 11 is provided in the middle of the injection-molded upper shell 6, and an LED light board 10 is provided below the silicone button 11. The LED light board 10 can emit red, yellow and green lights. The user can identify the working status of the charger by observing the light color and flashing frequency. A main circuit board 20 is provided below the LED light board 10. The four corners of the rear side of the main circuit board 20 are connected to the hexagonal studs by screws, and the studs are fixedly connected to the aluminum alloy structure 18. The aluminum alloy structure 18 is fixedly installed inside the injection-molded lower shell 7 by screws. The rear wall of the aluminum alloy structure 18 is provided with a heat sink 19. The left and right sides of the aluminum alloy structure 18 are respectively provided with an air inlet 15 and an air outlet 16. A cooling fan 17 is provided inside the right side of the injection-molded lower shell 7, and the cooling fan 17 is arranged on the inner side of the air inlet 15;

[0033] It should be noted that when the cooling fan 17 is working, outside air enters through the air inlet 15, flows through the heat sink inside the host, and then the gas is discharged through the air outlet 16. Because the cooling fan 17 is located in the middle of the right side of the injection-molded lower shell 7, the heat dissipation effect in the middle of the injection-molded lower shell 7 is better and faster. The arrangement of the aluminum alloy structural member 18 and the heat sink 19 can conduct the heat emitted by the charger when it is working to the heat sink 19 through the aluminum alloy structural member 18, and conduct the heat more concentratedly to the heat sink 19, so that the circulating air can discharge the heat to the outside more quickly, thereby avoiding heat accumulation on the electronic components, affecting the operation of the electronic components or even damaging them.

[0034] The right end of the input power harness 2 and the left end of the charging gun harness 3 are both provided with a harness protection coil structure 4, and the surfaces of the two harness protection coil structures 4 are both installed with sealing rings 5. The upper and lower ends of the injection molded upper shell 6 and the injection molded lower shell 7 are both provided with a power harness installation port 8 and a charging gun harness installation port 9 that match the harness protection coil structure 4. The setting of the sealing ring 5 enables the two harness structures 4 to be respectively installed in the power harness installation port 8 and the charging gun harness installation port 9. The sealing ring 5 can fill the gap between the harness structure 4 and the power harness installation port 8 and the charging gun harness installation port 9, thereby improving the firmness of the plug-in installation. The two harness structures 4 have a certain effect and can also fill the gap between the power harness installation port 8 and the charging gun harness installation port 9 and the harness protective coil structure 4 to prevent external dust from entering the interior of the host and polluting and damaging electronic components. The side walls of the two harness structures 4 are provided with a concave and convex card slot structure. The power harness installation port 8 and the charging gun harness installation port 9 are both provided with a plug-in slot 28 that matches the card slot structure. The setting of the card slot structure can stably clamp the two harness structures 4 inside the power harness installation port 8 and the charging gun harness installation port 9 to prevent the input power harness 2 or the charging gun harness 3 from loosening or even falling off from the charger host 1 when being pulled;

[0035] A 12V external power supply circuit board 21 is mounted at the bottom of the main circuit board 20. A control board 22 is plugged into the right side of the main circuit board 20, with the lower edge of the control board 22 maintaining a safe distance of 5 mm from the aluminum alloy structure 18. An insulation detection board 23 is mounted on the upper rear surface of the main circuit board 20. This board monitors the charger circuit and provides feedback on its insulation status, ensuring prompt shutdown in the event of a leakage, thus preventing the risk of electric shock.

[0036] An adapter plate 33 is provided in the middle of the lower surface of the main circuit board 20. Diodes, transistors and rectifier bridges are installed on the main circuit board. Transformers and inductors are installed on the adapter plate 33. A U-shaped heat conductor 24 is provided directly below the adapter plate 33. The diodes, transistors and rectifier bridges installed on the main circuit board 20 are fixed and pressed on both sides of the U-shaped heat conductor by pressure strips and screws. The inductor and transformer are installed inside the U-shaped heat conductor 24 and have a safety distance of 4-5mm from the inner surface. After the inductor and transformer are installed with the U-shaped heat conductor, the two ends of the U-shaped heat conductor are sealed, and then thermal conductive glue is poured inward to transfer the heat of the inductor and transformer to the heat conductor. The heat is transferred to the U-shaped heat conductor 24. The transformer 32 and the inductor 25 are centrally arranged on the adapter plate 33 on one side of the main circuit board 20, and are also centrally installed in the U-shaped heat conductor 24. The bottom surface of the U-shaped heat conductor 24 is in close contact with the aluminum alloy structure 18, so that when the charger is working, the heat emitted by the transformer 32 and the inductor 25 can be concentrated on the aluminum alloy structure 18, and then conducted to the heat dissipation area at the bottom of the charger through the aluminum alloy structure 18 and the heat sink 19, and discharged centrally through the cooling fan 17, avoiding the existing charger. The position of the heating elements is scattered, affecting the heat dissipation effect, resulting in excessive local heat that affects the use effect and causes danger.

[0037] When using the present invention, first carry the charger to the electric vehicle using the handle 14, then lay the charger body 1 flat so that the rubber feet on the rear side of the injection-molded lower housing 7 are in contact with the ground, thereby stably placing the charger body 1 on the ground. Then connect the plug of the input power harness 2 to the power socket, and then plug the charging gun harness 3 into the charging port of the electric vehicle to complete the preparation work;

[0038] The charger then automatically starts charging. You can check whether the charger is working properly by observing the color of the signal light inside the translucent silicone button 11. The green light on the LED light board 10 that it is breathing indicates normal charging. When the green light on the LED light board 10 is always on, it means that it is fully charged. When the charger is working properly, the diodes, transistors, rectifier bridge and other electronic components on its internal main circuit board 20 work and emit heat. The heat is transferred to the aluminum alloy structure 18 through the U-shaped heat conductor 24, and then to the heat sink 19. At the same time, the cooling fan 17 works, so that the outside air is sucked in through the air inlet 15, and then the air flow passes through the heat sink 19 from right to left, and is discharged from the air outlet 16. When the air flow passes through the heat sink 19, it can take away the heat and discharge it through the air outlet 16, thereby reducing the temperature inside the charger host 1 and preventing the internal temperature from being too high, affecting the use effect or even causing danger.

[0039] During charging, the insulation detection board 23 monitors the charger in real time, allowing the user to understand the charger's insulation status. If a leakage occurs, the charger cannot start normally, preventing the user from directly contacting the charger and potentially causing danger. When the LED panel 10 illuminates solid green, charging is complete. First, unplug the input power harness 2 to disconnect it from the power source. Then, remove the charging plug 3 from the electric vehicle to complete disassembly.

[0040] The preferred embodiments of the present invention disclosed above are intended only to help illustrate the present invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the present invention to specific embodiments. Obviously, many modifications and variations are possible based on the contents of this specification. These embodiments are selected and described in detail in this specification to better explain the principles and practical applications of the present invention, thereby enabling those skilled in the art to better understand and utilize the present invention. The present invention is limited only by the claims and their full scope and equivalents.

Claims

1. A DC charger with a centralized heat dissipation structure, comprising a charger host (1), an input power harness (2) being provided on the left side of the charger host (1), and a charging gun harness (3) being provided on the right side of the charger host (1), characterized in that: The external structure of the charger host (1) includes an injection molded upper shell (6) and an injection molded lower shell (7), and the injection molded upper shell (6) and the injection molded lower shell (7) are matched with each other through a step shape. A silicone button (11) is provided in the middle of the injection molded upper shell (6), an LED light board (10) is provided below the silicone button (11), a main circuit board (20) is provided below the LED light board (10), and stainless steel screws are fixedly connected to the four corners below the main circuit board (20) by bolts. The studs are stainless steel studs fixed on the aluminum alloy structural member (18), and the aluminum alloy structural member (18) is fixedly installed inside the injection molded lower shell (7) by bolts. The rear wall of the aluminum alloy structural member (18) is provided with a heat sink (19), and the left and right sides of the injection molded lower shell (7) are respectively provided with an air inlet (15) and an air outlet (16). A cooling fan (17) is provided inside the right side of the aluminum alloy structural member (18), and the cooling fan (17) is arranged on the inner side of the air inlet (15).

2. The DC charger with a centralized heat dissipation structure according to claim 1, characterized in that: The right end of the input power harness (2) and the left end of the charging gun harness (3) are both provided with a harness structure (4), and the surfaces of the two harness structures (4) are both provided with a sealing ring (5), and the upper and lower ends of the injection-molded upper shell (6) and the injection-molded lower shell (7) are both provided with a power harness installation port (8) and a charging gun harness installation port (9) that match the harness structure (4).

3. The DC charger with a centralized heat dissipation structure according to claim 2, characterized in that: The side walls of the two wiring harness structural members (4) are both provided with a concave-convex slot structure (27), and the interiors of the power harness mounting port (8) and the charging gun harness mounting port (9) are both provided with a convex-concave plug-in slot structure (28) that matches the concave-convex slot structure (27).

4. The DC charger with a centralized heat dissipation structure according to claim 1, characterized in that: A 12V external power supply circuit board (21) is provided below the front end of the main circuit board (20), a control board (22) is plugged into the right side of the main circuit board (20), and the top of the control board (22) is plugged into the main circuit board (20), and an insulation detection board (23) is provided at one end of the lower surface of the main circuit board (20).

5. The DC charger with a centralized heat dissipation structure according to claim 1, characterized in that: An adapter plate (33) is provided in the middle of the lower surface of the main circuit board (20), a diode (29), a triode (31), and a rectifier bridge (30) are installed on the main circuit board (20), and a transformer (32) and an inductor (25) are installed on the adapter plate (33). A U-shaped heat conductor (24) is provided directly below the adapter plate (33). The diode (29), transistor (31) and rectifier bridge (30) installed on the main circuit board (20) are fixed and pressed on the two sides of the U-shaped heat conductor (24) by means of pressure strips and screws. The inductor (25) and transformer (32) are installed inside the U-shaped heat conductor (24) and have a safety distance of 4-5 mm from the inner surface. The inductor (25) and transformer (32) are installed inside the U-shaped heat conductor (24). Then, after the two ends of the U-shaped heat conductor (24) are sealed with a film with adhesive backing, thermal conductive glue is injected into the interior. When the charger is working, the thermal conductive glue can transfer heat to the U-shaped heat conductor (24) and then conduct it to the aluminum alloy structural parts.

6. The DC charger with a centralized heat dissipation structure according to claim 1, characterized in that: A nameplate label (13) is provided in the middle of the injection-molded lower shell (7), and an injection-molded integrated handle (14) is provided at the upper end of the injection-molded lower shell (7).

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