A high-power liquid-cooled charging gun and a liquid-cooled charging system

Abstract

This invention discloses a high-power liquid-cooled charging gun, characterized by a heat dissipation unit housed within a power supply base. The heat dissipation unit comprises a fluid storage chamber, a heat exchange module, a circulation power module, and a cooling circuit extending to and at least partially covering a heat-dissipating element for direct energy extraction. The cooling circuit is filled with coolant, and the heat exchange module releases heat from the coolant. The coolant follows the cooling circuit sequentially through the heat-dissipating element, the fluid storage chamber, and the heat exchange module, ultimately circulating via the circulation power module. By integrating the heat dissipation unit, circulation power module, and heat exchange module into the power supply base, and utilizing the cooling circuit for direct contact cooling of the charging plug, heat dissipation efficiency is improved. Furthermore, the coordinated design of the liquid-cooled charging gun and the dual-phase cooling system in the main equipment area enables precise cooling of high-voltage, high-current heat-generating components, significantly increasing the upper limit of charging power.

Description

Technical Field

[0001] This invention patent relates to the field of energy storage cooling, and in particular to a high-power liquid-cooled charging gun and a liquid-cooled charging system. Background Technology

[0002] With the deepening of global green travel and sustainable development, the new energy vehicle industry has experienced explosive growth, and the market size continues to expand. At the same time, new energy vehicles are accelerating their upgrade to 800V high-voltage platforms, which places higher demands on the power output, heat dissipation efficiency, and system stability of the supporting charging infrastructure.

[0003] However, existing charging systems still face many bottlenecks: First, conventional air-cooling methods have limited heat dissipation capacity during high-power charging, which can easily lead to overheating of equipment, limiting the continuous output of charging power and shortening the lifespan of the equipment; second, existing systems are unable to achieve megawatt-level (MW) high-power charging, and cannot effectively alleviate users' "charging anxiety" during long-distance travel; in addition, existing systems mostly rely on direct power supply from the grid, lack effective coordination with high-rate energy storage systems, and are unable to cope with grid load fluctuations, and the overall system integration and energy utilization efficiency need to be further improved.

[0004] Invention Patent Content

[0005] In order to overcome the above-mentioned problems in the prior art, this invention provides a high-power liquid-cooled charging gun and a liquid-cooled charging system to improve the heat dissipation efficiency and power carrying capacity of the charging system.

[0006] A high-power liquid-cooled charging gun includes a heat dissipation unit disposed inside a power supply base. The heat dissipation unit has a fluid storage chamber, a heat exchange module, a circulation power module, and a cooling circuit extending to and at least partially covering a heat-dissipating element to achieve direct energy extraction through contact. The cooling circuit is filled with coolant, and the heat exchange module is used to release the heat energy in the coolant. The coolant follows the cooling circuit sequentially through the heat-dissipating element, the fluid storage chamber, and the heat exchange module, and is finally circulated by the circulation power module.

[0007] Furthermore, the heat-dissipating element is a charging plug, which has a positive power supply plug and a negative power supply plug for connecting to the charging socket. The cooling circuit achieves circulating cooling from the circulating power module through the positive power supply plug and the negative power supply plug.

[0008] Furthermore, the cooling circuit is extended via a connecting pipe between the charging plug and the power supply base.

[0009] Furthermore, the cooling liquid in the cooling circuit is any one of water, ethylene glycol, or aqueous ethylene glycol.

[0010] A liquid-cooled charging system includes the aforementioned high-power liquid-cooled charging gun.

[0011] Furthermore, the system is divided into a main equipment area and a terminal output area. The main equipment area contains a refrigeration circuit that utilizes phase change heat transfer. The main equipment area and the terminal output area are connected by a cooling circuit using a circulating single-phase working fluid. The cooling circuit and the refrigeration circuit are thermally coupled in an isolated manner through the heat exchange module.

[0012] Furthermore, the main equipment area includes a heat release module, a throttling module, and a compression module. The medium from the terminal output area enters the compression module in a low-temperature, low-pressure phase. After compression, it is converted into a high-temperature, high-pressure gas medium and transported to the heat release module. After releasing heat, it liquefies to form a low-temperature, high-pressure liquid and is then transported to the throttling module for throttling and cooling. Finally, it returns to the terminal output area for circulating cooling.

[0013] Furthermore, the terminal output area includes a first heat dissipation unit and a second heat dissipation unit having the fluid storage cavity, the heat exchange module, the circulating power module, and a cooling circuit extending to and at least partially covering the heat dissipation element to achieve energy extraction through direct contact. The first heat dissipation unit forms a secondary circuit cooling with the main equipment area, and the second heat dissipation unit is independent of the main equipment area.

[0014] Furthermore, the heat dissipation element is one of the high-power liquid-cooled charging gun, PCS unit, energy storage unit, and bidirectional stack.

[0015] The beneficial effects of this invention patent are as follows:

[0016] This invention patent provides a high-power liquid-cooled charging gun and liquid-cooled charging system. By integrating the heat dissipation unit, circulating power module, and heat exchange module into the power supply base, and utilizing a cooling circuit to directly contact and cool the charging plug, the heat dissipation efficiency is improved. Furthermore, the coordinated design of the liquid-cooled charging gun and the dual-phase cooling system in the main equipment area achieves precise cooling of high-voltage, high-current heat-generating components, significantly increasing the upper limit of charging power. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the embodiments of the present invention will be further described below with reference to the accompanying drawings.

[0018] Figure 1 This is a schematic diagram of the power supply base provided in this invention patent.

[0019] Figure 2 This is a schematic diagram of the internal structure of the liquid-cooled charging gun provided in this invention patent.

[0020] Figure 3 This is a schematic diagram of the overall structure of the liquid-cooled charging system provided by this invention patent.

[0021] Figure 4 This is a system logic diagram provided by the present invention patent. Detailed Implementation

[0022] In the description of this invention patent, it should be noted that the terms "upper", "lower", "left", "right", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are professional terms well known to those skilled in the art. The above description is for the purpose of simplifying the description of this invention patent, and does not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation on this invention patent.

[0023] Exemplary embodiments of this application will now be described with reference to the accompanying drawings. However, it should be understood that this application can be presented in many different ways and is not limited to the embodiments described below. It should also be understood that the embodiments disclosed herein can be combined in various ways to provide further additional embodiments. Throughout the drawings, the same reference numerals denote the same or functionally identical elements.

[0024] Figure 1 and Figure 2 The overall structure of this high-power charging gun is shown. An independent terminal output area 10 is set in the base 100. The terminal output area 10 is connected to the plug 200 through a pipe. Coolant circulates between the terminal output area 10 and the plug 200 to enable the plug 200 to be rapidly cooled by liquid cooling when high-power charging is performed.

[0025] The terminal output area 10 consists of a heat exchange module 14, a fluid storage chamber, a circulating power module 11, and a cooling circuit 201. The plug 200 has positive and negative power supply plugs 210 and 220 for connection to the charging base 300. The cooling circuit 201 circulates from the circulating power module 11, passes through the positive and negative power supply plugs 210 and 220, releases heat through the heat exchange module 14, and flows into the fluid storage chamber to await re-extraction and reuse by the circulating power module 11. Inside the terminal power supply base, located away from the main equipment compartment, is encapsulated a fluid storage chamber 15 forming an independent circulation loop, a heat dissipation unit, and a terminal fluid drive unit 11. The distal heat exchange section extends through the fluid network and at least partially covers the conductive core of the power transmission terminal formed by the aforementioned positive and negative power supply plugs 210 and 220, to perform direct interface contact heat extraction.

[0026] In some embodiments, the cooling circuit 201 is integrated into the connecting pipe 210.

[0027] In some implementations, the heat exchange module 14 is an air-cooled heat dissipation unit.

[0028] In some embodiments, the liquid in the cooling circuit 201 is any one of water, ethylene glycol, or water-ethylene glycol.

[0029] Figure 3 and Figure 4 The overall structure of the liquid-cooled charging system equipped with this high-power charging gun is shown, including the liquid cooling system and its various sub-working units. Each sub-working unit, acting as a heat-generating element 13, is connected to the liquid cooling system for rapid cooling. The liquid cooling system as a whole includes a main equipment area 20 and a terminal output area 10. The main equipment area 20 and the terminal output area 10 also constitute the refrigerant side and liquid cooling side of the system, which are cross-coupled through different media.

[0030] The main equipment area 20 consists of a two-phase cooling unit composed of a heat dissipation module 22, a throttling module 23, and a compression module 21. The gas enters the compression module 21 in a low-temperature and low-pressure phase through the refrigeration circuit on the heat dissipation unit side. After compression, it is converted into a high-temperature and high-pressure gas medium and transported to the heat dissipation module 22. After releasing heat, it liquefies to form a low-temperature and high-pressure liquid and is then transported to the throttling module 23 for throttling and cooling. Finally, it is transmitted to the terminal output area 10 for cooling.

[0031] In some embodiments, the refrigeration circuit filler is a fluorinated refrigerant. Preferably, it is R134a or R1234yf.

[0032] In some embodiments, the terminal output area 10 is a single-phase cooling unit consisting of a heat exchange module 14, a circulating power module 11, and a heat dissipation element 13, wherein the heat dissipation element 13 integrates a cooling circuit for liquid cooling. That is, the heat exchange module 14 is an isolated heat exchange component with independent first and second flow channel regions to block the physical mixing between heterogeneous working fluids and allow heat energy to be conducted through the flow channel interface.

[0033] Preferably, the heat exchange module 14 is an evaporator that exchanges heat with a refrigerant and a coolant respectively, and the terminal output area 10 and the main equipment area 20 work together to form a secondary circuit refrigeration.

[0034] In some embodiments, the sub-working unit is the aforementioned heat-dissipating element 13, including a PCS unit 600, an energy storage unit 500, a bidirectional stack 400, and a plug 200.

[0035] In some embodiments, the terminal output area 10 is an independently operating single-phase cooling unit consisting of a heat exchange module 14, a circulating power module 11, and a heat dissipation element 13. Preferably, the heat exchange module 14 is an air-cooled heat dissipation unit.

[0036] In some implementations, the terminal output area 10 includes a first heat dissipation unit and a second heat dissipation unit. The first heat dissipation unit is coupled with secondary cooling to the main device area 20, and the second heat dissipation unit is an independently operating single-phase cooling unit. This allows some sub-working units, such as the PCS unit 600, to implement single-phase cooling, while others, such as the energy storage unit 500, implement secondary coupled cooling.

[0037] In other embodiments, the main equipment area 20 is used to directly cool the heating unit 13.

[0038] Unless otherwise specified, the singular forms “a,” “the,” and “the” used in this specification include the plural forms. The terms “comprising,” “including,” and “containing” used in this specification indicate the presence of the claimed feature, but do not exclude the presence of one or more other features.

[0039] In the specification, when an element is described as being "on," "fixed" to, "connected" to, or "joined" to another element, the element may be directly located on, fixed to, connected to, joined to, or in contact with the other element, or there may be an intermediate element present. In the specification, the description of a feature being arranged "adjacent" to another feature may refer to a feature having a portion that overlaps with the adjacent feature or a portion located above or below the adjacent feature.

Claims

1. A high-power liquid-cooled charging gun, characterized in that, It includes a heat dissipation unit disposed inside the power supply base, the heat dissipation unit having a fluid storage chamber, a heat exchange module, a circulating power module, and a cooling circuit extending to and at least partially covering the heat dissipation element to achieve energy extraction through direct contact. The cooling circuit is filled with coolant, and the heat exchange module is used to release the heat energy in the coolant. The coolant follows the cooling circuit sequentially through the heat-releasing element, the fluid storage chamber, and the heat exchange module, and is finally circulated by the circulation power module.

2. The high-power liquid-cooled charging gun of claim 1, wherein, The heat dissipation element is a charging plug, which has a positive power supply plug and a negative power supply plug for connecting to the charging socket. The cooling circuit achieves circulating cooling from the circulating power module through the positive power supply plug and the negative power supply plug.

3. A high-power liquid-cooled charging gun according to claim 2, wherein, The cooling circuit is extended by a connecting pipe between the charging plug and the power supply base.

4. The high-power liquid-cooled charging gun of claim 1, wherein, The cooling liquid in the cooling circuit is any one of water, ethylene glycol, or water-ethylene glycol.

5. A liquid-cooled charging system, characterized by, The invention includes a high-power liquid-cooled charging gun as described in claim 1.

6. A liquid-cooled charging system as claimed in claim 5, characterized in that The system is divided into a main equipment area and a terminal output area. The main equipment area contains a refrigeration circuit that utilizes phase change heat transfer. The main equipment area and the terminal output area are connected by a cooling circuit with a circulating single-phase working fluid. The cooling circuit and the refrigeration circuit are thermally coupled in an isolated manner through the heat exchange module.

7. The liquid-cooled charging system as described in claim 6, characterized in that, The main equipment area includes a heat release module, a throttling module, and a compression module. The medium from the terminal output area enters the compression module in a low-temperature, low-pressure phase. After compression, it is converted into a high-temperature, high-pressure gas medium and transported to the heat release module. After releasing heat, it liquefies to form a low-temperature, high-pressure liquid and is then transported to the throttling module for throttling and cooling. Finally, it returns to the terminal output area for circulating cooling.

8. A liquid-cooled charging system as claimed in claim 7, characterized in that The terminal output area includes a first heat dissipation unit and a second heat dissipation unit having the fluid storage chamber, the heat exchange module, the circulating power module, and a cooling circuit extending to and at least partially covering the heat dissipation element to achieve energy extraction through direct contact. The first heat dissipation unit forms a secondary circuit cooling with the main equipment area, and the second heat dissipation unit is independent of the main equipment area.

9. A liquid-cooled charging system as claimed in claim 8, characterized in that The heat dissipation element is one of the high-power liquid-cooled charging gun, PCS unit, energy storage unit, and bidirectional stack.

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