Efficient heat dissipation vehicle-mounted charger device

Abstract

The utility model relates to an efficient heat dissipation vehicle-mounted charger device which comprises a shell, a water flowing channel is arranged in the shell, at least one electrical part is arranged on the inner side of the water flowing channel, a metal substrate is tightly attached to the inner side wall of the water flowing channel, a plurality of power tubes are fixedly connected to the inner side wall of the metal substrate, and the power tubes are arranged on the inner side wall of the metal substrate. A supporting pressing plate used for pressing the metal substrate or the power tube is arranged between the electrical part and the power tube. According to the efficient heat dissipation vehicle-mounted charger device, the power board is welded on the aluminum substrate for heat dissipation, compared with bonding glue, the heat resistance is smaller, the heat dissipation effect can be improved, and meanwhile the cost of the aluminum substrate is lower than that of a ceramic chip; the power tube is placed on the inner side of the water channel, so that the power tube can be completely covered by the pouring sealant, the heat dissipation effect is further improved, and the pouring sealant cannot be poured when the power tube is placed on the outer side; and the pressing plate is adopted to fix the power tube, which is more reliable than glue bonding, and meanwhile, the metal pressing plate can also realize an electromagnetic shielding effect.

Description

Technical Field

[0001] The utility model relates to the technical field of new energy vehicles, and in particular to a high-efficiency heat dissipation vehicle-mounted charger device. Background Art

[0002] With the popularity of new energy vehicles, the market share of electric vehicles is gradually expanding. As important electric power system components of electric vehicles, motor controllers, on-board chargers and converters need to improve product performance, reduce product costs and increase product power density. However, the current on-board chargers have unreasonable internal components and cannot effectively and quickly cool the large amount of heat generated by power devices, which affects the normal operation of the equipment and reduces the service life of the equipment.

[0003] At present, the heat dissipation method of on-board chargers is mostly liquid cooling, among which the three-dimensional flow channel structure is the mainstream design scheme. The Chinese utility model patent CN 211701524 U is a vehicle charger device, such as Figure 1 As shown, it includes a housing 100, a power module housing 200 arranged in the housing 100, and a connector 600 arranged on the housing 100. The inner cavity of the housing wall of the power module housing 100 is provided with a water flow channel 230, and the housing wall is provided with a water inlet 201 and a water outlet 202 connected to the water flow channel 230. The power module housing 200 is provided with a capacitor 400, an inductor 300, and a transformer 500, and the capacitor 400, the inductor 300, and the transformer 500 are filled and fixed by a thermal conductive potting glue 700. Through the filling of the thermal conductive potting glue 700, the heat is transferred to the power module housing 200 through the action of the thermal conductive potting glue 700, and finally the heat is taken away by the cooling water channel. The outer wall of the power module housing 200 is bonded with a plurality of power tubes 800 through a thermal conductive ceramic sheet 900, and the thermal conductive ceramic sheet 900 is cured after being heated at high temperature, and the power tube 900 and the power module housing 200 are bonded together to achieve good heat dissipation and fixing effects. This technology mainly relies on the U-shaped water flow channel to dissipate heat for the power tubes adhered to its outer wall and the magnetic devices (inductors, transformers) surrounding it. Since the power tubes are arranged outside the water channel, the structural tightness is unreliable, and the thermal conductivity of the power tubes depends on the ceramic sheet, resulting in low efficiency. As the power of the charger continues to increase, its heat dissipation requirements are also getting higher and higher. Among them, the power tubes have the largest power consumption and require good heat dissipation conditions the most. Utility Model Content

[0004] The embodiment of the utility model provides a high-efficiency heat dissipation vehicle-mounted charger device to solve the problem of low heat dissipation efficiency of the power tube due to unreasonable structure in the prior art.

[0005] In order to achieve the above purpose, the embodiment of the utility model provides the following technical solutions:

[0006] A high-efficiency heat dissipation vehicle-mounted charger device comprises a shell, a water flow channel is provided in the shell, at least one electrical component is provided on the inner side of the water flow channel, a metal substrate is closely arranged on the inner side wall of the water flow channel, a plurality of power tubes are fixedly connected to the inner side wall of the metal substrate, and a supporting pressure plate for pressing the metal substrate or the power tube is provided between the electrical component and the power tube.

[0007] Furthermore, the support pressure plate is provided with a plurality of first spring sheets for tightening the metal substrate or the power tube, the first spring sheets include a first tightening portion and a first connecting portion, the first connecting portion is arranged obliquely and respectively connects the first tightening portion and the support pressure plate, and the angle range between the first tightening portion and the support pressure plate is 0°-30°.

[0008] Furthermore, the tightening portion is an arc-shaped plate.

[0009] Furthermore, the support pressure plate is provided with a second spring sheet for tightening the electrical components, and the second spring sheet is a hemispherical structure or a raised wedge-shaped structure; or, the second spring sheet includes a second tightening portion and a second connecting portion, the second connecting portion is inclined and respectively connects the second tightening portion and the support pressure plate, and the angle between the second tightening portion and the support pressure plate ranges from 0° to 30°.

[0010] Furthermore, both sides of the supporting pressure plate are provided with fixing structures for fixed connection with the shell.

[0011] Furthermore, the power tube is welded and connected to the metal substrate.

[0012] Furthermore, the surface of the metal substrate body is covered with an insulating layer and copper foil.

[0013] Furthermore, a welding column is provided on the top of the supporting plate.

[0014] Furthermore, a connector for connecting the power tube and the PCB board is provided on the upper portion of the metal substrate.

[0015] The utility model embodiment has the following advantages:

[0016] 1. The utility model is a high-efficiency heat dissipation vehicle charger device that welds the power board to the aluminum substrate for heat dissipation. Compared with adhesive, the thermal resistance is smaller and the heat dissipation effect can be improved. At the same time, the cost of the aluminum substrate is lower than that of the ceramic sheet.

[0017] 2. The utility model provides an efficient heat dissipation vehicle-mounted charger device. The power tube is placed inside the water channel so that it can be completely covered by the potting glue, further improving the heat dissipation effect. However, if it is placed outside, it cannot be potted.

[0018] 3. The utility model adopts a high-efficiency heat dissipation vehicle charger device to fix the power tube with a pressing plate, which is more reliable than gluing. At the same time, the metal pressing plate can also achieve electromagnetic shielding. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the implementation of the utility model or the technical solution in the prior art, the following is a brief introduction to the drawings required for the implementation or the prior art description. Obviously, the drawings in the following description are only exemplary, and for ordinary technicians in this field, other implementation drawings can be derived from the provided drawings without creative work.

[0020] The structures, proportions, sizes, etc. illustrated in this specification are only used to match the contents disclosed in the specification so as to facilitate understanding and reading by persons familiar with the technology. They are not used to limit the conditions under which the present invention can be implemented, and therefore have no substantial technical significance. Any structural modification, change in proportion or adjustment of size shall still fall within the scope of the technical contents disclosed in the present invention without affecting the effects and purposes that can be achieved by the present invention.

[0021] Figure 1 The prior art of on-board charger device;

[0022] Figure 2 An exploded diagram of an efficient heat dissipation vehicle-mounted charger device provided by an embodiment of the utility model;

[0023] Figure 3 A cross-sectional view of a high-efficiency heat dissipation vehicle-mounted charger device provided by an embodiment of the utility model;

[0024] Figure 4-1 A structural diagram of a metal substrate in a high-efficiency heat dissipation vehicle charger device provided by an embodiment of the utility model;

[0025] Figure 4-2 A structural diagram of a metal substrate in a high-efficiency heat dissipation vehicle charger device provided by another embodiment of the utility model;

[0026] Figure 5 A structural diagram of a supporting pressure plate in a high-efficiency heat dissipation vehicle-mounted charger device provided by an embodiment of the utility model;

[0027] Figure 6 A structural diagram of a second spring sheet on a supporting pressure plate in a high-efficiency heat dissipation vehicle-mounted charger device provided by an embodiment of the utility model;

[0028] Figure 7 A structural diagram of a supporting pressure plate in a high-efficiency heat dissipation vehicle-mounted charger device provided in an embodiment of the utility model.

[0029] In the figure:

[0030] 1. Shell; 2. Water flow channel; 3. Electrical parts; 4. Metal substrate; 5. Power tube; 6. Support pressure plate; 7. First spring piece; 8. First tightening part; 9. First connecting part; 10. Welding column; 11. Fixed structure; 12. Connecting part; 13. Second spring piece; 14. Second tightening part; 15. Second connecting part; 16. Inclined surface; 17. Support surface. DETAILED DESCRIPTION

[0031] The following is a specific embodiment of the present invention. People familiar with the technology can easily understand the other advantages and functions of the present invention from the contents disclosed in this specification. Obviously, the described embodiment is a part of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0032] like Figure 2-3 As shown, a high-efficiency heat dissipation on-board charger device includes a shell 1, a water channel 2 is provided in the shell 1, and a water inlet and a water outlet connected to the water channel 2 are provided on the outer wall of the shell 1. In this technology, the water channel 2 is a U-shaped structure, and at least one electrical component 3 is provided on the inner side of the water channel 2. The electrical component 3 is an electrical component with high heat dissipation and large structure, such as a capacitor, an inductor, a transformer, and a relay.

[0033] like Figure 4-1As shown, a metal substrate 4 is closely arranged on the inner wall of the U-shaped structure surrounded by the water flow channel 2, and a plurality of power tubes 5 are fixedly connected to the inner side wall of the metal substrate 4. Specifically, the surface of one side of the metal substrate to be welded is covered with an insulating layer (about 0.05-0.1 mm), and the insulating layer is further covered with copper foil, and the power tubes are fixed on the copper foil. In this technology, the power tubes 5 are preferably welded to the metal substrate 4. Compared with the adhesive in the prior art, the welding connection is welded to a tin layer (the thermal conductivity of tin is about 60 W / (m·K)). The thermal resistance of the solder layer is much smaller than that of the adhesive layer (generally 2-4 W / (m·K)), and the heat dissipation effect is better. In the present technology, the metal substrate 4 is preferably an aluminum plate or an aluminum alloy plate, and the thickness of the aluminum substrate ranges from 1 to 2 mm. The thermal conductivity of the aluminum substrate Al 5052 model is about 160W / (m·K); the thermal conductivity of the Al 1060 model is about 240W / (m·K); the thermal conductivity of the insulating layer on the surface of the aluminum substrate is usually 1.0W / (m·K), 1.5W / (m·K), 2.0W / (m·K), etc. The higher the thermal conductivity, the better the performance of the aluminum substrate, but the price will increase. The thermal conductivity of the ceramic substrate is generally between 20-30W / (m·K) due to different materials, but the price of the aluminum substrate is lower than that of the ceramic substrate, and the ceramic substrate is not easy to process, so the processing cost of the aluminum substrate is lower. According to the calculation of the thermal resistance model, within the area of ​​a single power tube, the overall thermal resistance of the 1.5mm aluminum substrate plus welding in the aluminum substrate welding power tube solution is about 0.21K / W, which is much smaller than the existing ceramic sheet plus adhesive solution. The thermal resistance of the existing 1.0mm ceramic sheet plus adhesive solution is about 1.25K / W. In addition, the power tube 5 is set on the inner side of the water channel 2, and the power tube 5 is completely covered by the potting glue, which further improves the heat dissipation effect, thereby achieving an overall improvement in the heat dissipation effect and reducing costs.

[0034] like Figure 4-2 As shown, a connector 12 for connecting the power tube 5 and the PCB board is provided on the upper part of the metal substrate 4. The power tube 5 is connected to the upper PCB through the connector 12. Compared with the structure without the connector 12, the power tube 5 does not need a specific sorting structure, so that more power tubes 5 can be arranged, further improving the overall space utilization.

[0035] like Figure 5As shown, a support plate 6 for pressing the metal substrate 4 or the power tube 5 is provided between the electrical component 3 and the power tube 5. In order to increase the stability of the power tube 5, it is preferred that the support plate 6 presses the power tube 5, and the metal substrate 4 will be pressed at the same time when the power tube 5 is pressed. Specifically, the support plate 6 is provided with a plurality of first spring pieces 7 for pressing the metal substrate 4 or the power tube 5. The first spring pieces 7 include a first pressing portion 8 and a first connecting portion 9. The first connecting portion 9 is tilted and respectively connects the first pressing portion 8 and the support plate 6. The angle between the first pressing portion 8 and the support plate 6 is in the range of 0°-30°, so that the larger the contact surface between the pressing portion and the power tube 5 and the metal substrate 4, the more dispersed the pressure between the two is, and the better the stability of the support is. In the present technology, it is preferred that the first pressing portion 8 is an arc-shaped plate to increase the supporting effect of the first pressing portion 8.

[0036] The top of the support plate 6 is provided with a welding column 10, which is welded to the PCB and grounded to play a role in structural reinforcement and electromagnetic shielding. Both sides of the support plate 6 are provided with a fixing structure 11 for fixing with the housing 1. Figure 1 In the embodiment, fixing feet are provided on the top of both sides of the supporting pressing plate 6, which are fixed to the housing 1 by screws, and are used for positioning and fixing the supporting pressing plate 6.

[0037] The supporting plate 6 is provided with a second spring piece 13 for tightening the electrical component 3. An implementation scheme of the second spring piece 13 is as follows: Figure 6 As shown, the second spring piece 13 includes a second pressing portion 14 and a second connecting portion 15, the second connecting portion 15 is tilted and respectively connects the second pressing portion 14 and the supporting plate 6, and the angle between the second pressing portion 14 and the supporting plate 6 is in the range of 0°-30°. If both sides of the supporting plate 6 are elastic structures, the deformation of the spring pieces on both sides is not easy to control, such as Figure 7 As shown, the second spring piece 13 is preferably a stamped fixed structure, that is, a hemispherical structure or a raised wedge-shaped structure, and the installation side of the second spring piece 13 forms a slope 16, and the top of the second spring piece 13 forms a supporting surface 17, which is convenient for supporting the pressure plate 6 to be inserted from top to bottom. The second spring piece 13 has walls on three sides to provide good support, which can meet the clamping work of the electrical component 3. The processing cost of this hemispherical structure is relatively low.

[0038] Comparing this technical solution with the existing ceramic bonding solution, the following data is obtained based on the area of ​​a single power tube calculated according to the thermal resistance model:

[0039] The thermal resistance of a 1.5mm aluminum substrate (including insulation layer and copper foil) is approximately 0.20K / W; the thermal resistance of the solder layer is 0.01K / W.

[0040] The thermal resistance of a 1mm ceramic sheet is approximately 0.50K / W; the thermal resistance of the adhesive layer is 0.75K / W.

[0041] Although the utility model has been described in detail above with general descriptions and specific embodiments, it is obvious to those skilled in the art that some modifications or improvements can be made to the utility model. Therefore, these modifications or improvements made without departing from the spirit of the utility model are within the scope of protection claimed by the utility model.

Claims

1. An efficient heat dissipation vehicle charger device, characterized in that: It comprises a shell, a water flow channel is arranged in the shell, at least one electrical component is arranged on the inner side of the water flow channel, a metal substrate is tightly arranged on the inner side wall of the water flow channel, a plurality of power tubes are fixedly connected to the inner side wall of the metal substrate, and a supporting pressure plate for pressing the metal substrate or the power tube is arranged between the electrical component and the power tube.

2. The high-efficiency heat dissipation vehicle charger device according to claim 1, characterized in that: The support platen is provided with a plurality of first spring sheets for tightening the metal substrate or the power tube, the first spring sheets include a first tightening portion and a first connecting portion, the first connecting portion is inclined and respectively connects the first tightening portion and the support platen, and the angle between the first tightening portion and the support platen is in the range of 0°-30°.

3. The high-efficiency heat dissipation vehicle charger device according to claim 2, characterized in that: The tightening portion is an arc-shaped plate.

4. The high-efficiency heat dissipation vehicle charger device according to claim 1, characterized in that: The supporting pressing plate is provided with a second elastic piece for tightening the electrical component, and the second elastic piece is a hemispherical structure or a protruding wedge-shaped structure; Alternatively, the second elastic sheet includes a second tightening portion and a second connecting portion, the second connecting portion is arranged obliquely and respectively connects the second tightening portion and the supporting pressing plate, and the angle between the second tightening portion and the supporting pressing plate ranges from 0° to 30°.

5. The high-efficiency heat dissipation vehicle charger device according to claim 1, characterized in that: Both sides of the support plate are provided with fixing structures for fixed connection with the shell.

6. The high-efficiency heat dissipation vehicle charger device according to claim 1, characterized in that: The power tube is welded and connected to the metal substrate.

7. The high-efficiency heat dissipation vehicle charger device according to claim 1, characterized in that: The surface of the metal substrate is covered with an insulating layer and copper foil.

8. The high-efficiency heat dissipation vehicle charger device according to claim 1, characterized in that: A welding column is provided on the top of the supporting pressing plate.

9. The high-efficiency heat dissipation vehicle charger device according to claim 1, characterized in that: A connector for connecting the power tube and the PCB board is provided on the upper part of the metal substrate.

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