Integrated capacitive dual-module inverter brick water-cooling heat dissipation system

Abstract

The utility model relates to an integrated capacitive dual-module inverter brick water-cooling heat dissipation system, which comprises a power device, a capacitor, an inverter brick shell and a cooling device, wherein the cooling device comprises a first water channel, a second water channel and a third water channel which penetrate through the inversion brick main shell, and the first water channel is arranged in the first power module and is communicated with the first water inlet and the first water outlet; the second water channel is arranged in the second power module and is communicated with the second water inlet and the second water outlet; the third water channel is arranged above the capacitor and is communicated with the third water inlet and the third water outlet; the first water outlet and the second water inlet are communicated to form a first communication corner, and the second water outlet and the third water inlet are communicated to form a second communication corner. Compared with the prior art, the system is compact, the heat dissipation efficiency is high, and the operation performance is high.

Description

Technical Field

[0001] This utility model relates to the field of controller technology, and in particular to an integrated capacitor-type dual-module inverter brick water-cooled heat dissipation system. Background Technology

[0002] With the rapid development of the new energy market, the modularization trend of electric drive systems, especially inverters, is becoming increasingly prominent and has become an important force driving technological progress in the industry. This trend is inseparable from the profound accumulation and continuous innovation of past technologies. As market demands change and technological levels improve, compact, highly integrated, fully functional, and flexibly installable inverter modules have gradually become the mainstream direction of product development.

[0003] However, technical challenges arose during the development of the aforementioned high-power inverter brick modules. Among these, the heat dissipation of the power modules and capacitors within the inverter brick was particularly prominent, affecting not only the inverter's performance stability but also its lifespan. To address this challenge, new solutions need to be continuously explored, striving to effectively improve heat dissipation while maintaining the module's compactness, thereby ensuring the overall output performance and stability of the controller.

[0004] While the current module and water channel structure meets the power module's current requirements and improves heat dissipation to some extent, it also leads to problems such as excessively long cooling channels and increased flow resistance. At the same time, the size limitations of the inverter brick make capacitor design difficult, and capacitor heat dissipation also carries certain risks.

[0005] Therefore, optimizing the internal layout design and improving heat dissipation efficiency while maintaining the compact structure and complete functions of the inverter brick has become a major focus in the current integrated and modular development of inverters. Utility Model Content

[0006] The purpose of this utility model is to overcome the defects of the existing technology.

[0007] The objective of this utility model can be achieved through the following technical solutions:

[0008] An integrated capacitor-type dual-module inverter brick water-cooled heat dissipation system, the system includes a power device, a capacitor 4, an inverter brick housing 3 and a cooling device;

[0009] The power device includes a first power module 1 and a second power module 2;

[0010] The cooling device includes a first water channel, a second water channel, and a third water channel, all of which transversely penetrate the inverter brick housing 3 and are connected to the inverter brick housing 3. The first water channel is located in the first power module 1 and connects the first water inlet 71 and the first water outlet 72. The second water channel is located in the second power module 2 and connects the second water inlet 81 and the second water outlet 82. The third water channel is located above the capacitor 4 and connects the third water inlet 91 and the third water outlet 92. The first water inlet 71 is connected to the main water inlet 6, and the third water outlet 92 is connected to the main water outlet 10. The first water outlet 72 is connected to the second water inlet 81, and the water channels converge to form a first connecting corner. The second water outlet 82 and the third water inlet 91 are connected, and the water channels converge to form a second connecting corner.

[0011] Preferably, capacitor 4 is a potted capacitor 4, and capacitor 4 is connected to the main housing of inverter brick through potting.

[0012] Preferably, capacitor 4 includes capacitor core 41, capacitor copper busbar 42, output terminal and input terminal; wherein, the input terminal includes a first power module input terminal 423 and a second power module input terminal 424, the first power module input terminal 423 is connected to the first power module 1, and the second power module input terminal 424 is connected to the second power module 2.

[0013] More preferably, the inverter brick housing 3 includes a main housing, a plastic plate and a water channel plate, wherein the plastic plate includes at least a first plastic plate 35; the first plastic plate 35 is located on the side of the capacitor 4 closer to the external environment, and is connected to the main housing by bolts, and has an output terminal opening on it.

[0014] More preferably, the plastic plate also includes a second plastic plate 34, a third plastic plate 33, and a fourth plastic plate 32, which are located between the first power module input terminal 423 and the second power module input terminal 424, and are all connected to the main housing through slots.

[0015] More preferably, the water channel plate is fixedly connected to the main shell by friction welding. The water channel plate includes a first water channel plate 36, a second water channel plate 37 and a third water channel plate 38, wherein the first water channel plate 36 and the second water channel plate 37 are located on the side of the first water inlet 71, and the third water channel plate 38 is located on the side of the third water outlet 92.

[0016] More preferably, both the first water channel plate 36 and the third water channel plate 38 are provided with bosses, which are distributed at both ends of the inner side of the water channel plate. One side of the boss is fixedly connected to the inner wall of the water channel plate by friction welding, and the other side is a sloping surface with the outer side higher than the inner side.

[0017] Preferably, in the cooling device, rounded corners are provided inside the water channels.

[0018] Preferably, inclined planes are used instead of right-angled planes at the first and second connecting corners.

[0019] Preferably, a sealing ring 5 is provided between the main housing of the inverter brick and the power device; there are four sealing rings 5 ​​in total, one sealing ring 5 is provided at the inlet and outlet of the first power module 1 and the second power module 2; a heat-conducting pad is provided on the side of the power device that contacts the inverter brick housing 3.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] 1. In this utility model, the system includes a power device, a capacitor, an inverter brick housing, and a cooling device. The cooling device includes a first water channel, a second water channel, and a third water channel. The water channel structure is designed based on the principle of optimal performance. Through the combined design of the first, second, and third water channels, the coolant first cools the two-stage power modules and then the capacitor module, improving the output current capability of the power modules. Ultimately, this ensures that the inverter brick generates stable power while reducing the risk of thermal runaway. This improves the system's heat dissipation efficiency and provides good heat dissipation performance.

[0022] 2. In this utility model, the capacitor is a potted capacitor with a through water channel at the top. The capacitor is directly potted together with the shell, which reduces the overall height of the capacitor and makes the heat dissipation of the capacitor more uniform, preventing the risk of thermal runaway due to heat accumulation. This improves the heat dissipation efficiency and stability of the capacitor.

[0023] 3. In this utility model, the potted capacitor has advantages in terms of space and weight compared to the capacitor with a freestanding shell, and is highly practical.

[0024] 4. In this utility model, the inverter brick main shell and water channel are integrated into one piece, and the water channel is sealed through the shell by double-sided friction welding. By welding bosses onto the friction welding plate and designing rounded corners inside the water channel, the flow path of the coolant is optimized, thereby reducing abrupt changes in flow rate gradient, avoiding eddy current generation, and reducing overall pressure drop.

[0025] 5. In this utility model, because the capacitor copper busbars have a dual-outlet structure on the same side, and the middle shell portion of the main housing is sandwiched between the capacitor copper busbars, the copper busbars inside the capacitor can only be installed from the side of the housing. This leads to the versatility of the housing design. Through the design of the plastic plates, the plastic parts are combined with the metal parts to achieve the purpose of encapsulating the capacitor inside the housing. The first plastic plate is installed with bolts, and the second, third, and fourth plastic plates are installed with the housing through slots. The installation is simple and can also achieve the function of insulation and protection of the capacitor.

[0026] 6. In this utility model, the design of sealing rings, plastic plates, etc., not only meets the needs of high-power applications, but also improves heat dissipation efficiency while ensuring the stability and long-term reliability of the system. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the inverter brick cooling system in this utility model;

[0028] Figure 2 This is an exploded view of the inverter brick cooling system structure in this utility model;

[0029] Figure 3 This is a cross-sectional view of the internal structure of the inverter brick cooling system in this utility model;

[0030] Figure 4 This is a schematic diagram of the cooling system flow channel in this utility model;

[0031] Figure 5 This is a schematic diagram of the cooling system flow channels connected in series in this utility model;

[0032] Figure 6 This is an exploded view of the shell structure in this utility model;

[0033] Figure 7 This is a front view of the waterway cover plate of this utility model;

[0034] Figure 8 This is a rear view of the waterway cover plate of this utility model;

[0035] Figure 9 This is a schematic diagram of the potting capacitor in this utility model;

[0036] In the diagram, 1 represents the first power module; 2 represents the second power module; 3 represents the inverter housing; 31 represents the cooling channel; 32 represents the fourth plastic plate; 33 represents the third plastic plate; 34 represents the second plastic plate; 35 represents the first plastic plate; 36 represents the first water channel plate; 37 represents the second water channel plate; 38 represents the third water channel plate; 381 represents the first boss; 382 represents the second boss; 4 represents the capacitor; 41 represents the capacitor core; 42 represents the capacitor copper busbar; 421 represents the positive terminal of the capacitor output terminal; 42 represents the capacitor core; 42 represents the capacitor copper busbar; 42 represents the positive terminal of the capacitor output terminal; 42 represents the capacitor core ... 2 is the negative terminal of the capacitor output terminal; 423 is the input terminal of the first power module; 424 is the input terminal of the second power module; 43 is the capacitor potting area; 5 is the sealing ring; 6 is the main water inlet; 7 is the first stage cooling module; 71 is the first water inlet; 72 is the first water outlet; 8 is the second stage cooling module; 81 is the second water inlet; 82 is the second water outlet; 9 is the capacitor cooling module; 91 is the third water inlet; 92 is the third water outlet; 10 is the main water outlet. Detailed Implementation

[0037] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0038] With the rapid development of the new energy market, the modularization trend of electric drive systems, especially inverters, is becoming increasingly prominent and has become an important force driving technological progress in the industry. This trend is inseparable from the profound accumulation and continuous innovation of past technologies. As market demands change and technological levels improve, compact, highly integrated, fully functional, and flexibly installable inverter modules have gradually become the mainstream direction of product development.

[0039] However, technical challenges arose during the development of the aforementioned high-power inverter brick modules. Among these, the heat dissipation of the power modules and capacitors within the inverter brick was particularly prominent, affecting not only the inverter's performance stability but also its lifespan. To address this challenge, new solutions need to be continuously explored, striving to effectively improve heat dissipation while maintaining the module's compactness, thereby ensuring the overall output performance and stability of the controller.

[0040] The current module and water channel structure, while meeting the power module's current requirements and improving heat dissipation to some extent, also introduces problems such as excessively long cooling channels and increased flow resistance. Furthermore, the size limitations of the inverter brick make capacitor design difficult, and capacitor heat dissipation carries certain risks.

[0041] Therefore, optimizing the internal layout design and improving heat dissipation efficiency while maintaining the compact structure and complete functions of the inverter brick has become a major focus in the current integrated and modular development of inverters.

[0042] In this application, the inverter brick, as an important form of inverter module, is particularly notable for its compact structure and flexible installation. The inverter brick proposed in this application has a dual-module structure, consisting of upper and lower power modules, with the inlet and outlet water outlets located on opposite sides of the inverter brick. Because the current requirements of the power modules need to be met, the water channels are designed in series.

[0043] This heat dissipation system can be applied to the new energy vehicle industry; motor controller field, internal water cooling system, bus capacitor cooling, power module cooling; others include: bus capacitor, power module, cooling water channel, capacitor side cover plate, shell water channel friction welding plate, etc.

[0044] Example 1

[0045] The working principle diagram of this application is as follows: Figure 1 As shown, the coolant enters the inverter brick through the housing inlet, flows through the second power module 2, then flows upward through the first power module 1, then through the capacitor cooling channel 31, and finally flows out through the outlet.

[0046] The main implementation method of this application focuses on optimizing the overall structural design, and includes the following key steps:

[0047] 1. Optimize the layout design of the housing and water channels, ensuring not only the stability and compactness of the housing, but also maximizing the heat dissipation performance of the power module.

[0048] 2. Regarding the design of the capacitor, the commonly used independent capacitor not only lacks advantages in terms of structural space, but also makes it difficult for the water channels in the casing to achieve the purpose of heat dissipation. Therefore, the potting capacitor method is adopted, which utilizes the metal material characteristics of the inverter brick casing 3 to effectively improve the heat dissipation efficiency of the capacitor.

[0049] Based on the above steps, the shell waterway design is optimized as follows: while meeting the overall functional requirements of the inverter brick, the waterway design minimizes its length. On the one hand, when the length cannot be adjusted, the cross-section of the waterway is increased using existing space; on the other hand, optimization measures are taken at waterway corners and intersections, such as setting rounded corners and sloped treatment of right-angled water flow surfaces, to reduce the impact of turbulence on the overall pressure drop.

[0050] In the optimized design of the waterway, such as the treatment of the right-angle area of ​​water flow as a slope, due to the process requirements of injection molding shell and friction welding, special design is required for the friction welded waterway plate that is matched and installed with the waterway shell. This application designs a boss structure on the waterway plate. One side of the boss is attached to the inner wall of the shell waterway, and the other side is designed as a long slope to reduce the generation of turbulence and reduce the overall flow resistance and pressure drop.

[0051] Due to the spatial limitations of the inverter brick's overall structure, capacitor 4 is potted in the design. Furthermore, because it's a dual-power module structure with vertically distributed components, the copper busbar terminals connecting capacitor 4 to the power modules can only be on the same side, top and bottom. Therefore, considering the installation method of the capacitor and its housing, it can only be installed from the side of the inverter brick, and then potted from the bottom.

[0052] In the aforementioned capacitor 4 design, capacitor 4 is tightly bonded to the casing using potting compound. Part of the heat from capacitor 4 can be dissipated directly through the inverter's metal casing, while the remaining heat can be carried away by the water channels on the top of the capacitor 4 casing. This structural design maximizes the heat dissipation requirements of capacitor 4. Simultaneously, it simplifies the installation process and improves space utilization. The water channels on the top of capacitor 4 run directly across the capacitor 4, with the internal core of capacitor 4 evenly distributed beneath them, ensuring uniform heat dissipation and achieving better cooling performance.

[0053] The two functional modules are arranged symmetrically, with the inverter brick housing in the middle. Thermal pads are designed on the contact surfaces with the housing to support the functional modules and to provide buffering and heat dissipation.

[0054] The inverter brick housing 3 has eight components. Three of these components are friction-welded water channel plates located at the inlet and outlet on both sides of the housing: two plates on the inlet side and one plate on the outlet side. The other four components are four independent plastic parts, which are installed together with the main housing by means of slots and bolts.

[0055] In this embodiment, as Figure 2 As shown, the entire cooling system includes a first power module 1; a second power module 2; an inverter housing 3; a capacitor 4; and a sealing ring 5.

[0056] In this embodiment, the cooling system is a series structure channel. To ensure the overall airtightness, the shell water channel is connected to the two power modules with sealing rings 5. A sealing ring 5 is set at the inlet and outlet of each of the upper and lower power modules, for a total of four sealing rings 5.

[0057] like Figure 4 , Figure 5 As shown, the cooling system flow channel series connection method in this embodiment is as follows:

[0058] The coolant enters the first inlet 71 through the main inlet 66, flows through the first-stage cooling module 7, then through the second-stage cooling module 8 inlet 81 through the first outlet 72, flows through the second-stage cooling module 8, enters the capacitor cooling module 9 through the second outlet 82 via the side wall channel of the housing, and then reaches the main outlet 10 through the side wall channel of the housing, ensuring that each component can obtain the maximum cooling effect.

[0059] like Figure 5 As shown, the cooling system in this embodiment has a relatively long overall length due to its series structure and the addition of capacitor 4 for heat dissipation. However, this also results in a larger voltage drop. To achieve the aforementioned series structure and meet process requirements, this embodiment employs a side friction welding method, designing friction-welded water channel covers on both sides of the inlet and outlet of the casing.

[0060] To address the technical challenge of significant pressure drop, this embodiment improves pressure drop by incorporating rounded corners and designing right-angled areas as bevels within the flow channel. For example... Figure 8 As shown, the design of the first boss 381 and the second boss 382 effectively changes the right-angled surface inside the flow channel into an inclined surface, avoiding the generation of vortices and thus reducing the overall pressure drop.

[0061] Figure 3In this embodiment, cooling channel 31 is a flow channel designed for heat dissipation of capacitor 4. This flow channel is located at the center directly above capacitor 4, running horizontally through the inside of inverter brick housing 3. This design can better help dissipate heat from capacitor 4 and is more conducive to uniform heat dissipation of capacitor core 41, preventing heat accumulation. In addition, based on this flow channel structure design, the housing in this embodiment must use friction welding on both sides of the channel.

[0062] like Figure 6 As shown, the inverter brick housing 3 comprises three main parts: the main housing, plastic plates 32-35, and water channel plates 36-38. Plastic plates 32-34 are mounted on the housing via slots, plastic plate 35 is bolted to the side of the housing, and the water channel plates are welded to the housing via friction welding. A front view of the water channel cover plate in this invention is shown below. Figure 7 As shown, the rear view is as follows Figure 8 As shown.

[0063] like Figure 9 As shown, the first power module input terminal 423 and the second power module input terminal 424 are arranged in an upper and lower structure. Since capacitor 4 is encapsulated in housing 3, as... Figure 3 As shown in capacitor potting area 43, a board needs to be connected to the housing between the upper and lower copper busbar input terminals of capacitor 4 to form a sealed space in the potting area. Considering the feasibility of capacitor 4 installation, capacitor 4 needs to be installed from the side, therefore a design was made... Figure 6 The plastic parts 32-34 shown are installed via slots, and the input terminals of the capacitor copper busbar 42 are fixed in the housing.

[0064] According to the above installation method of capacitor 4, such as Figure 9 The positive terminal 421 and negative terminal 422 of the capacitor output terminal are located opposite the input terminal of capacitor 4. Therefore, considering ease of installation and structural simplicity, this embodiment is designed as follows: Figure 6 The plastic plate 35 shown is bolted to the housing, thereby forming a sealed potting space.

[0065] In summary, the invention method of this patent effectively solves the heat dissipation problem in high-power inverter brick modules through comprehensive optimization of the design of the shell, water channel, and capacitor 4, as well as special design of related components, while ensuring the compactness and high-performance operation of the system.

[0066] The above description of the embodiments is provided to enable those skilled in the art to understand and use the utility model. It will be apparent to those skilled in the art that various modifications can be easily made to these embodiments, and the general principles described herein can be applied to other embodiments without inventive effort. Therefore, the present utility model is not limited to the above embodiments, and any improvements and modifications made by those skilled in the art based on the disclosure of the present utility model without departing from its scope should be within the protection scope of the present utility model.

Claims

1. An integrated capacitor-type dual-module inverter brick water-cooled heat dissipation system, characterized in that, The system includes a power unit, a capacitor (4), an inverter housing (3), and a cooling unit; The power device includes a first power module (1) and a second power module (2); The cooling device includes a first water channel, a second water channel, and a third water channel, all of which transversely penetrate the inverter brick housing (3) and are connected to the inverter brick housing (3). The first water channel is located in the first power module (1) and connects the first water inlet (71) and the first water outlet (72). The second water channel is located in the second power module (2) and connects the second water inlet (81) and the second water outlet (82). The third water channel is located above the capacitor (4) and connects the third water inlet (91) and the third water outlet (92). The first water inlet (71) is connected to the main water inlet (6), and the third water outlet (92) is connected to the main water outlet (10). The first water outlet (72) and the second water inlet (81) are connected, and the water channels converge to form a first connecting corner. The second water outlet (82) and the third water inlet (91) are connected, and the water channels converge to form a second connecting corner.

2. The integrated capacitor-type dual-module inverter brick water-cooled heat dissipation system according to claim 1, characterized in that, The capacitor (4) is a potted capacitor, and the capacitor (4) is connected to the main housing of the inverter brick by potting.

3. The integrated capacitor-type dual-module inverter brick water-cooled heat dissipation system according to claim 1, characterized in that, The capacitor (4) includes a capacitor core (41), a capacitor copper busbar (42), an output terminal and an input terminal; wherein the input terminal includes a first power module input terminal (423) and a second power module input terminal (424), the first power module input terminal (423) is connected to the first power module (1), and the second power module input terminal (424) is connected to the second power module (2).

4. The integrated capacitor-type dual-module inverter brick water-cooled heat dissipation system according to claim 3, characterized in that, The inverter brick housing (3) includes a main housing, a plastic plate and a water channel plate, wherein the plastic plate includes at least a first plastic plate (35); the first plastic plate (35) is located on the side of the capacitor (4) closer to the external environment, and is connected to the main housing by bolts, and has an output terminal opening on it.

5. The integrated capacitor-type dual-module inverter brick water-cooled heat dissipation system according to claim 4, characterized in that, The plastic plate also includes a second plastic plate (34), a third plastic plate (33), and a fourth plastic plate (32). The second plastic plate (34), the third plastic plate (33), and the fourth plastic plate (32) are located between the first power module input terminal (423) and the second power module input terminal (424), and are all connected to the main housing through slots.

6. The integrated capacitor-type dual-module inverter brick water-cooled heat dissipation system according to claim 4, characterized in that, The water channel plate is fixedly connected to the main shell by friction welding. The water channel plate includes a first water channel plate (36), a second water channel plate (37) and a third water channel plate (38). The first water channel plate (36) and the second water channel plate (37) are located on the side of the first water inlet (71), while the third water channel plate (38) is located on the side of the third water outlet (92).

7. The integrated capacitor-type dual-module inverter brick water-cooled heat dissipation system according to claim 6, characterized in that, Both the first waterway plate (36) and the third waterway plate (38) are provided with protrusions. The protrusions are distributed at both ends of the inner side of the waterway plate. One side of the protrusion is fixedly connected to the inner wall of the waterway plate by friction welding, and the other side is a sloping surface with the outer side higher than the inner side.

8. The integrated capacitor-type dual-module inverter brick water-cooled heat dissipation system according to claim 1, characterized in that, In the cooling device described above, rounded corners are provided inside the water channels.

9. The integrated capacitor-type dual-module inverter brick water-cooled heat dissipation system according to claim 1, characterized in that, The first and second connecting corners are constructed using inclined planes instead of right angles.

10. The integrated capacitor-type dual-module inverter brick water-cooled heat dissipation system according to claim 1, characterized in that, A sealing ring (5) is provided between the inverter brick housing (3) and the power device; there are four sealing rings in total, one at the inlet and outlet of the first power module (1) and the second power module (2); the power device is provided with a heat-conducting pad on the side that contacts the inverter brick housing (3).

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