Spraying type liquid cooling charging module

Abstract

The utility model relates to a spray type liquid cooling charging module, which comprises a battery module and a box body, the battery module is arranged in the box body, an upper cover is detachably fixed on the box body, the bottom surface of the upper cover is provided with a spray pipeline for spraying cooling liquid towards the battery module, and the spray pipeline is communicated with the box body. A water inlet and a water outlet which are connected with the spraying pipeline are formed in the outer side wall of the box body. A cooling spraying type liquid cooling mode is adopted in the module, cooling liquid makes full contact with various heating devices in the module, heat is transferred, then the cooling liquid is discharged out of the module through a water outlet by means of an oil pump, meanwhile, the external cooling liquid flows into the module through a water inlet, and the process is repeated so that the cooling liquid can be circulated. A spraying type cooling mode is adopted, and problems existing in an existing air cooling charging module are well solved; meanwhile, the problems that the heat dissipation efficiency of the charging modules is low, and the temperature difference between the charging modules is too large are solved.

Description

Technical Field

[0001] The utility model relates to the technical field of power electronics, in particular to a spray-type liquid-cooling charging module. Background Art

[0002] The charging module is part of the charge management circuitry, primarily responsible for controlling the battery's charge status and protecting the battery. During the charging process, the charging module manages the battery's charge and discharge by controlling parameters such as current and voltage. For example, the charging module can implement functions such as automatic charging stop, over-discharge protection, and overcharge protection, thereby extending the battery's lifespan and ensuring safety.

[0003] Liquid-cooled supercharging, also known as liquid-cooled ultra-high power charging technology, is a highly efficient charging technology achieved through liquid cooling. Its principle is to remove the heat generated by charging through liquid circulation during the charging process, thereby achieving fast and stable charging. Currently, most liquid-cooled supercharging piles are based on traditional air-cooled charging piles and use liquid-cooled charging guns to achieve high-current charging output. High charging power leads to high noise, low reliability, and high maintenance costs.

[0004] Existing technology, such as Chinese patent publication number CN207416596U, discloses a charging pile with a cooling system controlled by a charging module. The charging pile includes a charging module, a controller, a data acquisition board, a relay, and a fan. The controller is connected to the temperature acquisition chip of the charging module to receive the temperature of the charging module itself. The controller sends a signal to the data acquisition board, which sends a signal to the relay. The relay's auxiliary contacts control the start or stop of the fan. This allows for precise control of fan start and stop. Compared to existing thermostat solutions, which only have one thermostat and can fail if the thermostat breaks or the temperature is inaccurate, a charging pile has multiple modules inside. Even if one module fails, it will not affect the temperature sent by other modules.

[0005] The above-mentioned existing technical solutions have the following defects: First, the air-cooling heat dissipation method may not provide sufficient heat dissipation when the charging device is running at high load, causing the device temperature to rise, which in turn affects the charging efficiency and device life. Second, the air-cooling heat dissipation system usually requires additional fans and heat sinks, which increases the complexity and cost of the equipment. In addition, the rotation of the fan may also generate noise and vibration, affecting the user experience. Finally, the air-cooling heat dissipation system is sensitive to environmental dust and humidity and requires regular maintenance and cleaning. Otherwise, dust accumulation may lead to reduced heat dissipation or equipment failure. Utility Model Content

[0006] In view of the shortcomings of the existing technology, the purpose of this utility model is to provide a spray-type liquid-cooled charging module, which can effectively reduce the temperature of the battery module in the box, solve the problems of low efficiency, short life and uneven heat dissipation under the air-cooled heat dissipation method, and achieve the advantages of high protection level, high efficiency, high power density and long life.

[0007] The above-mentioned utility model object of the present invention is achieved through the following technical solutions:

[0008] A spray-type liquid-cooled charging module includes a battery module and a box body. The battery module is arranged in the box body. A top cover is detachably fixed to the box body. The bottom surface of the top cover is provided with a spray pipe for spraying coolant toward the battery module. The outer side wall of the box body is provided with a water inlet and a water outlet connected to the spray pipe.

[0009] As a further technical solution of the present invention: the spray pipeline includes a water inlet pipe, a water distribution pipe, two transition pipes and two spray pipes, the water inlet pipe is provided with a water inlet hole at one end close to the edge of the upper cover, and the other end extends to the middle position of the upper cover and is connected to the middle part of the water distribution pipe, and the water distribution pipe is perpendicular to the water inlet pipe;

[0010] The two ends of the water distribution pipe are respectively connected to the middle part of the transition pipe, the water distribution pipe is perpendicular to the transition pipe, the two ends of the transition pipe are bent 90 degrees in a direction close to each other and then connected to the spray pipe, and the two ends of the spray pipe are bent 90 degrees in a direction close to each other.

[0011] As a further technical solution of the present invention: a plurality of water outlet holes are evenly spaced on the spray pipe.

[0012] As a further technical solution of the present invention: the battery module includes four groups of battery modules, an insulating cover is installed above each group of battery modules, and the spray pipeline is located above the insulating cover.

[0013] As a further technical solution of the present invention: a water inlet pipe is connected to the water inlet, and one end of the water inlet pipe away from the water inlet is connected to the water inlet hole.

[0014] As a further technical solution of the present invention: positive and negative electrodes electrically connected to the battery module are provided on the outer side wall of the box.

[0015] As a further technical solution of the present invention: the water inlet and the water outlet are arranged on the same side of the outer wall of the box.

[0016] As a further technical solution of the present invention: the liquid cooling cycle of the liquid cooling charging module includes the following steps:

[0017] Step 1: Power on the entire device: When the entire device is powered on, the liquid cooling charging module as part of it also begins to prepare to enter the working state.

[0018] Step 2: The oil pump starts to work: The oil pump in the liquid cooling circulation system starts to operate. Its main function is to provide power to circulate the coolant in the system.

[0019] Step 3: Coolant enters the box through the water inlet: Under the action of the oil pump, the coolant is pumped from the external reservoir or coolant source through the pipe and the water inlet into the box of the liquid-cooled charging module;

[0020] Step 4: Cooling spray method to dissipate heat to the main heat-generating components: After the coolant enters the box, it will contact the main heat-generating components (such as processors and power modules) through spraying, injection and immersion. In this process, the coolant absorbs the heat generated by the components;

[0021] Step 5: The coolant flows out of the box through the water outlet: After the coolant that has absorbed heat completes heat exchange in the box, it flows out of the box through the water outlet;

[0022] Step 6: External fan cooling: The coolant flowing out of the box usually passes through a radiator or heat exchanger, where the coolant transfers the absorbed heat to the external environment. To enhance the cooling effect, a fan is usually configured to accelerate air flow and help the radiator dissipate heat more quickly.

[0023] Step 7. The coolant enters the box through the water inlet again: After heat dissipation, the coolant temperature drops, is sucked into the oil pump again, and re-enters the box of the liquid-cooled charging module through the water inlet, starting the next round of circulation cooling process.

[0024] As a further technical solution of the present invention: a nozzle is installed on the spray pipeline, and the nozzle is used to atomize the coolant and then spray it on the battery module.

[0025] As a further technical solution of the present invention: a controller and a temperature sensor are provided in the box body, and the controller is connected to the nozzle and the temperature sensor respectively. The temperature of the battery module is monitored in real time through the temperature sensor. When the temperature exceeds the set value, the controller controls the valve on the spray pipe to open for spraying and heat dissipation.

[0026] In summary, the present invention has at least one of the following beneficial technical effects:

[0027] 1. The utility model discloses a spray-type liquid-cooled charging module. The module adopts a cooling spray-type liquid cooling method inside, so that the coolant and various heat-generating components inside the module are in full contact and heat is transferred. The coolant is then discharged to the outside of the module through the water outlet by an oil pump. At the same time, the external coolant flows into the module through the water inlet, and this cycle repeats, so that the coolant circulates. The use of a spray-type cooling method effectively solves the problems existing in existing air-cooled charging modules; it also solves the problems of low heat dissipation efficiency of charging modules and large temperature differences between charging modules.

[0028] 2. Spray-type liquid cooling technology significantly reduces infrastructure construction costs. Although device maintainability and compatibility are less favorable, it offers better space utilization and recyclability, significantly reducing component energy consumption. It effectively lowers component temperatures within the enclosure, minimizing temperature differences between electrical components, thereby extending lifespan and safety. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a schematic diagram of the overall structure of the utility model.

[0030] Figure 2 It is a structural schematic diagram of the upper cover of the utility model.

[0031] Figure numerals: 1. battery module; 11. battery module; 2. box body; 21. water inlet; 22. water outlet; 3. upper cover; 4. spray pipe; 41. water inlet pipe; 411. water inlet hole; 42. water distribution pipe; 43. transition pipe; 44. spray pipe; 441. water outlet hole; 5. insulating cover; 6. water inlet pipe; 7. positive and negative poles. DETAILED DESCRIPTION

[0032] The technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application; it is obvious that the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

[0033] In the description of this application, it should be noted that the terms "upper," "lower," "inner," "outer," "top / bottom," and the like, indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate the description of this application and simplify the description. They do not indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0034] In the description of this application, it should be noted that, unless otherwise expressly specified or limited, the terms "installed," "provided with," "mounted / connected," and "connected" should be understood in a broad sense. For example, "connected" can mean a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, or it can be internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in this application based on the specific circumstances.

[0035] Example 1:

[0036] Reference Figure 1 , which is a spray-type liquid-cooled charging module disclosed in the utility model, includes a battery module 1 and a box body 2. The battery module 1 is arranged in the box body 2. A top cover 3 is detachably fixed to the box body 2. A spray pipe 4 for spraying coolant toward the battery module 1 is provided on the bottom surface of the top cover 3. A water inlet 21 and a water outlet 22 connected to the spray pipe 4 are provided on the outer wall of the box body 2.

[0037] Reference Figure 2 The spray pipe 4 includes a water inlet pipe 41, a water distribution pipe 42, two transition pipes 43 and two spray pipes 44. The water inlet pipe 41 has a water inlet hole 411 at one end close to the edge of the upper cover 3, and the other end extends to the middle position of the upper cover 3 and is connected to the middle part of the water distribution pipe 42. The water distribution pipe 42 is perpendicular to the water inlet pipe 41;

[0038] The two ends of the water distribution pipe 42 are respectively connected to the middle part of the transition pipe 43. The water distribution pipe 42 is perpendicular to the transition pipe 43. The two ends of the transition pipe 43 are bent 90 degrees in a direction close to each other and then connected to the spray pipe 44. The two ends of the spray pipe 44 are bent 90 degrees in a direction close to each other.

[0039] The spray pipe 44 is provided with multiple water outlet holes 441 at even intervals. The battery module 1 includes four battery modules 11. An insulating cover plate 5 is mounted above each battery module 11, and the spray pipe 4 is located above the insulating cover plate 5. The water inlet 21 is connected to a water inlet pipe 6, the end of which is remote from the water inlet 21 and is connected to the water inlet hole 411. The outer wall of the housing 2 is provided with positive and negative electrodes 7, which are electrically connected to the battery module 1. The water inlet 21 and the water outlet 22 are located on the same side of the outer wall of the housing 2.

[0040] The liquid cooling cycle of the liquid-cooled charging module includes the following steps:

[0041] Step 1: Power on the entire device: When the entire device is powered on, the liquid cooling charging module as part of it also begins to prepare to enter the working state.

[0042] Step 2: The oil pump starts to work: The oil pump in the liquid cooling circulation system starts to operate. Its main function is to provide power to circulate the coolant in the system.

[0043] Step 3: Coolant enters the housing 2 through the water inlet 21: Under the action of the oil pump, the coolant is pumped from the external reservoir or coolant source through the pipe and the water inlet 21 into the housing 2 of the liquid-cooled charging module;

[0044] Step 4: Cooling and spraying to dissipate heat to the main heat-generating components: After the coolant enters the box 2, it will contact the main heat-generating components (such as processors and power modules) through spraying, injection, and immersion. During this process, the coolant absorbs the heat generated by the components;

[0045] Step 5: The coolant flows out of the box 2 through the water outlet 22: After the coolant that has absorbed heat completes heat exchange in the box 2, it flows out of the box 2 through the water outlet 22;

[0046] Step 6: External fan heat dissipation: The coolant flowing out of the box 2 usually passes through a radiator or heat exchanger, where the coolant transfers the absorbed heat to the external environment. To enhance the heat dissipation effect, a fan is usually configured to accelerate air flow and help the radiator dissipate heat more quickly.

[0047] Step 7: The coolant enters the box 2 through the water inlet 21 again: After heat dissipation, the coolant temperature drops, is sucked into the oil pump again, and re-enters the box 2 of the liquid-cooled charging module through the water inlet 21, starting the next round of circulation cooling process.

[0048] This cycle continues continuously, ensuring that the main heat-generating components of the equipment can be effectively cooled, thereby maintaining the normal operation and stable performance of the equipment.

[0049] This fully liquid-cooled charging architecture utilizes a spray-type liquid-cooled charging module. The entire system utilizes a liquid-cooled spray heat dissipation design, resulting in high charging current, low noise, and high reliability. This will promote the application of technologies such as liquid cooling, high-voltage protection, and flexible power distribution. Spray-type liquid cooling technology will be widely used in the context of high-voltage fast charging. Increasing voltage places greater emphasis on the safety and protection design of charging piles, utilizing new technologies for high-temperature, high-voltage DC protection devices. Furthermore, flexible power distribution technology dynamically distributes the power of a high-power charging pile to different charging terminals, addressing issues such as insufficient power, slow charging, and wasted power and insufficient utilization.

[0050] The spray liquid cooling module also offers superior heat dissipation to traditional air cooling, resulting in lower internal module temperature rise and higher device operating efficiency than air-cooled modules. The total cost of ownership (TCO) of charging equipment using liquid-cooled charging modules over the entire charging station lifecycle is significantly lower than that of traditional air-cooled charging equipment.

[0051] Supercharging and fast charging raise the technical bar for charging modules. The charging module is the core component of a charging pile, accounting for up to 50% of the total cost. Its complex internal structure makes it a crucial component that impacts the overall performance and safety of the charging pile. As voltage and charging levels increase, the module must possess even stronger high-voltage resistance and power, further raising the technical bar for charging modules. In the future, with the trend towards higher power, 30kW, 40kW, and above may become the mainstream market. Liquid-cooled modules meet the heat dissipation requirements of high-power charging. Compared to traditional air-cooled charging modules, liquid-cooled charging modules feature a fully enclosed design, effectively isolating dust and flammable and explosive gases, providing enhanced protection. The cables used in liquid-cooled charging piles also undergo tests for high-temperature, corrosion, explosion, extreme cold, and low-temperature resistance. Therefore, the technical barriers and production costs for liquid-cooled supercharging are higher, placing higher demands on the R&D and manufacturing capabilities of charging module companies.

[0052] The utility model also has the following technical effects:

[0053] 1. Compatibility: Spray-type liquid cooling (similar to a shower head) has a relatively low modification cost, and its operation and maintenance mode and load-bearing capacity are basically the same as those of air cooling.

[0054] 2. Heat dissipation effect and energy saving: The cooling effect and energy saving are much better than air cooling, and the components are cooled directly;

[0055] 3. Maintainability: easy to carry out maintainability design and realize online maintenance plan;

[0056] 4. It is necessary to solve the problem of module commercialization, reduce manufacturing costs, and enable scalable production.

[0057] Spray-type liquid cooling technology significantly reduces infrastructure construction costs. While device maintainability and compatibility are limited, it offers improved space utilization and recyclability, significantly reducing component energy consumption. It effectively lowers component temperatures within enclosure 2, minimizing temperature differences between electrical components, thereby extending lifespan and safety.

[0058] The implementation principle of this utility model is as follows: This utility model discloses a spray-type liquid-cooled charging module. The module adopts a cooling spray-type liquid cooling method inside, so that the coolant and various heat-generating components inside the module are fully in contact and heat is transferred. The coolant is then discharged to the outside of the module through the water outlet 22 by an oil pump. At the same time, the external coolant flows into the module through the water inlet 21. This cycle repeats, so that the coolant circulates. The use of a spray-type cooling method effectively solves the problems existing in existing air-cooled charging modules; it also solves the problems of low heat dissipation efficiency of charging modules and large temperature differences between charging modules.

[0059] Example 2:

[0060] A spray-type liquid-cooled charging module differs from the first embodiment in that a nozzle is installed on the spray pipe 4, which is used to atomize the coolant and spray it on the battery module 1. A controller and a temperature sensor are installed in the box 2. The controller is connected to the nozzle and the temperature sensor respectively. The temperature sensor monitors the temperature of the battery module 1 in real time. When the temperature exceeds the set value, the controller controls the valve on the spray pipe 4 to open, spraying and dissipating heat.

[0061] The implementation principle of this utility model is as follows: This utility model discloses a spray-type liquid-cooled charging module. The module adopts a cooling spray-type liquid cooling method inside, so that the coolant and various heat-generating components inside the module are fully in contact and heat is transferred. The coolant is then discharged to the outside of the module through the water outlet by an oil pump. At the same time, the external coolant flows into the module through the water inlet, and this cycle repeats, so that the coolant circulates. The use of a spray-type cooling method effectively solves the problems existing in existing air-cooled charging modules; it also solves the problems of low heat dissipation efficiency of charging modules and large temperature differences between charging modules.

[0062] The embodiments of this specific implementation method are all preferred embodiments of the present utility model, and are not intended to limit the scope of protection of the present utility model. Therefore, any equivalent changes made based on the structure, shape, and principle of the present utility model should be included in the scope of protection of the present utility model.

Claims

1. A spray-type liquid-cooled charging module, comprising a battery module (1), characterized in that: The invention also includes a box body (2), wherein the battery module (1) is arranged in the box body (2), and an upper cover (3) is detachably fixed on the box body (2), and a spray pipe (4) for spraying coolant toward the battery module (1) is provided on the bottom surface of the upper cover (3), and a water inlet (21) and a water outlet (22) connected to the spray pipe (4) are provided on the outer wall of the box body (2).

2. The spray-type liquid-cooled charging module according to claim 1, characterized in that: The spray pipeline (4) includes a water inlet pipe (41), a water distribution pipe (42), two transition pipes (43) and two spray pipes (44); one end of the water inlet pipe (41) close to the edge of the upper cover (3) is provided with a water inlet hole (411); the other end extends to the middle position of the upper cover (3) and is connected to the middle position of the water distribution pipe (42); the water distribution pipe (42) is perpendicular to the water inlet pipe (41); The two ends of the water distribution pipe (42) are respectively connected to the middle part of the transition pipe (43), the water distribution pipe (42) is perpendicular to the transition pipe (43), the two ends of the transition pipe (43) are bent 90 degrees in a direction close to each other and then connected to the spray pipe (44), and the two ends of the spray pipe (44) are bent 90 degrees in a direction close to each other.

3. The spray-type liquid-cooled charging module according to claim 2, characterized in that: The spray pipe (44) is provided with a plurality of water outlet holes (441) at even intervals.

4. The spray-type liquid-cooled charging module according to claim 1, characterized in that: The battery module (1) comprises four groups of battery modules (11), an insulating cover plate (5) is installed above each group of battery modules (11), and the spray pipeline (4) is located above the insulating cover plate (5).

5. The spray-type liquid-cooled charging module according to claim 2, characterized in that: The water inlet (21) is connected to a water inlet pipe (6), and one end of the water inlet pipe (6) away from the water inlet (21) is connected to the water inlet hole (411).

6. The spray-type liquid-cooled charging module according to claim 1, characterized in that: Positive and negative electrodes (7) electrically connected to the battery module (1) are provided on the outer side walls of the box (2).

7. The spray-type liquid-cooled charging module according to claim 1, characterized in that: The water inlet (21) and the water outlet (22) are arranged on the same side of the outer wall of the box body (2).

8. The spray-type liquid-cooled charging module according to claim 1, characterized in that: A spray head is installed on the spray pipeline (4), and the spray head is used to atomize the coolant and then spray it on the battery module (1).

9. The spray-type liquid-cooled charging module according to claim 8, characterized in that: A controller and a temperature sensor are provided in the box (2). The controller is connected to the nozzle and the temperature sensor respectively. The temperature of the battery module (1) is monitored in real time by the temperature sensor. When the temperature exceeds a set value, the controller controls the valve on the spray pipe (4) to open for spraying and heat dissipation.

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