Power converter and power conversion equipment

Abstract

The invention discloses a power converter and power conversion equipment. A boost module and a buck module of the power converter are opposite in a first direction and are arranged at an interval; the inductance module is arranged between the step-down module and the step-up module in the first direction, and the inductance module is electrically connected with the step-down module and the step-up module; the first input assembly comprises a first connecting piece and a first input end; the first input end is electrically connected to the step-down module, and in the second direction, the first input end is arranged between two opposite ends of the step-down module; the first connecting piece is electrically connected with the step-down module and the step-up module; the second input assembly comprises a second connecting piece and a second input end; the second input end is electrically connected to the boosting module, and in the second direction, the second input end is arranged between the two opposite ends of the boosting module in the second direction; the second connecting piece is electrically connected with the step-down module and the step-up module. According to the power converter, the design of short power flow between the buck-boost module can be realized, and meanwhile, the size of the power converter is reduced.

Description

Technical Field

[0001] This application belongs to the field of power conversion technology, and in particular relates to a power converter and power conversion device. Background Technology

[0002] Fuel cells, as an important technological approach for carbon reduction in transportation, have already met the conditions for large-scale commercial application in fields such as vehicles, ships, rail transit, distributed power generation, and energy storage. Current fuel cells typically employ power converters to adjust the input and output voltages.

[0003] Current power converters typically separate the boost and buck converter modules, connecting them via long circuits. This design leads to significant power losses during high-power transmission due to the long circuits, impacting the overall conversion efficiency and power density of the system. Furthermore, the separate design results in a larger device size, hindering integration and miniaturization. Summary of the Invention

[0004] The purpose of this application is to provide a power converter and power conversion device that can realize a short power flow design between the buck and boost modules of the power converter, while reducing the size of the power converter.

[0005] To achieve the objectives of this application, the following technical solution is provided: In a first aspect, this application provides a power converter, including a buck module, a boost module, an inductor module, a first input component, and a second input component. The boost module and the buck module are disposed opposite to each other and spaced apart in a first direction. The inductor module is disposed between the buck module and the boost module in the first direction and is electrically connected to the buck module and the boost module. The first input component includes a first connector and a first input terminal. The first input terminal is electrically connected to the buck module, and in a second direction, the first input terminal is disposed between opposite ends of the buck module. The first connector is electrically connected to the buck module and the boost module. The second input component includes a second connector and a second input terminal. The second input terminal is electrically connected to the boost module, and in the second direction, the second input terminal is disposed between opposite ends of the boost module in the second direction. The second connector is electrically connected to the buck module and the boost module, and the second direction is perpendicular to the first direction.

[0006] In one embodiment, in a third direction, the first input terminal and the second input terminal are located on the same side of the power converter; wherein, the third direction is perpendicular to the first direction and the third direction is perpendicular to the second direction.

[0007] In one embodiment, in the first direction, the inductor module, the first connector, and the second connector are all disposed between the buck module and the boost module; in the third direction, the inductor module is disposed between the first connector and the second connector.

[0008] In one embodiment, the first input component further includes a first mounting portion, and the first connector, the first input end, and the first mounting portion are integrally formed. The first input terminal is disposed on the side of the first connector closer to the step-down module in the first direction, and the first input terminal extends along the third direction toward the side away from the step-down module; The first mounting portion is disposed on the side of the first connector closer to the step-down module in the first direction and is connected to the step-down module, and the first mounting portion extends along the third direction.

[0009] In one embodiment, the second input component further includes a second mounting portion and a third mounting portion, wherein the second connector, the second input end, the second mounting portion, and the third mounting portion are integrally formed; The second input terminal is disposed on the side of the second connector closer to the boost module in the first direction, and the second input terminal extends along the third direction toward the side away from the boost module; The second mounting portion is disposed on the side of the second connector in the first direction close to the boost module and connected to the boost module, and the second mounting portion extends along the third direction; The third mounting portion is disposed on the side of the second connector in the first direction close to the step-down module and connected to the step-down module, and the third mounting portion extends along the third direction.

[0010] In one embodiment, there are multiple first mounting portions and multiple third mounting portions, and the multiple first mounting portions and multiple third mounting portions are staggered in the second direction.

[0011] In one embodiment, the power converter further includes a first output component and a second output component, both of which are electrically connected to the boost module; in the second direction, the first output component and the second output component are both disposed between opposite ends of the boost module; in the third direction, the first output component and the second output component are both located on the same side of the power converter away from the first input terminal and the second input terminal.

[0012] In one embodiment, the inductor module includes a liquid cooling component and an inductor component. The liquid cooling component has a receiving cavity and an annular heat dissipation channel. The annular heat dissipation channel is disposed around the outside of the receiving cavity, and the inductor component is housed inside the receiving cavity.

[0013] In one embodiment, the buck module includes a buck circuit board and a buck power component, the buck power component being mounted on the side of the buck circuit board near the annular heat dissipation channel; and / or, the boost module includes a boost circuit board and a boost power component, the boost power component being mounted on the side of the boost circuit board near the annular heat dissipation channel.

[0014] In a second aspect, this application also provides a power conversion device, including a housing and a power converter as described in any of the various embodiments of the first aspect, the housing having a mounting cavity and a communication port, the power converter being mounted in the mounting cavity, and the first input component and the second input component being connected to the outside through the communication port.

[0015] By sequentially arranging the buck module, inductor module, and boost module in the first direction, the overall size of the power converter is reduced, which is conducive to the integration and miniaturization of the power converter. By placing both the first and second input terminals in the middle position of the power converter in the second direction, the current can be split and transmitted from the middle position of the power converter to both sides, shortening the path of high current transmission, realizing a short power flow design, reducing losses in the power flow transmission process, and improving the conversion efficiency and power density of the power converter. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0017] Figure 1 This is a perspective view of a power converter according to one embodiment; Figure 2 This is an exploded view of a power converter according to one embodiment; Figure 3 This is a perspective view of a power converter according to one embodiment; Figure 4 This is a perspective view of a power converter according to one embodiment; Figure 5 This is a perspective view of a step-down module according to one embodiment; Figure 6This is a perspective view of a partial structure of an inductor component according to one embodiment; Figure 7 This is a perspective view of a magnetic bracket according to one embodiment; Figure 8 This is a perspective view of a liquid cooling assembly according to one embodiment; Figure 9 Another perspective view of a liquid cooling assembly according to one embodiment; Figure 10 This is a side view of a liquid cooling assembly according to one embodiment; Figure 11 This is an exploded view of an inductor assembly according to one embodiment; Figure 12 This is a cross-sectional schematic diagram of a partial structure of a power converter according to one embodiment; Figure 13 This is a perspective view of a power conversion device according to one embodiment; Figure 14 This is a bottom view schematic diagram of a power conversion device according to one embodiment.

[0018] Explanation of reference numerals in the attached figures: 1000 - Power conversion equipment; 100-Power converter, 10-Step-down module, 11-Step-down circuit board, 12-Step-down power component, 13-Current sensor, 14-Capacitor, 20-Boost module, 21-Boost circuit board, 22-Boost power component, 30-Inductor module, 31-Liquid cooling assembly, 311-Receiving cavity, 312-Annular heat dissipation channel, 3121-First heat dissipation channel, 3121a-First sub-channel, 3121b-Second sub-channel, 3122-Second heat dissipation channel, 3122a-Third sub-channel, 3122b-Fourth sub-channel, 313-Liquid inlet, 314-Liquid outlet, 315-Heat dissipation body, 315a-First end, 315b-Second end, 315c-Third end, 315d-Fourth end, 315e-Fifth end, 315f-Sixth end, 3 151-First connecting hole, 3152-Second connecting hole, 3154-First limiting part, 3155-First fixing part, 32-Inductor assembly, 321-Magnetic bracket, 3211-First end plate, 3212-Second end plate, 3213-First winding post, 3214-Second winding post, 3215-Support post, 322-First inductor, 323-Second inductor, 324-Second limiting part, 325-Second fixing part, 326-First connecting end, 327-Second connecting end, 40-First input assembly, 41-First connector, 42-First input end, 43-First mounting part, 50-Second input assembly, 51-Second connector, 52-Second input end, 53-Second mounting part, 54-Third mounting part, 60-First output assembly, 70-Second output assembly; 200-Housing, 201-Conducting port, 202-Water inlet, 203-Water outlet, 204-First output terminal, 205-Second output terminal, 206-Air compressor interface, 207-Hydrogen pump output interface, 208-Fan interface, 209-PTC plug-in; Z - First direction, X - Second direction, Y - Third direction. Detailed Implementation

[0019] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0020] It should be noted that when a component is said to be "fixed" to another component, it can be directly on the other component or it can be in a middle component. When a component is said to be "connected" to another component, it can be directly connected to the other component or it may be in a middle component.

[0021] Unless otherwise defined, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains. The terminology used in the specification of this application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The term "and / or" as used in this application includes any and all combinations of one or more of the associated listed items.

[0022] The following detailed description of some embodiments of this application is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0023] Fuel cells, as an important technological approach for carbon reduction in transportation, have already met the conditions for large-scale commercial application in fields such as vehicles, ships, rail transit, distributed power generation, and energy storage. Current fuel cells typically employ power converters to adjust the input and output voltages.

[0024] The power converter 100 in the embodiments of this application will be described in detail below.

[0025] First, define the direction. Please refer to [the relevant documentation / reference]. Figure 1 Z is the first direction, X is the second direction, and Y is the third direction. The first direction Z, the second direction X, and the third direction Y intersect each other. Optionally, the first direction Z, the second direction X, and the third direction Y are perpendicular to each other.

[0026] Please refer to Figures 1 to 12This application provides a power converter 100, including a buck module 10, a boost module 20, an inductor module 30, a first input component 40, and a second input component 50. The boost module 20 and the buck module 10 are opposite to each other and spaced apart in the first direction Z. The inductor module 30 is disposed between the buck module 10 and the boost module 20 in the first direction Z. The inductor module 30 is electrically connected to the buck module 10 and the boost module 20.

[0027] The step-down module 10 is used to convert the high input voltage to a lower voltage to meet the voltage requirements of a specific load (such as a fuel cell) under light load conditions; the boost module 20 is used to boost the lower input voltage to the required higher voltage to provide sufficient energy to the load.

[0028] Inductor module 30, acting as an energy storage element, plays a role in energy transfer and buffering between buck module 10 and boost module 20. Inductor module 30 is electrically connected to both boost module 20 and buck module 10. During buck conversion, inductor module 30 stores some energy; during boost conversion, inductor module 30 releases the stored energy to assist boost module 20 in increasing the voltage. Simultaneously, the electrical connection between inductor module 30 and buck module 10 and boost module 20 enables series energy storage between the buck and boost modules 10, allowing for efficient energy transfer between the modules.

[0029] Optionally, in the orthographic projection in the first direction Z, at least part of the buck module 10, boost module 20, and inductor module 30 overlap. Optionally, in the first direction Z, the inductor module 30 may be in contact with the buck module 10 or the boost module 20, or there may be a gap between them, without limitation.

[0030] The first input component 40 includes a first connector 41 and a first input terminal 42. The first input terminal 42 is electrically connected to the step-down module 10 and is located between the two opposite ends of the step-down module 10 in the second direction X. The first connector 41 is electrically connected to the step-down module 10 and the step-up module 20. The second input component 50 includes a second connector 51 and a second input terminal 52. The second input terminal 52 is electrically connected to the step-up module 20 and is located between the two opposite ends of the step-up module 20 in the second direction X. The second connector 51 is electrically connected to the step-down module 10 and the step-up module 20.

[0031] The first input component 40 and the second input component 50 are respectively used to receive positive and negative input signals from an external power source (such as the hydrogen-oxygen reactor of a fuel cell) to provide the required electrical energy to the buck module 10 and the boost module 20. Optionally, the first input terminal 42 and the second input terminal 52 can be designed with different interface structures according to actual needs to adapt to different types of external power sources.

[0032] Optionally, the first connector 41 and the first input terminal 42 can be an integral structure or a separate structure, without limitation. Optionally, the first connector 41 can be directly connected to the step-down module 10, and the connection method can be welding, bonding, snap-fitting, screwing, riveting, etc., without limitation. Alternatively, the first connector 41 can also be indirectly connected to the step-down module 10, without limitation. Optionally, the first connector 41 can be directly connected to the step-up module 20, without limitation.

[0033] Optionally, the number of first input terminals 42 can be one or more, without limitation. When there are multiple first input terminals 42, the multiple first input terminals 42 can be spaced apart along the second direction X, and all the multiple first input terminals 42 are located between the two ends of the buck module 10 in the second direction X. This arrangement makes the path of current from the first input terminal 42 into the buck module 10 relatively short and direct, which helps to reduce current loss during transmission and improve energy conversion efficiency.

[0034] Optionally, the configuration of the second connector 51 and the second input terminal 52 is similar to that of the first connector 41 and the second input terminal 52 described above, and can be referred to without further explanation.

[0035] In one implementation, such as Figures 1 to 3 As shown, in the third direction Y, the first input terminal 42 and the second input terminal 52 are located on the same side of the power converter 100.

[0036] Optionally, in the orthographic projection in the first direction Z, at least part of the first input terminal 42 and the second input terminal 52 overlap; or, in the orthographic projection in the first direction Z, the first input terminal 42 and the second input terminal 52 are spaced apart, without limitation.

[0037] In other embodiments, the first input terminal 42 may be disposed between opposite ends of the buck module 10 in the third direction Y, and the second input terminal 52 may be disposed between opposite ends of the boost module 20 in the third direction Y. In the third direction Y, the first input terminal 42 and the second input terminal 52 are located on the same side of the power converter 100.

[0038] With this configuration, the first input terminal 42 and the second input terminal 52 are located on the same side of the power converter 100, which facilitates the connection of the two input terminals to the hydrogen-oxygen reactor.

[0039] In one implementation, such as Figures 1 to 3 As shown, in the first direction Z, the inductor module 30, the first connector 41 and the second connector 51 are all disposed between the buck module 10 and the boost module 20; in the third direction Y, the inductor module 30 is disposed between the first connector 41 and the second connector 51.

[0040] In the first direction Z, the inductor module 30, the first connector 41, and the second connector 51 can make full use of the space between the buck module 10 and the boost module 20, avoiding the spatial dispersion of the components and effectively reducing the size of the power converter 100 in the first direction Z, making the structure of the power converter 100 more compact. Since the first connector 41 and the second connector 51 generate heat during operation, in the third direction Y, the first connector 41 and the second connector 51 are located on both sides of the inductor module 30, which can better dissipate the heat generated during operation, avoid local overheating, and also avoid electromagnetic interference between the first connector 41 and the second connector 51 when transmitting current or signals.

[0041] With this configuration, the components of the power converter 100 are arranged in a compact and reasonable manner, which can reduce the size of the power converter 100 and meet the requirements of equipment integration and miniaturization design.

[0042] In existing power converters 100, the boost and buck conversion modules are typically designed separately, with long connecting lines between them. This design leads to significant power loss during high-power transmission due to the long lines, thus affecting the overall conversion efficiency and power density of the power conversion system. Furthermore, the separate design results in a larger device size, hindering integration and miniaturization.

[0043] The power converter 100 in this embodiment reduces the overall size of the power converter 100 by sequentially arranging a buck module 10, an inductor module 30, and a boost module 20 in the first direction Z, which is beneficial for the integration and miniaturization of the power converter 100. By placing the first input terminal 42 and the second input terminal 52 at the middle position of the power converter 100 in the second direction X, the current can be split and transmitted from the middle position of the power converter 100 to both sides, shortening the path of high current transmission, realizing a short power flow design, reducing losses in the power flow transmission process, and improving the conversion efficiency and power density of the power converter 100.

[0044] In addition, the power converter 100 has a brick-shaped structure design, which is conducive to integration and application with hydrogen fuel cell systems, and is easy to maintain and assemble, effectively improving the product's competitiveness.

[0045] In one implementation, such as Figures 1 to 3 As shown, the first input component 40 also includes a first mounting part 43, and the first connector 41, the first input end 42 and the first mounting part 43 are integrally formed.

[0046] The first input component 40 can be made of a material with high conductivity, such as copper and its alloys (e.g., pure copper, brass, phosphor bronze, beryllium bronze, chromium zirconium copper, etc.), silver and silver-plated materials, etc., without limitation. Optionally, the first connector 41, the first input end 42 and the first mounting part 43 can be an integrally formed structure manufactured by an integral molding process, which can specifically be stamping, casting, etc., without limitation.

[0047] The first input terminal 42 is disposed on the side of the first connector 41 in the first direction Z close to the step-down module 10, and the first input terminal 42 extends in the third direction Y toward the side away from the step-down module 10; the first mounting part 43 is disposed on the side of the first connector 41 in the first direction Z close to the step-down module 10 and connected to the step-down module 10, and the first mounting part 43 extends in the third direction Y.

[0048] Optionally, the connection method between the first mounting part 43 and the step-down module 10 can be adhesive, snap-fit, plug-in, screw-fit, riveting, etc., without restriction.

[0049] Optionally, in the third direction Y, the size of the first mounting portion 43 is smaller than the size of the first input terminal 42. This arrangement facilitates the connection of the first input terminal 42 to the hydrogen-oxygen reactor. Optionally, both the first input terminal 42 and the first mounting portion 43 can be generally block-shaped or sheet-shaped, and both can be generally perpendicular to the first connector 41.

[0050] Optionally, there can be multiple first input terminals 42 and multiple first mounting portions 43, which can be alternately arranged in the second direction X; or, multiple first input terminals 42 can be located on the same side of multiple first mounting portions 43 in the second direction X; or, the first input terminals 42 and first mounting portions 43 can also adopt other feasible arrangements without limitation. Specifically, there are two first input terminals 42 and two first mounting portions 43, which are arranged alternately, and the two first input terminals 42 are located between the two first mounting portions 43 in the second direction X.

[0051] With this configuration, the layout of the first input component 40 is compact and reasonable, which can reduce the size of the power converter 100 and meet the requirements of device integration and miniaturization design.

[0052] In one implementation, such as Figures 1 to 3 As shown, the second input component 50 also includes a second mounting part 53 and a third mounting part 54, and the second connector 51, the second input end 52, the second mounting part 53 and the third mounting part 54 are integrally formed.

[0053] The second input component 50 can be made of materials with relatively high conductivity, such as copper and its alloys (such as pure copper, brass, phosphor bronze, beryllium bronze, chromium zirconium copper, etc.), silver and silver-plated materials, etc., without limitation. Optionally, the second connecting piece 51, the second input end 52, the second mounting portion 53 and the third mounting portion 54 can be an integrally formed structure made by an integrally formed process. The integrally formed process can specifically be stamping, casting, etc., without limitation.

[0054] The second input end 52 is disposed on the side of the second connecting piece 51 close to the boost module 20 in the first direction Z, and the second input end 52 extends in the third direction Y toward the side away from the boost module 20. The second mounting portion 53 is disposed on the side of the second connecting piece 51 close to the boost module 20 in the first direction Z and is connected to the boost module 20, and the second mounting portion 53 extends in the third direction Y. The third mounting portion 54 is disposed on the side of the second connecting piece 51 close to the buck module 10 in the first direction Z and is connected to the buck module 10, and the third mounting portion 54 extends in the third direction Y.

[0055] Optionally, the connection manner between the second mounting portion 53 and the boost module 20 and the connection manner between the third mounting portion 54 and the buck module 10 can both be bonding, clamping, plugging, screwing, riveting, etc., without limitation.

[0056] Optionally, in the second direction X, the shapes of the second mounting portion 53, the second connecting piece 51 and the third mounting portion 54 can be approximately "S" - shaped or "匚" - shaped, etc., without limitation.

[0057] Optionally, in the third direction Y, the sizes of both the second mounting portion 53 and the third mounting portion 54 are smaller than the size of the second input end 52. With such a setting, it is convenient for the second input end 52 to be connected to the hydrogen - oxygen reactor. Optionally, both the first input end 42 and the first mounting portion 43 can be approximately block - shaped or sheet - shaped. In the third direction Y, the sizes of the first mounting portion 43, the second mounting portion 53 and the third mounting portion 54 can be approximately the same, and the sizes of the first input end 42 and the second input end 52 can be approximately the same.

[0058] Optionally, in the orthographic projection in the first direction Z, at least part of the second mounting portion 53 and the third mounting portion 54 can overlap, or there can also be a gap between the second mounting portion 53 and the third mounting portion 54, without limitation. Optionally, in the third direction Y, the first connecting piece 41 is located between the second connecting piece 51 and the inductor module 30, or the second connecting piece 51 is located between the first connecting piece 41 and the inductor module 30, without limitation.

[0059] In the specific implementation, such as Figure 2As shown, the step-down module 10, the second connecting member 51, and the boost module 20 are connected in sequence, and the second connecting member 51 is disposed on one side of the inductor module 30 in the third direction Y. The step-down module 10, the second connecting member 51, and the boost module 20 are generally in a "C" shape, and the inductor module 30 is accommodated in the space between the step-down module 10, the second connecting member 51, and the boost module 20. The first connecting member 41 is disposed on the side of the second connecting member 51 facing away from the inductor module 30.

[0060] With such an arrangement, while the second input component 50 realizes the electrical connection between the boost module 20 and the step-down module 10, it can also provide structural support for the boost module 20 and the step-down module 10, improving the connection stability between the components of the power converter 100. The layout of the power converter 100 is compact and reasonable, which can reduce the volume of the power converter 100, meeting the requirements of device integration and miniaturization design.

[0061] In one implementation, as Figure 3 shown, the number of the first mounting portions 43 is multiple, and the number of the third mounting portions 54 is multiple. The multiple first mounting portions 43 and the multiple third mounting portions 54 are arranged alternately in the second direction X.

[0062] Optionally, in the second direction X, the size of the first mounting portion 43 and the size of the third mounting portion 54 may be the same or different, without limitation.

[0063] Since the first input component 40 is connected to the step-down module 10 through the first mounting portion 43, and the second input component 50 is connected to the step-down module 10 through the third mounting portion 54, arranging the multiple first mounting portions 43 and the multiple third mounting portions 54 alternately in the second direction X can avoid structural interference between the first mounting portion 43 and the third mounting portion 54, and both the first input component 40 and the second input component 50 are connected to the step-down module 10 through multiple mounting portions, ensuring the connection stability.

[0064] In one implementation, as Figure 3 and Figure 4 shown, the power converter 100 further includes a first output component 60 and a second output component 70, and both the first output component 60 and the second output component 70 are electrically connected to the boost module 20.

[0065] The first output component 60 and the second output component 70 are respectively used to connect to the positive and negative electrodes of the load to provide the required electrical energy for the load. Optionally, the first output component 60 and the second output component 70 can be designed with different interface structures according to actual needs to adapt to different types of load requirements.

[0066] Optionally, the first input component 40 and the second output component 70 can be directly connected to the boost module 20 or indirectly, without limitation. Optionally, the first input component 40 and the second output component 70 and the boost module 20 can be an integrated structure or a separate structure, without limitation. The number of the first output component 60 and the second output component 70 can be one or more, without limitation. Optionally, in the second direction X, the first output component 60 and the second output component 70 are spaced apart to avoid interference between them.

[0067] In the second direction X, the first output component 60 and the second output component 70 are disposed between the opposite ends of the boost module 20. This arrangement positions both the first output component 60 and the second output component 70 at the middle position of the power converter 100 in the second direction X. Current can be transmitted from both sides of the power converter 100 towards the middle, shortening the path of high current transmission, achieving a short power flow design, reducing losses during power flow transmission, and improving the conversion efficiency and power density of the power converter 100.

[0068] In the third direction Y, the first output component 60 and the second output component 70 are both located on the same side of the power converter 100 away from the first input terminal 42 and the second input terminal 52. This arrangement, with the input and output components located on opposite sides of the power converter 100 in the third direction Y, facilitates connection of the input terminal to the hydrogen-oxygen reactor and the output terminal to the load, preventing interference between the input and output terminals or incorrect connection during installation.

[0069] In a specific implementation, the positive and negative terminals of the external power supply are electrically connected to the first input component 40 and the second input component 50, respectively, and the positive and negative terminals of the electrical load are electrically connected to the first output component 60 and the second output component 70, respectively. Taking the connection of the positive terminal of the external power supply to the first input component 40, the negative terminal of the external power supply to the second input component 50, the negative terminal of the electrical load to the first output component 60, and the positive terminal of the electrical load to the second output component 70 as an example, the power flow direction when the power converter 100 is working is as follows: the positive power flow passes sequentially through the first input component 40, the step-down module 10, the inductor module 30, and the boost module 20 and is output from the second output component 70; the negative power flow passes sequentially through the second input terminal 52, the second connector 51, the step-down module 10, the inductor module 30, and the boost module 20 and is output from the second output component 70.

[0070] In one implementation, such as Figure 2 as well as Figures 6 to 12As shown, the inductor module 30 includes a liquid cooling component 31 and an inductor component 32. The liquid cooling component 31 has a receiving cavity 311 and an annular heat dissipation channel 312. The annular heat dissipation channel 312 is arranged around the outside of the receiving cavity 311, and the inductor component 32 is housed inside the receiving cavity 311.

[0071] The inductor component 32 may adopt any feasible inductor structure in the art, without limitation.

[0072] Please refer to Figures 6 to 7 In one specific embodiment, the inductor assembly 32 includes a magnetic support 321, a first inductor 322, and a second inductor 323. The magnetic support 321 includes a first end plate 3211, a second end plate 3212, a first winding post 3213, a second winding post 3214, and a support post 3215. The first winding post 3213, the second winding post 3214, and the support post 3215 are all supported in the third direction Y between the first end plate 3211 and the second end plate 3212. The support post 3215 is located between the first winding post 3213 and the second winding post 3214. The first inductor 322 is wound around the first winding post 3213 and spaced apart from the support post 3215. The second inductor 323 is wound around the second winding post 3214 and spaced apart from the support post 3215.

[0073] For a detailed implementation, please refer to Figure 11 The inductor assembly 32 further includes a first connection terminal 326 and a second connection terminal 327, which are respectively disposed on opposite sides of the magnetic bracket 321 in the third-party direction. Optionally, there are two first connection terminals 326 and two second connection terminals 327, and each of the first inductor 322 and the second inductor 323 is connected to one first connection terminal 326 and one second connection terminal 327.

[0074] Taking the first inductor 322 as an example, both the first connection terminal 326 and the second connection terminal 327 are electrically connected to the first inductor 322. The first connection terminal 326 is also electrically connected to the buck module 10, and the second connection terminal 327 is also electrically connected to the boost module 20. This configuration achieves the electrical connection between the first inductor 322 and both the buck module 10 and the boost module 20. The configuration of the second inductor 323 is the same as that of the first inductor 322 and will not be described further.

[0075] Optionally, the receiving cavity 311 extends through the liquid cooling assembly 31 in the third direction Y, so that the inductor assembly 32 can be exposed on opposite sides of the inductor module 30 in the third direction Y, facilitating electrical connection between the inductor assembly 32 and the buck module 10 and the boost module 20. In other embodiments, the receiving cavity 311 may also have an opening facing the first direction Z or the second direction X, without limitation.

[0076] The annular heat dissipation channel 312 is used for the flow of cooling medium to exchange heat with the device. In some embodiments, the cooling medium may be water, ethylene glycol solution, mineral oil, fluorinated liquid, deionized water, etc., and there is no specific limitation.

[0077] Optionally, there is no specific limitation on the number of receiving cavities 311 and the number of inductor components 32. Optionally, there is one receiving cavity 311 and one inductor component 32, with the inductor component 32 housed in the receiving cavity 311; or, there are multiple receiving cavities 311 and multiple inductor components 32, with the number of receiving cavities 311 and the number of inductor components 32 being the same, and multiple inductor components 32 being housed in multiple receiving cavities 311 in a one-to-one correspondence; or, there are multiple receiving cavities 311 and multiple inductor components 32, with each receiving cavity 311 housing at least one inductor component 32, and there is no specific limitation.

[0078] With this configuration, the inductor 32 is housed within the receiving cavity 311, and the annular heat dissipation channel 312 is arranged around the outside of the receiving cavity 311. This allows for timely dissipation of the heat generated by the inductor 32 during operation, improving heat dissipation and cooling efficiency, and ensuring the safe and stable operation of the power converter 100.

[0079] In one implementation, such as Figure 2 and Figure 5 As shown, the step-down module 10 includes a step-down circuit board 11 and a step-down power component 12, with the step-down power component 12 mounted on the side of the step-down circuit board 11 near the annular heat dissipation channel 312; and / or, the boost module 20 includes a boost circuit board 21 and a boost power component 22, with the boost power component 22 mounted on the side of the boost circuit board 21 near the annular heat dissipation channel 312.

[0080] Both the step-down circuit board 11 and the step-up circuit board 21 can adopt any feasible circuit board structure in the art, such as a PCBA circuit board, without specific limitations. Optionally, the step-down power component 12 and the step-down circuit board 11 can be connected by means of welding, bonding, snap-fitting, screwing, riveting, etc., and the step-up power component 22 and the step-up circuit board 21 can be connected by means of welding, bonding, snap-fitting, screwing, riveting, etc., without specific limitations.

[0081] Optionally, the step-down power component 12 and the step-up power component 22 are located on opposite sides of the annular heat dissipation channel 312 in the first direction Z, and both are thermally conductively connected to the annular heat dissipation channel 312.

[0082] Optional, such as Figure 5 and Figure 12As shown, the buck module 10 also includes a current sensor 13 and a capacitor 14. Both the current sensor 13 and the capacitor 14 are mounted on the side of the buck circuit board 11 near the annular heat dissipation channel 312. The annular heat dissipation channel 312 can also dissipate the heat generated by the current sensor 13 and the capacitor 14 during operation. Similarly, the power devices of the boost module 20 can be configured with reference to the buck module 10, and will not be described further.

[0083] With this configuration, the annular heat dissipation channel 312 can also dissipate the heat generated by the step-down power component 12 and / or the step-up power component 22 during operation in a timely manner, thereby improving the heat dissipation and cooling efficiency.

[0084] In specific implementation methods, such as Figure 8 and Figure 9 As shown, the annular heat dissipation channel 312 includes a first heat dissipation channel 3121 and a second heat dissipation channel 3122; in the first direction Z, the first heat dissipation channel 3121 is disposed between the step-down module 10 and the inductor component 32, and the second heat dissipation channel 3122 is disposed between the step-up module 20 and the inductor component 32.

[0085] Optionally, the liquid cooling assembly 31 further includes a liquid inlet 313 and a liquid outlet 314 spaced apart on the same side in the first direction Z, both of which are connected to the annular heat dissipation channel 312. The cooling medium flows into the annular heat dissipation channel 312 from the liquid inlet 313 and flows to dissipate heat from the inductor assembly 32, the boost module 20, and the buck module 10, and finally flows out through the liquid outlet 314.

[0086] In specific implementation methods, such as Figures 8 to 9 As shown, the liquid cooling assembly 31 includes a heat dissipation body 315, which includes a first end 315a and a second end 315b disposed opposite each other in a first direction Z. A first heat dissipation channel 3121 is disposed at the first end 315a, and the first heat dissipation channel 3121 includes a first sub-channel 3121a and a second sub-channel 3121b that are isolated from each other. The first sub-channel 3121a communicates with the liquid inlet 313, and the second sub-channel 3121b communicates with the liquid outlet 314. A second heat dissipation channel 3122 is disposed at the second end 315b. The heat dissipation channel 3122 includes a third sub-channel 3122a and a fourth sub-channel 3122b. One end of the third sub-channel 3122a is isolated from one end of the fourth sub-channel 3122b, and the other end of the third sub-channel 3122a is connected to the other end of the fourth sub-channel 3122b. The isolated ends of the third sub-channel 3122a and the fourth sub-channel 3122b are connected to the first sub-channel 3121a, and the isolated ends of the fourth sub-channel 3122b and the third sub-channel 3122a are connected to the second sub-channel 3121b.

[0087] Optionally, the heat dissipation body 315 also includes a third end 315c and a fourth end 315d disposed opposite each other along the second direction X, with the liquid inlet 313 and the liquid outlet 314 both disposed at the third end 315c.

[0088] The first heat dissipation channel 3121 and the second heat dissipation channel 3122 are respectively disposed at the first end 315a and the second end 315b of the heat dissipation body 315 in the first direction Z. The first heat dissipation channel 3121 includes a first sub-channel 3121a and a second sub-channel 3121b that are isolated from each other. The second heat dissipation channel 3122 includes a third sub-channel 3122a and a fourth sub-channel 3122b. One end of the third sub-channel 3122a is isolated from one end of the fourth sub-channel 3122b, and the other end of the third sub-channel 3122a is connected to the other end of the fourth sub-channel 3122b, so that the liquid inlet hole 313, the first sub-channel 3121a, the third sub-channel 3122a, the fourth sub-channel 3122b, the second sub-channel 3121b and the liquid outlet hole 314 form a sequentially connected loop. Therefore, the liquid inlet 313, the first sub-channel 3121a, and the third sub-channel 3122a are connected in sequence to form an annular heat dissipation channel 312 parallel to the first direction Z. The third sub-channel 3122a and the fourth sub-channel 3122b are connected to form an annular heat dissipation channel 312 perpendicular to the first direction Z. The fourth sub-channel 3122b, the second sub-channel 3121b, and the liquid outlet 314 are connected in sequence to form an annular heat dissipation channel 312 parallel to the first direction Z. That is, three annular heat dissipation channels 312 are formed in the heat dissipation body of the heat dissipation structure. Two of the annular heat dissipation channels 312 are parallel to the first direction Z, and the other annular heat dissipation channel 312 is perpendicular to the first direction Z. This enables the heat dissipation structure to achieve three-dimensional heat dissipation, which allows the cooling medium to flow for a longer time in the heat dissipation structure. This can improve the utilization rate of the cooling medium in the heat exchange process, thereby improving the overall heat dissipation efficiency of the heat dissipation structure.

[0089] In a specific embodiment, the first sub-channel 3121a, the second sub-channel 3121b, the third sub-channel 3122a, and the fourth sub-channel 3122b all extend along the second direction X. The first sub-channel 3121a and the third sub-channel 3122a are arranged opposite each other along the first direction Z, and the second sub-channel 3121b and the fourth sub-channel 3122b are arranged opposite each other along the first direction Z. The heat dissipation body 315 also has a first connecting hole 3151 and a second connecting hole 3152 that are isolated from each other. The first connecting hole 3151 and the second connecting hole 3152 are both located at the fourth end 315d. The first connecting hole 3151 and the second connecting hole 3152 both extend along the first direction Z. The first connecting hole 3151 connects the first sub-channel 3121a and the third sub-channel 3122a, and the second connecting hole 3152 connects the second sub-channel 3121b and the fourth sub-channel 3122b.

[0090] In specific implementation methods, such as Figure 6 , Figures 8 to 10 As shown, the heat dissipation body 315 also includes a fifth end 315e and a sixth end 315f disposed opposite each other along the third direction Y. The receiving cavity 311 has a first limiting part 3154 on the side near the fifth end 315e, and the inductor assembly 32 has a second limiting part 324. When the inductor assembly 32 is received in the receiving cavity 311, the first limiting part 3154 and the second limiting part 324 cooperate.

[0091] With this configuration, when the inductor assembly 32 is housed in the receiving cavity 311, the first limiting part 3154 of the receiving cavity 311 near the fifth end 315e of the heat dissipation body 315 and the second limiting part 324 of the inductor assembly 32 can be used to limit the installation of the inductor assembly 32 in the receiving cavity 311, thereby improving the accuracy of the inductor assembly 32 being installed in the receiving cavity 311.

[0092] In a specific embodiment, the receiving cavity 311 has a first fixing part 3155 on the side near the sixth end 315f, and the inductor assembly 32 has a second fixing part 325. When the inductor assembly 32 is received in the receiving cavity 311, the first fixing part 3155 is connected to the second fixing part 325.

[0093] With this configuration, when the inductor assembly 32 is housed in the receiving cavity 311, the first fixing part 3155 of the receiving cavity 311 near the sixth end 315f of the heat dissipation body 315 and the second fixing part 325 of the inductor assembly 32 are fixedly connected, so as to realize the installation and fixation of the inductor assembly 32 in the receiving cavity 311, thereby improving the stability of the inductor assembly 32 installed in the receiving cavity 311.

[0094] In one implementation method, please refer to Figure 13 and Figure 14 This application provides a power conversion device 1000, including a housing 200 and a power converter 100 in this application embodiment. The housing 200 has a mounting cavity, and the power converter 100 is mounted in the mounting cavity.

[0095] The shell 200 can be made of a material with high structural strength, specifically metal, high-strength plastic, ceramic, etc. Metal materials include, for example, aluminum, aluminum alloys, magnesium alloys, iron, and iron alloys, without limitation. The shell 200 can be a one-piece structure, meaning it can be a single-piece structure manufactured using a one-piece molding process. The shell 200 can also be a modular structure, with its various parts connected and fixed by welding, bonding, snap-fitting, screwing, riveting, etc., without limitation. Optionally, the wall thickness of the shell 200 can be approximately uniform throughout.

[0096] Optionally, the power converter 100 is housed in the mounting cavity and connected to the housing 200. The connection method can be welding, bonding, snap-fitting, screwing, riveting, etc., without limitation.

[0097] The power conversion device 1000 in this application embodiment can reduce the size of the power conversion device 1000 and realize short power flow transmission of the power converter 100 by adopting the power converter 100 in this application embodiment.

[0098] In one implementation method, please refer to Figure 13 and Figure 14 The housing 200 also has a communication port 201, in which the power converter 100 is mounted, and the first input component 40 and the second input component 50 are connected to the outside through the communication port 201.

[0099] The shape of the communication port 201 can be circular, square, rectangular, regular polygonal, elliptical, trapezoidal, etc., without limitation. Optionally, the shape of the communication port 201 can be one or more, without limitation. Optionally, there can be one communication port 201, through which the first input component 40 and the second input component 50 are connected to the outside; or, there can be two communication ports 201, which are spaced apart and correspond to the first input component 40 and the second input component 50 respectively, without limitation.

[0100] With this configuration, the first input component 40 and the second input component 50 can be connected to the outside (e.g., a hydrogen-oxygen reactor) through the through port 201, thus avoiding structural interference between the first input component 40 and the second input component 50 and the housing 200.

[0101] In specific implementation methods, such as Figure 13 and Figure 14 As shown, the housing 200 also has a water inlet 202 and a water outlet 203. The water inlet 202 is connected to the liquid inlet hole 313, and the water outlet 203 is connected to the liquid outlet hole 314. The water inlet 202 and the water outlet 203 are used to deliver or output cooling medium into the liquid cooling assembly 31. Optionally, the water inlet 202 and the liquid inlet hole 313 can be directly connected or indirectly connected, without limitation.

[0102] In specific implementation methods, such as Figure 13 As shown, the housing 200 is also provided with a first output terminal 204, a second output terminal 205, an air compressor interface 206, a hydrogen pump output interface 207, a fan interface 208, and a PTC plug-in 209 at intervals.

[0103] Optionally, one of the first output terminal 204 and the second output terminal 205 is electrically connected to the first output component 60, and the other is electrically connected to the second output component 70, so as to output the required electrical energy to the electrical load.

[0104] Optionally, the power conversion device 1000 also includes an air compressor module (not shown in the figure) and a hydrogen pump control module (not shown in the figure), both of which are housed in a housing cavity. The air compressor interface 206 is electrically connected to the output terminal of the air compressor module, which can provide high-pressure, high-flow-rate air (oxygen) to the fuel cell stack to support the electrochemical reaction. The hydrogen pump output interface 207 is electrically connected to the output terminal of the hydrogen pump control module, which can realize the recycling of unreacted hydrogen and improve hydrogen utilization.

[0105] The fan interface 208 is used to ensure the safe operation of the power conversion device 1000. Optionally, during the operation of the power conversion device 1000, hydrogen emission can be precisely controlled through the fan interface to maintain stable internal pressure and improve fuel conversion efficiency; when the hydrogen pressure inside the power conversion device 1000 exceeds a safety threshold, the fan interface will open and release hydrogen to reduce the risk of explosion.

[0106] PTC connector 209 is used for startup at low temperatures to enable thermal management of the power conversion device 1000. In the description of the embodiments of this application, it should be noted that the orientation or positional relationship of the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" and other indicators are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0107] The above-disclosed embodiments are merely preferred embodiments of this application and should not be construed as limiting the scope of this application. Those skilled in the art will understand that all or part of the processes for implementing the above embodiments and equivalent variations made in accordance with the claims of this application are still within the scope of this application.

Claims

1. A power converter (100), characterized in that, include: Step-down module (10); The boost module (20) is positioned opposite to and spaced apart from the buck module (10) in a first direction; An inductor module (30) is disposed between the buck module (10) and the boost module (20) in the first direction, and the inductor module (30) is electrically connected to the buck module (10) and the boost module (20); The first input component (40) includes a first connector (41) and a first input terminal (42); the first input terminal (42) is electrically connected to the step-down module (10), and in a second direction, the first input terminal (42) is disposed between opposite ends of the step-down module (10); the first connector (41) is electrically connected to the step-down module (10) and the boost module (20); The second input component (50) includes a second connector (51) and a second input terminal (52); the second input terminal (52) is electrically connected to the boost module (20), and in the second direction, the second input terminal (52) is disposed between opposite ends of the boost module (20); the second connector (51) is electrically connected to the buck module (10) and the boost module (20), and the second direction is perpendicular to the first direction.

2. The power converter (100) according to claim 1, characterized in that, In a third direction, the first input terminal (42) and the second input terminal (52) are located on the same side of the power converter (100); wherein the third direction is perpendicular to the first direction and the third direction is perpendicular to the second direction.

3. The power converter (100) according to claim 2, characterized in that, In the first direction, the inductor module (30), the first connector (41), and the second connector (51) are all disposed between the step-down module (10) and the step-up module (20); in the third direction, the inductor module (30) is disposed between the first connector (41) and the second connector (51).

4. The power converter (100) according to claim 3, characterized in that, The first input component (40) further includes a first mounting part (43), and the first connector (41), the first input end (42) and the first mounting part (43) are integrally formed; The first input terminal (42) is disposed on the side of the first connector (41) close to the step-down module (10) in the first direction, and the first input terminal (42) extends along the third direction toward the side away from the step-down module (10); The first mounting part (43) is disposed on the side of the first connector (41) close to the step-down module (10) in the first direction and is connected to the step-down module (10), and the first mounting part (43) extends along the third direction.

5. The power converter (100) according to claim 4, characterized in that, The second input component (50) further includes a second mounting part (53) and a third mounting part (54), wherein the second connector (51), the second input end (52), the second mounting part (53) and the third mounting part (54) are integrally formed; The second input terminal (52) is disposed on the side of the second connector (51) close to the boost module (20) in the first direction, and the second input terminal (52) extends along the third direction toward the side away from the boost module (20); The second mounting part (53) is disposed on the side of the second connector (51) in the first direction close to the boost module (20) and connected to the boost module (20), and the second mounting part (53) extends along the third direction; The third mounting part (54) is disposed on the side of the second connector (51) in the first direction close to the step-down module (10) and connected to the step-down module (10), and the third mounting part (54) extends along the third direction.

6. The power converter (100) according to claim 5, characterized in that, There are multiple first mounting parts (43) and multiple third mounting parts (54), and the multiple first mounting parts (43) and multiple third mounting parts (54) are staggered in the second direction.

7. The power converter (100) according to claim 2, characterized in that, The power converter (100) further includes a first output component (60) and a second output component (70), both of which are electrically connected to the boost module (20). In the second direction, the first output component (60) and the second output component (70) are both disposed between opposite ends of the boost module (20). In the third direction, the first output component (60) and the second output component (70) are both located on the same side of the power converter (100) away from the first input terminal (42) and the second input terminal (52).

8. The power converter (100) according to claim 1, characterized in that, The inductor module (30) includes a liquid cooling component (31) and an inductor component (32). The liquid cooling component (31) has a receiving cavity (311) and an annular heat dissipation channel (312). The annular heat dissipation channel (312) is arranged around the receiving cavity (311), and the inductor component (32) is housed in the receiving cavity (311).

9. The power converter (100) according to claim 8, characterized in that, The step-down module (10) includes a step-down circuit board (11) and a step-down power component (12), wherein the step-down power component (12) is mounted on the side of the step-down circuit board (11) near the annular heat dissipation channel (312); and / or, the boost module (20) includes a boost circuit board (21) and a boost power component (22), wherein the boost power component (22) is mounted on the side of the boost circuit board (21) near the annular heat dissipation channel (312).

10. A power conversion device (1000), characterized in that, include: The power converter (100) as described in any one of claims 1 to 9; The housing (200) has a mounting cavity and a communication port (201), in which the power converter (100) is mounted, and the first input component (40) and the second input component (50) are connected to the outside through the communication port (201).

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