Planar power converter and vehicle including same

Abstract

The utility model provides a planar power converter and a vehicle comprising the same. The planar power converter comprises a transformer assembly, a power inductor assembly and a housing. Wherein each of the transformer assembly and the power inductor assembly comprises a first magnetic core, a second magnetic core and a printed circuit board, a planar winding is arranged on the printed circuit board, and the printed circuit board is arranged between the first magnetic core and the second magnetic core; a heat conduction layer is arranged between the first magnetic core and the printed circuit board and / or between the second electric core and the printed circuit board so as to reduce the temperature difference between the first magnetic core and the second magnetic core; the transformer assembly and the power inductor assembly are arranged in the containing space of the shell. The planar power converter provided by the utility model solves the problems of low internal heat dissipation efficiency and failure of the planar power converter caused by temperature difference between the magnetic cores.

Description

Technical Field

[0001] This utility model belongs to the field of power converter technology, specifically relating to a planar power converter and a vehicle including the same. Background Technology

[0002] Planar power converters are power converters that lay the windings on a PCB to achieve planar magnetic components. Planar power converters significantly reduce high-frequency parasitic parameters due to their unique planar structure and tight coupling of the windings. Furthermore, they eliminate the need for a winding frame, increasing current density, simplifying manufacturing, and providing high power density. They also offer advantages such as small size, high frequency, and low height. As electronic devices continue to evolve towards smaller size, higher power density, and higher efficiency, planar power converters are widely used in electronic equipment. However, the application of planar power converters presents the following problems:

[0003] 1. The windings of the planar power converter are concentrated inside the circuit board, and the current density is constantly increasing. The line loss inside the PCB board will generate a lot of heat, causing local overheating.

[0004] 2. Due to the limitations of the external heat exchange system, the planar power converter in application basically removes heat from the planar power converter through single-sided heat dissipation. This results in a large temperature difference between the two magnetic core components. The high temperature area leads to a decrease in inductance, which causes magnetic saturation and ultimately leads to the failure of the power converter. Utility Model Content

[0005] This invention provides a planar power converter and a vehicle including the planar power converter, in order to solve the problems of low internal heat dissipation efficiency and temperature difference between magnetic cores causing planar power converter failure.

[0006] To solve or improve the above-mentioned technical problems to a certain extent, this utility model provides a planar power converter, comprising: a transformer assembly, a power inductor assembly, and a housing;

[0007] The transformer assembly and the power inductor assembly each include a first magnetic core, a second magnetic core, and a printed circuit board. The printed circuit board is provided with a planar winding and is disposed between the first magnetic core and the second magnetic core.

[0008] A thermally conductive layer is provided between the first magnetic core and the printed circuit board and / or between the second magnetic core and the printed circuit board to reduce the temperature difference between the first magnetic core and the second magnetic core;

[0009] Both the transformer assembly and the power inductor assembly are disposed within the accommodating space of the housing.

[0010] In some embodiments, the housing includes a first heat dissipation housing and a second heat dissipation housing, wherein the first heat dissipation housing is in contact with an external cooling system, the first magnetic core is close to the first heat dissipation housing, and the thermally conductive layer is disposed between the first magnetic core and the printed circuit board.

[0011] In some embodiments, the housing includes a first heat dissipation housing and a second heat dissipation housing, wherein the first heat dissipation housing is in contact with an external cooling system, the first magnetic core is close to the first heat dissipation housing, and the first magnetic core and the second magnetic core are both provided with the thermal conductive layer between the printed circuit board, and the thermal conductivity of the thermal conductive layer between the first magnetic core and the printed circuit board is less than the thermal conductivity of the thermal conductive layer between the second magnetic core and the printed circuit board.

[0012] In some embodiments, thermally conductive material is filled in the gaps between the transformer assembly and the power inductor assembly and the housing.

[0013] In some embodiments, the printed circuit board of the transformer assembly and the printed circuit board of the power inductor assembly are electrically connected via connectors; or

[0014] The printed circuit board of the transformer assembly and the printed circuit board of the power inductor assembly are integrated into one structure.

[0015] In some embodiments, the first magnetic core of the transformer assembly is integrally formed with the first magnetic core of the power inductor assembly; and / or

[0016] The second magnetic core of the transformer assembly is integrally formed with the second magnetic core of the power inductor assembly.

[0017] In some embodiments, the housing includes a first heat dissipation housing and a second heat dissipation housing, wherein the first heat dissipation housing and / or the second heat dissipation housing serve as cover plates for the coolant flow channels of the external cooling system, so that the first heat dissipation housing and / or the second heat dissipation housing are in direct contact with the coolant of the external cooling system.

[0018] In some embodiments, the housing includes a first heat dissipation housing and a second heat dissipation housing, wherein the interior of the first heat dissipation housing and / or the second heat dissipation housing is provided with a coolant channel, which communicates with the coolant flow channel of an external cooling system.

[0019] In some embodiments, a power transistor is provided on the printed circuit board, and the power transistor is electrically connected to the low-voltage side of the transformer assembly and the power inductor assembly.

[0020] According to another aspect of the present invention, a vehicle is provided, comprising the electric drive system described in any of the above embodiments.

[0021] In this invention, a heat-conducting layer is added between the magnetic cores of the transformer assembly and the power inductor assembly of the planar power converter and the printed circuit board. On the one hand, the heat generated by the line loss of the printed circuit board can be smoothly discharged. On the other hand, the temperature difference between the magnetic cores can be effectively reduced, avoiding the failure of the planar power converter caused by the decrease in inductance in the high-temperature area due to the temperature difference between the first magnetic core and the second magnetic core, which leads to magnetic saturation.

[0022] The above description is merely an overview of the technical solution of this utility model. In order to better understand the technical means of this utility model and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this utility model more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0023] Figure 1 This is an exploded view of the transformer assembly and power inductor assembly of a planar power converter according to an embodiment of the present invention;

[0024] Figure 2 This is a schematic diagram of the assembly structure of the transformer assembly and power inductor assembly of a planar power converter according to an embodiment of the present invention;

[0025] Figure 3 This is a schematic diagram of the external structure of a planar power converter according to an embodiment of the present invention;

[0026] Figure 4 This is an exploded view of a planar power converter according to an embodiment of the present invention;

[0027] Figure 5 This is a cross-sectional view of a planar power converter according to an embodiment of the present invention.

[0028] [Symbol Explanation]

[0029] 10. Voltage converter assembly

[0030] 20. Power Inductor Components

[0031] 100. Printed Circuit Board

[0032] 1000, Planar winding

[0033] 101. First magnetic core

[0034] 102. Second magnetic core

[0035] 103. Current terminals

[0036] 104. Thermal conductive layer

[0037] 105. Thermally conductive materials

[0038] 30. Outer shell

[0039] 301. First heat sink housing

[0040] 302. Second heat sink housing Detailed Implementation

[0041] To further illustrate the technical means and effects adopted by this utility model to achieve its intended purpose, the following detailed description, in conjunction with the accompanying drawings and preferred embodiments, provides a detailed explanation of the specific implementation methods and effects of a planar power converter and a vehicle including the same according to this utility model.

[0042] According to an embodiment of the present invention, a planar power converter is provided, such as... Figures 1-5 As shown, the planar power converter includes: a transformer assembly 10, a power inductor assembly 20, and a housing 30.

[0043] Among them, such as Figure 1 As shown, both the transformer assembly 10 and the power inductor assembly 20 include a printed circuit board 100, a first magnetic core 101, and a second magnetic core 102. The printed circuit board 100 is disposed between the first magnetic core 101 and the second magnetic core 102, and a planar winding 1000 is provided on the printed circuit board 100.

[0044] Optionally, the first magnetic core 101 is an E-type magnetic core or a U-type magnetic core, and the second magnetic core 102 is an I-type magnetic core, or the first magnetic core 101 is an I-type magnetic core and the second magnetic core 102 is an E-type magnetic core or a U-type magnetic core.

[0045] In one embodiment, the planar winding 1000 on the printed circuit board 100 of the transformer assembly 10 and the planar winding 1000 on the printed circuit board 100 of the power inductor assembly 20 are electrically connected by a connector.

[0046] Optionally, such as Figure 5 As shown, the printed circuit board 100 of the transformer assembly 10 and the printed circuit board 100 of the power inductor assembly 20 are electrically connected by soldering current terminals 103 (i.e., connectors). This enables current conduction between the power inductor assembly 20 and the transformer assembly 10, and also ensures a fixed connection between the printed circuit boards 100 of the transformer assembly 10 and the power inductor assembly 20.

[0047] In another embodiment, the printed circuit board 100 of the transformer assembly 10 and the printed circuit board 100 of the power inductor assembly 20 are integrated into one structure, that is, the transformer assembly 10 and the power inductor assembly 20 share a single printed circuit board 100. The planar winding 1000 of the transformer assembly 10 and the planar winding 1000 of the power inductor assembly 20 are respectively formed on the printed circuit board 100, and the planar windings 1000 of the two are directly electrically connected.

[0048] In one embodiment, such as Figure 1 and Figure 2 As shown, the first magnetic core 101 of the transformer assembly 10 and the power inductor assembly 20 are separate structures, and the second magnetic core 102 of the transformer assembly 10 and the power inductor assembly 20 are also separate structures. That is, both the transformer assembly 10 and the power inductor assembly 20 have independent first magnetic core 101 and second magnetic core 102.

[0049] In another embodiment, the first magnetic core 101 of the transformer assembly 10 and the power inductor assembly 20 is an integrally formed structure, that is, the transformer assembly 10 and the power inductor assembly 20 share a single first magnetic core 101; and / or the second magnetic core 102 of the transformer assembly 10 and the power inductor assembly 20 is an integrally formed structure, that is, the transformer assembly and the power inductor assembly 20 share a single second magnetic core 102. By setting the magnetic cores of the transformer assembly 10 and the power inductor assembly 20 as an integrally formed structure, the number of molds required for the magnetic cores can be reduced to lower costs, and the assembly process can be simplified to improve assembly efficiency.

[0050] It is known that the heat on the side of the planar power converter closer to the external cooling system is more easily absorbed by the external cooling system, thus achieving a better cooling effect. On the other hand, the heat on the side farther away from the external cooling system is relatively more difficult to be conducted to the external cooling system. As a result, the heat of the magnetic core closer to the external cooling system is lower than that of the magnetic core farther away from the external cooling system, thus creating a temperature difference between the magnetic cores.

[0051] In order to effectively dissipate the heat generated by the line loss of the printed circuit board 100, and to avoid magnetic saturation caused by a temperature difference between the first magnetic core 101 and the second magnetic core 102, which could lead to a decrease in inductance in the high-temperature area and thus failure of the planar power converter, such as... Figure 1 and Figure 5 As shown, a heat-conducting layer 104 is provided between the first magnetic core 101 and the printed circuit board 100 and / or between the second magnetic core and the printed circuit board 100.

[0052] In one embodiment, such as Figure 3 and Figure 4As shown, the outer casing 30 includes a first heat dissipation casing 301 and a second heat dissipation casing 302, wherein the first heat dissipation casing 301 is in contact with an external cooling system (not shown in the figure), the first magnetic core 101 is close to the first heat dissipation casing 301, and a thermally conductive layer 104 is provided between the second magnetic core 102 and the printed circuit board 100.

[0053] In this embodiment, a thermally conductive layer 104 is provided between the second magnetic core 102, which is far from the external cooling system, and the printed circuit board 100. The thermally conductive layer 104 is used to improve the thermal conductivity of the planar power converter far from the external cooling system, so as to transfer heat to the second heat sink more smoothly, thereby realizing the rapid heat dissipation of the second magnetic core 102 and reducing the temperature difference between the first magnetic core 101 and the second magnetic core 102.

[0054] In another embodiment, such as Figure 3 As shown, the outer casing 30 includes a first heat dissipation shell 301 and a second heat dissipation shell 302. The first heat dissipation shell 301 is in contact with an external cooling system. The first magnetic core 101 is close to the first heat dissipation shell 301. A thermally conductive layer 104 is provided between the first magnetic core 101 and the second magnetic core 102 and the printed circuit board 100. The thermal conductivity of the thermally conductive layer 104 between the first magnetic core 101 and the printed circuit board 100 is less than that between the second magnetic core 102 and the printed circuit board 100.

[0055] In this embodiment, a heat-conducting layer 104 is provided between the first magnetic core 101 and the second magnetic core 102 and the printed circuit board 100, so as to improve the heat dissipation efficiency generated by the printed circuit board 100. Furthermore, the heat conduction of the heat-conducting layer 104 between the second magnetic core 102, which is farther away from the external cooling system, and the printed circuit board 100 is greater than that between the first magnetic core 101 and the printed circuit board 100, which is closer to the external cooling system, thereby balancing the heat dissipation between the first magnetic core 101 and the second magnetic core 102 and reducing the temperature difference between the first magnetic core 101 and the second magnetic core 102.

[0056] In the above embodiments, optionally, the thermally conductive layer 104 is a thermally conductive adhesive applied between the magnetic core and the printed circuit board 100 during the assembly of the planar power converter. Of course, other thermally conductive materials that meet thermal conductivity requirements can also be used, such as thermally conductive pads, phase change materials, etc. This invention is not limited to the specific material used for the thermally conductive layer 104.

[0057] In one embodiment, such as Figure 4 and Figure 5 As shown, during the assembly of the planar power converter, thermally conductive material 105 is filled in the gap between the housing 30 and the transformer assembly 10 and the power inductor assembly 20 to further improve the heat dissipation efficiency inside the planar power converter.

[0058] Optionally, the thermally conductive material 105 used to fill the gap between the housing 30 and the transformer assembly 10 and the power inductor assembly 20 is thermally conductive adhesive. Of course, other thermally conductive materials 105 that meet thermal conductivity requirements can also be used, such as thermally conductive pads, phase change materials, etc. This invention is not limited to the type of thermally conductive material 105 used.

[0059] In one embodiment, such as Figure 3 As shown, the outer casing 30 includes a first heat dissipation casing 301 and a second heat dissipation casing 302, wherein the first heat dissipation casing 301 and / or the second heat dissipation casing 302 serve as cover plates for the coolant flow channels of the external cooling system, so that the first heat dissipation casing 301 and / or the second heat dissipation casing 302 are in direct contact with the coolant of the external cooling system.

[0060] In this embodiment, the first heat dissipation shell 301 and / or the second heat dissipation shell 302 of the outer casing 30 are used as part of the external cooling system, so that the outer casing 30 can directly contact the coolant of the external cooling system. This reduces the thermal resistance caused by a layer of thermally conductive adhesive and the cover plate of the coolant flow channel of the external cooling system, and effectively improves the cooling efficiency of the planar power converter.

[0061] In one embodiment, such as Figure 3 As shown, the outer casing 30 includes a first heat dissipation casing 301 and a second heat dissipation casing 302, wherein the interior of the first heat dissipation casing 301 and / or the second heat dissipation casing 302 is provided with a coolant channel, which is connected to the coolant flow channel of the external cooling system.

[0062] In this embodiment, a coolant channel is formed inside the first heat dissipation housing 301 and / or the second heat dissipation housing 302 of the outer casing 30, and this coolant channel is connected to the coolant flow channel of the external cooling system. This allows the coolant from the external cooling system to flow through the interior of the first heat dissipation housing 301 and / or the second heat dissipation housing 302, thereby further improving the heat conduction rate inside the planar power converter and thus further improving the cooling efficiency of the planar power converter.

[0063] In one embodiment, a power transistor (not shown) is provided on the printed circuit board 100. The power transistor is electrically connected to the low-voltage side of the transformer assembly 10 and the power inductor assembly 20, so as to shorten the high current path on the low-voltage side, reduce losses, and reduce parasitic parameters between the power transistor and the inductor.

[0064] In any of the above embodiments, the first heat dissipation shell 301 and the second heat dissipation shell 302 of the outer shell 30 are aluminum shells with high thermal conductivity, and the first heat dissipation shell 301 and the second heat dissipation shell 302 are connected by means of screws, welding, riveting, etc.

[0065] Another embodiment of the present invention provides a vehicle that includes the planar power converter described in the above embodiments.

[0066] In this invention, a heat-conducting layer is added between the magnetic cores of the transformer assembly and the power inductor assembly of the planar power converter and the printed circuit board. On the one hand, the heat generated by the line loss of the printed circuit board can be smoothly discharged. On the other hand, the temperature difference between the magnetic cores can be effectively reduced, avoiding the failure of the planar power converter caused by the decrease in inductance in the high-temperature area due to the temperature difference between the first magnetic core and the second magnetic core, which leads to magnetic saturation.

[0067] The above are merely preferred embodiments of the present utility model and are not intended to limit the present utility model in any way. Although the present utility model has been disclosed above with reference to preferred embodiments, it is not intended to limit the present utility model. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present utility model. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present utility model without departing from the scope of the present utility model shall still fall within the scope of the present utility model.

Claims

1. A planar power converter, characterized by, The transformer assembly, the power inductor assembly and the shell; The transformer assembly and the power inductor assembly each comprise a first magnetic core, a second magnetic core and a printed circuit board, the printed circuit board is provided with a planar winding, and the printed circuit board is arranged between the first magnetic core and the second magnetic core; A heat-conducting layer is arranged between the first magnetic core and the printed circuit board and / or between the second magnetic core and the printed circuit board to reduce the temperature difference between the first magnetic core and the second magnetic core; The transformer assembly and the power inductor assembly are arranged in the accommodating space of the shell. The shell comprises a first heat dissipation shell and a second heat dissipation shell, the first heat dissipation shell is in contact with an external cooling system, the first magnetic core is close to the first heat dissipation shell, and the heat-conducting layer is arranged between the first magnetic core and the printed circuit board.

2. The planar power converter of claim 1, wherein, The shell comprises a first heat dissipation shell and a second heat dissipation shell, the first heat dissipation shell is in contact with an external cooling system, the first magnetic core is close to the first heat dissipation shell, and the heat-conducting layer is arranged between the first magnetic core and the printed circuit board.

3. The planar power converter of claim 1, wherein, The transformer assembly and the power inductor assembly are arranged in the accommodating space of the shell.

4. The planar power converter of claim 1, wherein, The printed circuit board of the transformer assembly and the printed circuit board of the power inductor assembly are electrically connected through a connecting piece; or 5. The planar power converter of claim 1, wherein, The printed circuit board of the transformer assembly and the printed circuit board of the power inductor assembly are an integral structure. The first magnetic core of the transformer assembly and the first magnetic core of the power inductor assembly are integrally formed; and / or 6. The planar power converter of claim 1, wherein, The second magnetic core of the transformer assembly and the second magnetic core of the power inductor assembly are integrally formed. The shell comprises a first heat dissipation shell and a second heat dissipation shell, the first heat dissipation shell and / or the second heat dissipation shell serve as a cover plate of a cooling liquid flow channel of an external cooling system, so that the first heat dissipation shell and / or the second heat dissipation shell directly contact the cooling liquid of the external cooling system.

7. The planar power converter of claim 1, wherein, The shell comprises a first heat dissipation shell and a second heat dissipation shell, the first heat dissipation shell and / or the second heat dissipation shell are internally provided with a cooling liquid channel, and the cooling liquid channel is in communication with a cooling liquid flow channel of an external cooling system.

8. The planar power converter of claim 1, wherein, The printed circuit board is provided with a power tube, and the power tube is electrically connected to the low-voltage side of the transformer assembly and the power inductor assembly.

9. The planar power converter of claim 1, wherein, The planar power converter comprises any one of claims 1-9.

10. A vehicle characterized by comprising: The planar power converter comprises any one of claims 1-9.

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