Vehicle-mounted module with cooling flow channel
By designing an on-board module with cooling channels, the problems of difficult installation and heat dissipation of OBC and DC-DC converters in new energy electric vehicles have been solved. Stable installation and efficient heat dissipation of core components have been achieved. The module features modularity and platformization, reducing the overall weight and assembly difficulty.
Patent Information
- Application Number
- CN202423299007.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-30
- Publication Date
- 2026-02-03
- Estimated Expiration
- 2034-12-30
AI Technical Summary
In existing technologies, it is difficult to achieve modular and platform-based design after OBC and DC-DC converters are integrated in new energy electric vehicles. They are also difficult to install, have a high degree of difficulty in heat dissipation structure design, and have large size and weight of core components such as MOSFETs, inductors and transformers, which are difficult to dissipate heat.
Design an on-board module with cooling channels, including a housing, cooling channels and heat dissipation plane. The housing is equipped with a cooling water tank and a cover plate. The cooling channels exchange heat through a cooling medium to provide heat dissipation for the core components. The electronic components are mounted in an adapter structure to achieve stable installation and heat dissipation.
It achieves reliable installation and efficient heat dissipation of core components, features modularity and platformization, reduces the overall weight and assembly difficulty, and shortens the assembly cycle.
Smart Images
Figure CN223872614U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of automotive parts technology, and in particular to an on-board module with cooling channels. Background Technology
[0002] For new energy electric vehicles, the on-board charger (OBC) and DC-DC converter are two indispensable components. The former is used to replenish the on-board battery, and the latter is used to provide energy for the on-board low-voltage equipment.
[0003] In the current architecture of new energy electric vehicles, the OBC and DC-DC converter are usually integrated into a single housing to form a two-in-one on-board component. The purpose of doing so is to reduce weight, size and cost, which is more conducive to the integrated design of the vehicle assembly.
[0004] However, since OBCs and DC-DC converters provide different functions for automobiles, their internal electronic components and structural designs differ accordingly. Therefore, when they are combined into one unit, the casing needs to be adapted to the internal component layout. In particular, due to the functional requirements of OBCs and DC-DC converters, a large number of power devices and magnetic components, such as MOSFETs, inductors, and transformers, are required. These core components are not only large and heavy, making installation difficult, but also generate a lot of heat during operation, requiring heat dissipation. Adapting the mounting structure and heat dissipation structure to these core components is quite challenging, making it difficult to achieve the design goals of modularization and platformization. Utility Model Content
[0005] This application aims to address at least one of the technical problems existing in the prior art. To this end, this application proposes an automotive module with cooling channels to achieve reliable installation of core components and provide effective heat dissipation for the core components.
[0006] This application provides an automotive module with cooling channels, the automotive module comprising:
[0007] The housing includes an electronic device mounting cavity, a cooling channel, and a heat dissipation plane, wherein the electronic device mounting cavity and the heat dissipation plane are respectively located on two sides of the cooling channel;
[0008] The heat dissipation plane is used to mount the first core device;
[0009] The electronic device mounting cavity is used to accommodate and mount the second core device, and its cavity structure is adapted to the second core device.
[0010] The cooling channel includes a cooling water tank for the flow of cooling medium and a cover plate. After the cover plate covers the cooling water tank, it forms the heat dissipation plane.
[0011] In one embodiment of the aforementioned vehicle-mounted module with cooling channels,
[0012] The cooling water tank is disposed inside the housing and is integrally cast with the housing. The cooling water tank and the cover plate cooperate to form the cooling flow channel.
[0013] In one embodiment of the aforementioned vehicle-mounted module with cooling channels,
[0014] The cooling water tank is equipped with guide ribs.
[0015] In one embodiment of the aforementioned vehicle-mounted module with cooling channels,
[0016] The housing is provided with a water inlet and a water outlet, which are respectively located at both ends of the cooling channel and are connected to the cooling channel.
[0017] In one embodiment of the aforementioned vehicle-mounted module with cooling channels,
[0018] The electronic device mounting cavity has at least two cavities arranged along the flow direction of the cooling medium, and each cavity is configured to mount one of the second core devices.
[0019] In one embodiment of the aforementioned vehicle-mounted module with cooling channels,
[0020] The electronic device mounting cavity is provided with positioning posts and support posts adapted to the second core device installed thereon; the electronic device mounting cavity and the housing are integrally die-cast.
[0021] In one embodiment of the aforementioned vehicle-mounted module with cooling channels,
[0022] The first core component is mounted on the heat dissipation plane;
[0023] The second core device is installed inside the electronic device mounting cavity.
[0024] In one embodiment of the aforementioned vehicle-mounted module with cooling channels,
[0025] The first core device is a power device; the second core device is a magnetic device.
[0026] In one embodiment of the aforementioned vehicle-mounted module with cooling channels,
[0027] The first core component is fixed to the heat dissipation plane by adhesive; the second core component is fixed inside the electronic device mounting cavity by thermally conductive potting compound.
[0028] In one embodiment of the aforementioned vehicle-mounted module with cooling channels,
[0029] The housing is provided with several fixing holes and positioning holes adapted to the overall installation of the vehicle module.
[0030] The above-described one or more embodiments of this application have at least one or more of the following beneficial effects:
[0031] In implementing the technical solution of this application, the vehicle module, by setting the heat dissipation plane and the electronic device mounting cavity on both sides of the cooling channel, can concentrate the large and heat-generating core electronic components together, providing a mechanical structure for the installation and heat dissipation of the core components. This mechanical structure can simultaneously provide heat dissipation for various types of core components on both sides through the heat exchange effect of the cooling medium in the cooling channel, and has the characteristics of modularity and platformization. The heat dissipation plane is easy to process, providing effective heat dissipation for core components that can be fixed on the plane. The cavity structure of the electronic device mounting cavity is designed according to the structural shape of the core components, which can achieve stable installation of the core components, ensure the reliability of component application, prevent the components from being damaged during operation vibration, and does not occupy extra space, which helps to reduce the weight of the whole machine. Furthermore, with the vehicle module of this application, it can be pre-assembled with the core components into a whole part, and during the whole machine assembly process, this vehicle module can be directly assembled into the corresponding position, which helps to reduce the difficulty of the whole machine assembly and shorten the cycle of the whole machine assembly.
[0032] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description
[0033] The disclosure of this application will become more readily understood with reference to the accompanying drawings. It will be readily understood by those skilled in the art that these drawings are for illustrative purposes only and are not intended to limit the scope of protection of this application. Furthermore, similar numbers in the drawings are used to denote similar components, wherein:
[0034] Figure 1 This is a schematic diagram of the vehicle module structure according to one embodiment of this application;
[0035] Figure 2 This is an exploded structural diagram of a vehicle module according to one embodiment of this application;
[0036] Figure 3 This is a schematic diagram of the cooling water tank of an on-board module according to one embodiment of this application;
[0037] Figure 4 This is a schematic diagram of the vehicle module from another perspective, representing one embodiment of this application.
[0038] Figure 5This is a schematic diagram of the vehicle module structure after installing the core components according to one embodiment of this application;
[0039] Figure 6 This is an exploded structural diagram of the vehicle module after the core components are installed, according to one embodiment of this application;
[0040] Figure 7 This is a schematic diagram of the mounting extension surface structure of a vehicle module according to one embodiment of this application.
[0041] Explanation of reference numerals in the attached figures:
[0042] 100. Housing; 101. Heat dissipation plane; 102. Cooling water tank; 1021. Guide ribs; 103. Cover plate; 104. Water inlet; 105. Water outlet; 106. Mounting extension surface; 107. Fixing hole; 108. Positioning hole;
[0043] 200. Electronic component mounting cavity; 201. Cavity; 202. Positioning post; 203. Support post;
[0044] 300, First core component; 400, Second core component; 401, LLC transformer; 402, PFC inductor; 403, DC-DC inductor / transformer. Detailed Implementation
[0045] Some embodiments of this application are described below with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely illustrative of the technical principles of this application and are not intended to limit the scope of protection of this application.
[0046] As described in the background section, although OBC and DC-DC converters are two indispensable automotive components, and both require a large number of core devices such as power devices and magnetic devices, the integrated installation of some core components has become a trend in the automotive parts industry. However, these core components generally suffer from large size and weight, difficult installation, and heat dissipation problems. Based on this, this application proposes an automotive module with cooling channels to solve the above problems.
[0047] See appendix Figure 1 and Figure 2In one or more embodiments, a vehicle-mounted module with a core and cooling channel according to this application includes: a housing 100, the housing 100 including an electronic device mounting cavity 200, a cooling channel and a heat dissipation plane 101, the electronic device mounting cavity 200 and the heat dissipation plane being located on two sides of the cooling channel respectively; the heat dissipation plane 101 is used to mount a first core device; the electronic device mounting cavity 200 is used to accommodate and mount a second core device, the cavity 201 structure being adapted to the second core device; the cooling channel includes a cooling water tank 102 for cooling medium to flow through and a cover plate 103, the cover plate 103 covering the cooling water tank 102 to form the heat dissipation plane 101, the cooling channel providing heat dissipation for both the first core device and the second core device mounted on both sides.
[0048] Specifically, in this application, the first core device can be a surface-mount power device, such as a MOSFET, which can be mounted on the heat dissipation plane 101. Cooling channels can dissipate the heat generated by the MOSFET from one side. The second core device can be a larger magnetic device, such as a DC-DC inductor / transformer, a PFC inductor, or an LLC transformer. The magnetic device is installed in a cavity of the similarly structured electronic device mounting cavity 200, and cooling channels dissipate the heat generated by the magnetic device from the other side. It should be understood that the core device can also be other important automotive components, suitable for conformal mounting, integration, or planar mounting, thus enabling effective heat dissipation for components integrated on both sides simultaneously.
[0049] The vehicle-mounted module of this application embodiment, by respectively setting the heat dissipation plane 101 and the electronic device mounting cavity 200 on both sides of the cooling channel, can concentrate the large-volume and high-heat-generating core electronic components together, providing a mechanical structure for the installation and heat dissipation of the core components. This mechanical structure can simultaneously provide heat dissipation for various types of core components on both sides through the heat exchange effect of the cooling medium in the cooling channel, and has the characteristics of modularity and platformization. The heat dissipation plane 101 is easy to process and provides effective heat dissipation for core components that can be fixed on the plane. The cavity 201 structure of the electronic device mounting cavity 200 is designed according to the structural shape of the core components, which can achieve stable installation of the core components, ensure the reliability of component application, prevent the components from being damaged during operation vibration, and does not occupy extra space, which helps to reduce the weight of the whole machine. Furthermore, with the vehicle-mounted module of this application, it can be pre-assembled with the core components into a whole part, and during the whole machine assembly process, this vehicle-mounted module can be directly assembled into the corresponding position, which helps to reduce the difficulty of the whole machine assembly and shorten the cycle of the whole machine assembly.
[0050] In one implementation, refer to Figure 1 and Figure 2The cooling water tank 102 is disposed inside the housing 100 and integrally cast with the housing 100. The cooling water tank 102 and the cover plate 103 cooperate to form a cooling channel. The cooling channel provides a container for the flow path of the cooling medium, such as coolant. The coolant flows in the cooling channel and carries away the heat generated by the first core device installed on the heat dissipation plane 101 and the second core device installed in the electronic device mounting cavity 200 through heat exchange. It makes full use of the space on both sides of the cooling channel and effectively shortens the volume and weight of the vehicle module.
[0051] Specifically, the housing 100 and the cooling water tank 102 inside the housing 100 can be made of die-cast aluminum using a die-casting process, and the cover plate 103 can be welded to the housing 100 using a friction stir welding process. Since the vehicle module is an independent part relative to the entire electronic control device, rather than being initially set in the housing, the processing of the surface of the cover plate 103 is very simple. It is only necessary to mill the surface of the cover plate 103 flat, and the flatness and roughness of the surface can be easily processed to meet the heat dissipation requirements of the core components. The heat dissipation plane 101 with sufficient area can meet the heat dissipation requirements of the first core component installed on it. If the vehicle module is not an independent part, but is integrated into the housing, then when it is necessary to process a plane with heat dissipation function, the plane is in a vertical state, which is difficult to process, has a long processing cycle, and will affect the heat dissipation performance and increase the processing cost.
[0052] In one possible implementation, refer to Figure 2 and Figure 3 The cooling water tank 102 is equipped with guide ribs 1021. The guide ribs 1021 can ensure that the coolant in the cooling channel flows in the ideal direction, while increasing the contact area between the cooling channel and the coolant, making the heat exchange efficiency higher, thereby providing better heat dissipation for the core components on both sides.
[0053] Specifically, in this application, due to the heat dissipation area requirements of the heat dissipation plane 101 and the installation requirements of sufficient area for the core components, the housing 100 and the cover plate 103 are extended along the flow direction of the cooling medium, which can have more heat dissipation area. Therefore, in order to further improve the heat exchange efficiency, the guide ribs 1021 can be extended along the flow direction of the cooling medium, so that the coolant flows in the cooling channel along the original flow direction of the cooling medium. In order to increase the contact area between the cooling channel and the coolant, multiple guide ribs 1021 can be provided, and the ends of the multiple guide ribs 1021 are connected to each other, and the coolant flows along the multiple guide ribs 1021 in the cooling channel.
[0054] In one possible implementation, refer to Figure 4The housing 100 is provided with an inlet 104 and an outlet 105. The inlet 104 and the outlet 105 are respectively located at both ends of the cooling channel and are connected to the cooling channel. The coolant flows into the cooling channel from the inlet 104 and finally flows out of the cooling channel from the outlet 105.
[0055] In one possible implementation, refer to Figure 4 The housing 100 is provided with mounting extension surfaces 106 around the water inlet 104 and the water outlet 105. That is, the water inlet 104 and the water outlet 105 have a plane with sufficient area around them, which can provide space for compression sealing of the sealing ring. When the cooling channel in the housing 10 is connected to the water channel or external water channel of the housing to be installed through the sealing ring, the connection and sealing between the water channels is realized.
[0056] In one implementation, refer to Figure 1 and Figure 2 The electronic device mounting cavity 200 has at least two connected cavities 201, which are arranged along the direction of the cooling medium flow. Each cavity 201 is configured to install a second core device, and the structure of each cavity 201 is similar to that of the corresponding installed second core device. That is, multiple cavities 201 for installing second core devices can be set in the electronic device mounting cavity 200. The structure of each cavity 201 is modeled according to the structural shape of the corresponding installed core device. The modeled structure can realize the stable and reliable installation of the device, and at the same time, it does not occupy extra space, which helps to reduce the overall weight and volume.
[0057] In one possible implementation, refer to Figure 2 The electronic device mounting cavity 200 is provided with positioning posts 202 and support posts 203 adapted to the second core device to be installed, which can ensure the positioning and support of the core device during installation. It should be understood that the positioning posts 202 and support posts 203 shown in the figure are only for illustrative purposes and are not specific restrictions on their specific positions and quantities. In actual use, the corresponding settings are made according to the specific core device to be installed.
[0058] In one possible implementation, refer to Figures 1-4 The housing 100 and the electronic component mounting cavity 200 are integrally die-cast. Specifically, since the vehicle module of this application is an independent structural part, the contoured structure of its housing 100 and electronic component mounting cavity 200 can be integrally processed by die casting. The machining difficulty of the curved surface is low, which can effectively ensure the process requirement of uniform wall thickness of the die-cast part. However, if the vehicle module is not an independent part but is integrated into the housing of the whole machine to be installed, then due to the limitations of the die casting process, some contoured curved surfaces cannot be machined, and the uniform wall thickness of the die-cast part cannot be guaranteed. The independent design of the vehicle module of this application effectively reduces the volume and weight of the overall device.
[0059] Furthermore, in one or more embodiments, reference is made to Figures 1-5 In the vehicle module of this application, the first core device 300 is installed on the heat dissipation plane 101; the second core device 400 is installed in the electronic device mounting cavity 200. Through the housing 100, it can be pre-assembled with the core device into an integral part, that is, the vehicle module with the device installed. During the assembly process of the whole machine, this vehicle module can be directly assembled into the corresponding position, which helps to reduce the difficulty of the whole machine assembly and shorten the cycle of the whole machine assembly.
[0060] In one implementation, refer to Figure 5 and Figure 6 , Figure 6 yes Figure 5 The exploded structural diagram shows that the first core device 300 is a power device, such as a MOSFET. The MOSFET is attached to the heat dissipation plane 101 of the cover plate 103 for heat dissipation, and they are fixed together by thermally conductive and insulating adhesive. Coolant flows in the cooling channel, carrying away the heat generated by the MOSFET through heat exchange. The power device realizes the power conversion function of the OBC and DC-DC converter. The second core device 400 is a magnetic device. For example, in this application, the second core device 400 includes an LLC transformer 401, a PFC inductor 402, and a DC-DC inductor / transformer 403, which are respectively installed in cavities 201 with corresponding structures and shapes. The DC-DC inductor / transformer 403 is... The PFC inductor 402 and LLC transformer 401 are key components that convert the high-voltage DC output from the OBC into low-voltage DC to provide energy for the vehicle's low-voltage equipment. They are crucial for charging the vehicle's battery by converting the high-voltage AC output from the grid into high-voltage DC. After these magnetic components are installed, thermally conductive potting compound is poured into the contoured electronic component mounting cavity 200 to fill the gaps between the magnetic components and the cavity. Once the potting compound has fully cured, it ensures the magnetic components are fixed and will not be damaged during operation. At the same time, coolant flows through cooling channels on the side of the contoured electronic component mounting cavity 200, and the coolant carries away the heat generated by the magnetic components through heat exchange.
[0061] In one possible implementation, refer to Figure 4 and Figure 7The vehicle-mounted module is provided with several fixing holes 107 and positioning holes 108 adapted for overall installation. After all core components, including power devices and magnetic devices, are installed and fixed into the vehicle-mounted module to form a whole, the positioning holes 108 facilitate the installation and positioning of this whole vehicle-mounted module. Screws are installed through the fixing holes 107, ensuring the installation reliability of this whole vehicle-mounted module and effectively reducing the difficulty and cycle time of the overall assembly. It should be understood that the two mutually symmetrical reference positioning holes 108 and five fixing holes 107 provided on the mounting extension surface 106 are shown in the illustrations of this application only for the purpose of understanding the structural arrangement and function of the fixing holes 107 and positioning holes 108, and are not a limitation on their specific positions and numbers. In actual use, the positions and numbers of fixing holes 107 and positioning holes 108 can be set according to the specific installation position and method of the vehicle-mounted module in the whole machine.
[0062] Based on the above implementation methods, refer to Figures 1-7 An optional installation process for the vehicle module in this embodiment is as follows: Identify and select core components. In this application, core components include power devices and magnetic devices. These devices typically generate a large amount of heat, with magnetic devices usually having the largest volume and weight. A die-cast aluminum housing 100 and an electronic device mounting cavity 200 are integrally formed using a die-casting process. A cover plate 103 adapted to the housing 100 is also die-cast. The outer surface of the cover plate 103 is milled to form a heat dissipation plane 101. The housing 100 contains a cooling water tank 102. The electronic device mounting cavity 200 is designed according to the magnetic... The number and structure of the power devices are conformally die-cast; the cover plate 103 is welded to the housing 100 by friction stir welding, forming a cooling channel with the cooling water tank 102; the power devices are attached to the heat dissipation plane 101 with thermally conductive insulating adhesive; the magnetic devices are installed into the electronic device mounting cavity 200 according to the corresponding conformal structural position. After installation, thermally conductive potting compound is poured into the electronic device mounting cavity 200 to fill the gap between the magnetic devices and the electronic device mounting cavity 200. After curing, the installation and fixation of the magnetic devices are completed, thus completing the installation of the entire vehicle module. During use, coolant flows into the cooling water channel through the inlet 104. The coolant carries away the heat generated by the power devices and magnetic devices on both sides of the cooling channel through heat exchange. The coolant finally flows out of the cooling water channel through the outlet 105.
[0063] Furthermore, this application provides an electronic control device, including the vehicle module described above.
[0064] Specifically, the electronic control device can be a two-in-one vehicle-mounted OBC and DC-DC converter. Its vehicle-mounted module includes the power devices and magnetic devices of the vehicle-mounted OBC and DC-DC converter. The vehicle-mounted module concentrates the largest and hottest electronic components in the vehicle-mounted OBC and DC-DC converter together and designs an appropriate structure for heat dissipation. It has the characteristics of modularity and platformization, and helps to reduce the difficulty of overall assembly and shorten the assembly cycle. The specific structural settings and effects of the vehicle-mounted module are described in the above implementation method, and the repeated parts will not be repeated.
[0065] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.
[0066] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.
[0067] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.
Claims
1. A vehicle-mounted module with cooling channels, characterized in that, The vehicle-mounted module includes: The housing includes an electronic device mounting cavity, a cooling channel, and a heat dissipation plane, wherein the electronic device mounting cavity and the heat dissipation plane are respectively located on two sides of the cooling channel; The heat dissipation plane is used to mount the first core device; The electronic device mounting cavity is used to accommodate and mount the second core device, and its cavity structure is adapted to the second core device. The cooling channel includes a cooling water tank for the flow of cooling medium and a cover plate. After the cover plate covers the cooling water tank, it forms the heat dissipation plane.
2. The vehicle-mounted module with cooling channels according to claim 1, characterized in that, The cooling water tank is disposed inside the housing and is integrally cast with the housing. The cooling water tank and the cover plate cooperate to form the cooling flow channel.
3. The vehicle-mounted module with cooling channels according to claim 2, characterized in that, The cooling water tank is equipped with guide ribs.
4. The vehicle-mounted module with cooling channels according to claim 3, characterized in that, The housing is provided with a water inlet and a water outlet, which are respectively located at both ends of the cooling channel and are connected to the cooling channel.
5. The vehicle-mounted module with cooling channels according to claim 1, characterized in that, The electronic device mounting cavity has at least two cavities arranged along the flow direction of the cooling medium, and each cavity is configured to mount one of the second core devices.
6. The vehicle-mounted module with cooling channels according to claim 1, characterized in that, The electronic device mounting cavity is provided with positioning posts and support posts adapted to the second core device installed thereon; the electronic device mounting cavity and the housing are integrally die-cast.
7. The vehicle-mounted module with cooling channels according to claim 1, characterized in that, The first core component is mounted on the heat dissipation plane; The second core device is installed inside the electronic device mounting cavity.
8. The vehicle-mounted module with cooling channels according to claim 7, characterized in that, The first core device is a power device; the second core device is a magnetic device.
9. The vehicle-mounted module with cooling channels according to claim 7, characterized in that, The first core component is fixed to the heat dissipation plane by adhesive; the second core component is fixed inside the electronic device mounting cavity by thermally conductive potting compound.
10. The vehicle-mounted module with cooling channels according to claim 7, characterized in that, The housing is provided with several fixing holes and positioning holes adapted to the overall installation of the vehicle module.