Low-power water-cooled rectifier power supply

Abstract

This utility model discloses a low-power water-cooled rectifier power supply, including a chassis with a heat sink installed inside. Transformer assemblies and synchronous rectifier modules are mounted on both sides of the heat sink. The transformer assembly includes a magnetic core, which is horizontally mounted above the synchronous rectifier module. Heat sinks are mounted on both the top and bottom of one end of the heat sink, and IGBT modules are mounted on both heat sinks. The heat sink and heat sinks form a gradient thermal bridging structure. This utility model uses an integrated magnetic core, which not only reduces the size but also reduces magnetic leakage by more than 10%. It also employs a copper-aluminum gradient thermal bridging structure, indirectly connecting the IGBT module and the heat sink via heat sinks, changing the heat conduction mode and making it unaffected by water temperature, thus solving the condensation problem. Simultaneously, the copper heat sink acts as a high thermal conductivity zone, making close contact with the IGBT module, while the aluminum heat sink expands the heat dissipation area, resulting in a 60% reduction in thermal resistance.

Description

Technical Field

[0001] This utility model relates to the field of rectifier power supply technology, specifically to a low-power water-cooled rectifier power supply. Background Technology

[0002] A rectifier power supply is an electronic device or circuit that converts alternating current (AC) into direct current (DC). With the continuous development of technology, traditional rectifier power supplies are gradually failing to meet usage requirements and have many drawbacks:

[0003] (1) The transformer 1' of the traditional low-power water-cooled rectifier power supply usually adopts a toroidal magnetic core. The toroidal magnetic core is usually composed of two U-shaped parts. However, when the two U-shaped parts are combined, there are inevitably some air gaps, which are prone to magnetic leakage. In addition, the U-shaped parts need to be fixed by a complex frame, which increases the cost of parts and assembly time. At the same time, the existing toroidal magnetic core is usually placed vertically, with only the bottom in contact with the heat sink 2'. The heat generated by the transformer is mainly released at the bottom, while the heat dissipation speed at the top is slow, resulting in uneven heat dissipation. Furthermore, the vertical placement is susceptible to shock, which can damage the base plate or deform the magnetic core.

[0004] (2) Traditional low-power water-cooled rectifier power supplies usually have an IGBT device 3' inside. To solve the heat dissipation problem of the IGBT device 3', the IGBT device 3' is usually installed on the heat sink 2'. The heat sink 2' is used to quickly remove heat. However, when the temperature difference between the inside and outside of the heat sink 2' is too large, condensation will occur. Furthermore, since the IGBT device 3' and the heat sink 2' are usually rigidly connected, the vibration of the heat sink 2' will be directly transmitted to the IGBT device 3', which can easily damage the IGBT device 3'. Utility Model Content

[0005] The purpose of this invention is to address the shortcomings of existing technologies by providing a low-power water-cooled rectifier power supply to solve the problems mentioned in the background art.

[0006] To achieve this objective, the present invention adopts the following technical solution:

[0007] A low-power water-cooled rectifier power supply includes a chassis, in which a heat sink is installed. A transformer assembly and a synchronous rectification module are arranged on both sides of the heat sink. The transformer assembly includes a magnetic core with a circular structure, and the magnetic core is horizontally mounted above the synchronous rectification module. Heat sinks are installed on both the upper and lower sides of one end of the heat sink, and IGBT modules are installed on both heat sinks. The heat sink and the heat sinks form a gradient thermal bridging structure.

[0008] As a preferred solution for a low-power water-cooled rectifier power supply, the heat sink is made of aluminum and the heat dissipation plate is made of copper.

[0009] As a preferred embodiment of a low-power water-cooled rectifier power supply, the transformer assembly further includes a first circuit board and a coil. The coil is wound on the magnetic core, and the magnetic core is fixed to and electrically connected to the first circuit board. The first circuit board is fixed to the synchronous rectification module.

[0010] As a preferred embodiment of a low-power water-cooled rectifier power supply, the synchronous rectification module includes a second circuit board, a first output element, and two second output elements. The second circuit board is stacked on the first output element, and the two second output elements are symmetrically arranged on both sides of the first output element. The first output element has two rows of MOSFETs arranged symmetrically and parallel to each other. The second circuit board has through holes, through which the MOSFETs pass and are electrically connected to the second circuit board. Each row of MOSFETs is electrically connected to the second output element on the same side.

[0011] As a preferred embodiment of a low-power water-cooled rectifier power supply, a first conductive plate is connected to the first circuit board, and a first output copper busbar is connected to the end of the first conductive plate away from the first circuit board. A first protrusion is provided at one end of the first output element, and a second conductive plate is connected to the first protrusion. A second output copper busbar is connected to the end of the second conductive plate away from the first protrusion. Both the first output copper busbar and the second output copper busbar extend outside the chassis as output terminals.

[0012] As a preferred embodiment of a low-power water-cooled rectifier power supply, each of the second output elements includes a flat plate base, and a second protrusion is provided on the side of each of the two flat plate bases that are far apart from each other. The first circuit board is mounted on the two second protrusions.

[0013] As a preferred embodiment of a low-power water-cooled rectifier power supply, an insulating layer is attached to the surface of both the first output element and the second output element, and the other side of the insulating layer is attached to the heat sink.

[0014] As a preferred solution for a low-power water-cooled rectifier power supply, the heat sink is provided with a fluid channel, which is connected to an inlet and an outlet, and the inlet and outlet extend outside the chassis.

[0015] The beneficial effects of this utility model are:

[0016] (1) The small power water-cooled rectifier power supply of this utility model has optimized the transformer structure. By adopting an integrated magnetic core, it is not only smaller in size, but also reduces the leakage magnetic flux by more than 10%. At the same time, by utilizing the geometric symmetry of the circular magnetic core, the coil can be directly wound and the magnetic core can be self-locked and fixed, eliminating the skeleton structure and reducing the component cost. The transformer assembly is installed horizontally, which not only increases the contact area and improves the heat dissipation effect of the transformer assembly, but also lowers the center of gravity of the transformer assembly and significantly improves the shock resistance.

[0017] (2) The low-power water-cooled rectifier power supply of this utility model adopts a copper-aluminum gradient thermal bridging structure. The IGBT module and the heat sink are indirectly connected by a copper heat sink plate, which changes the thermal conduction mode and is not affected by water temperature, thus solving the condensation problem. At the same time, the copper heat sink plate, as a high thermal conductivity area, is in close contact with the IGBT module, while the aluminum heat sink is responsible for expanding the heat dissipation area, which reduces the thermal resistance by 60%. Furthermore, the vibration of the heat sink will be buffered by the heat sink plate, which can absorb some mechanical stress, thereby reducing the impact on the IGBT module. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments of this utility model will be briefly described below. Obviously, the drawings described below are merely some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0019] Figure 1 This is a schematic diagram of the structure of a water-cooled rectifier power supply in the prior art.

[0020] Figure 2 This is a schematic diagram of the overall structure of the low-power water-cooled rectifier power supply described in this utility model.

[0021] Figure 3 This is a schematic diagram of the structure of the low-power water-cooled rectifier power supply described in this utility model after removing the chassis.

[0022] Figure 4 This is a schematic diagram showing the disassembled structure of the low-power water-cooled rectifier power supply described in this utility model.

[0023] Figure 5 This is a schematic diagram of the structure of the transformer assembly described in this utility model.

[0024] Figure 6 This is a schematic diagram of the synchronous rectification module described in this utility model.

[0025] Figure 7 This is a schematic diagram of the cross-sectional structure of the synchronous rectification module described in this utility model.

[0026] Figure 1 middle:

[0027] 1' Transformer; 2' Heat sink; 3' IGBT device.

[0028] Figure 2-7 middle:

[0029] 1. Chassis; 2. Heat sink; 21. Water inlet; 22. Water outlet; 3. Transformer assembly; 31. Magnetic core; 32. First circuit board; 33. Coil; 34. First conductive plate; 35. First output copper busbar; 4. Synchronous rectification module; 41. Second circuit board; 42. First output element; 421. First protrusion; 422. Second conductive plate; 423. Second output copper busbar; 43. Second output element; 431. Flat base; 432. Second protrusion; 44. MOSFET; 5. Heat sink; 6. IGBT module; 7. Insulating layer. Detailed Implementation

[0030] The technical solution of this utility model will be further described below with reference to the accompanying drawings and specific embodiments.

[0031] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual images. They should not be construed as limiting the scope of this patent. To better illustrate the embodiments of this utility model, some components in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0032] In the accompanying drawings of this utility model, the same or similar reference numerals correspond to the same or similar components. In the description of this utility model, it should be understood that if terms such as "upper," "lower," "left," "right," "inner," and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting this patent. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0033] In the description of this utility model, unless otherwise explicitly specified and limited, the term "connection" or similar designation indicating the connection relationship between components should be interpreted broadly. For example, it can refer to a fixed connection, a detachable connection, or an integral part; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0034] like Figure 2 and Figure 3 As shown, this utility model provides a low-power water-cooled rectifier power supply, including a chassis 1, a heat sink 2 installed inside the chassis 1, and a transformer assembly 3 and a synchronous rectification module 4 on both sides of the heat sink 2.

[0035] like Figure 5 As shown, the transformer assembly 3 specifically includes a magnetic core 31, a first circuit board 32, and a coil 33. The coil 33 is wound on the magnetic core 31, the magnetic core 31 is fixed on the first circuit board 32 and electrically connected to it, and the first circuit board 32 is fixed on the synchronous rectification module 4.

[0036] In this embodiment, the magnetic core 31 is an integrated magnetic core, which is not only smaller in size but also reduces the leakage flux by more than 10%. Furthermore, the magnetic core 31 preferably adopts a circular structure. Utilizing the geometric symmetry of the circular magnetic core 31, it is self-locked and fixed to the magnetic core 31 by winding the coil 33, eliminating the need for a skeleton structure and reducing component costs. At the same time, the magnetic core 31 in this embodiment adopts a horizontal installation method, which is horizontally installed above the synchronous rectification module 4. This not only increases the contact area and improves the heat dissipation effect of the magnetic core 31, but also lowers the center of gravity of the transformer assembly 3 and significantly improves its shock resistance.

[0037] like Figure 4 As shown, heat sink 2 has heat sink plates 5 installed on both the top and bottom sides of one end, and IGBT modules 6 are installed on both heat sink plates 5. The IGBT modules 6 and heat sink 2 are indirectly connected by copper heat sink plates 5, which changes the heat conduction mode and makes it no longer affected by water temperature, thus solving the condensation problem.

[0038] Preferably, in this embodiment, the heat sink 2 is preferably made of aluminum, while the heat sink 5 is preferably made of copper. The heat sink 2 and the heat sink 5 form a copper-aluminum gradient thermal bridging structure. The copper heat sink 5, as a high thermal conductivity zone, is in close contact with the IGBT module 6, while the aluminum heat sink 2 is responsible for expanding the heat dissipation area, thereby reducing the thermal resistance by 60%. Furthermore, the vibration of the heat sink 2 will be buffered by the heat sink 5, which can absorb some of the mechanical stress, thereby reducing the impact on the IGBT module 6.

[0039] like Figure 6 and Figure 7 As shown, the synchronous rectification module 4 includes a second circuit board 41, a first output element 42, and two second output elements 43. The second circuit board 41 is stacked on the first output element 42, and the two second output elements 43 are symmetrically arranged on both sides of the first output element 42. The first output element 42 has two rows of MOSFETs 44 arranged symmetrically and parallel to each other. The second circuit board 41 has through holes through which the MOSFETs 44 pass and are electrically connected to the second circuit board 41. Each row of MOSFETs 44 is electrically connected to the second output element 43 on the same side.

[0040] More specifically, each second output element 43 includes a flat plate base 431. A second protrusion 432 is provided on the side of the two flat plate bases 431 that are far apart from each other. The first circuit board 32 is mounted on the two second protrusions 432. The induced current generated by the transformer assembly 3 is conducted to the flat plate base 431 through the second protrusions 432, and then to the two columns of MOSFETs 44 through the flat plate base 431, and then to the first output element 42 through the MOSFETs 44.

[0041] Preferably, the second protrusion 432 and the flat plate base 431 are designed as a single piece, and the two are combined in an L-shaped structure, so as to avoid the influence of the difference in processing technology on the conductivity uniformity of the second output element 43.

[0042] In this embodiment, a first conductive plate 34 is also connected to the first circuit board 32. The end of the first conductive plate 34 away from the first circuit board 32 is connected to a first output copper busbar 35. At the same time, a first protrusion 421 is provided on one end of the first output element 42. The first protrusion 421 is connected to a second conductive plate 422. The end of the second conductive plate 422 away from the first protrusion 421 is connected to a second output copper busbar 423. Both the first output copper busbar 35 and the second output copper busbar 423 extend outside the chassis 1 as output poles and are directly electrically connected to the positive and negative terminals of the load to provide the load with the required stable current or stable voltage.

[0043] Specifically, an insulating layer 7 is attached to the surface of both the first output element 42 and the second output element 43. The other side of the insulating layer 7 is attached to the heat sink 2. The insulating layer 7 can prevent the current on the synchronous rectification module 4 from being guided to the heat sink 2.

[0044] Preferably, the insulating layer 7 in this embodiment is made of ceramic material. Ceramic not only has high mechanical strength, but also high thermal conductivity, which can effectively conduct heat and is beneficial to the heat dissipation of the synchronous rectifier module 4 and the transformer assembly 3.

[0045] Specifically, the heat sink 2 has a fluid channel for heat exchange inside. The fluid channel is connected to an inlet 21 and an outlet 22. The inlet 21 and the outlet 22 extend outside the chassis 1 and are connected to an external water supply device, thereby realizing water circulation, which facilitates heat dissipation inside the chassis 1 and removes heat in time, so that the surface of the heat sink 2 is kept at a suitable operating temperature for the components.

[0046] It should be stated that the above-described specific embodiments are merely preferred embodiments of this utility model and the technical principles employed. Those skilled in the art should understand that various modifications, equivalent substitutions, and variations can be made to this utility model. However, such variations, as long as they do not depart from the spirit of this utility model, should be within the protection scope of this utility model. Furthermore, some terminology used in this application specification and claims is not limiting, but merely for ease of description.

Claims

1. A low-power water-cooled rectifier power supply, characterized in that, The device includes a chassis (1), a heat sink (2) is installed inside the chassis (1), a transformer assembly (3) and a synchronous rectification module (4) are provided on both sides of the heat sink (2), the transformer assembly (3) includes a magnetic core (31), the magnetic core (31) adopts a circular structure and is horizontally installed above the synchronous rectification module (4), a heat sink plate (5) is installed on both the upper and lower sides of one end of the heat sink (2), and an IGBT module (6) is installed on each of the two heat sink plates (5), and the heat sink (2) and the heat sink plate (5) form a gradient thermal bridge structure.

2. The low-power water-cooled rectifier power supply according to claim 1, characterized in that, The radiator (2) is made of aluminum, and the heat sink (5) is made of copper.

3. The low-power water-cooled rectifier power supply according to claim 1, characterized in that, The transformer assembly (3) further includes a first circuit board (32) and a coil (33). The coil (33) is wound on the magnetic core (31). The magnetic core (31) is fixed on the first circuit board (32) and electrically connected to it. The first circuit board (32) is fixed on the synchronous rectification module (4).

4. The low-power water-cooled rectifier power supply according to claim 3, characterized in that, The synchronous rectification module (4) includes a second circuit board (41), a first output element (42), and two second output elements (43). The second circuit board (41) is stacked on the first output element (42), and the two second output elements (43) are symmetrically arranged on both sides of the first output element (42). The first output element (42) has two rows of MOSFETs (44) arranged symmetrically and parallelly. The second circuit board (41) has through holes, through which the MOSFETs (44) pass and are electrically connected to the second circuit board (41). Each row of MOSFETs (44) is electrically connected to the second output element (43) on the same side.

5. The low-power water-cooled rectifier power supply according to claim 4, characterized in that, A first conductive plate (34) is connected to the first circuit board (32). A first output copper busbar (35) is connected to one end of the first conductive plate (34) away from the first circuit board (32). A first protrusion (421) is provided at one end of the first output element (42). A second conductive plate (422) is connected to the first protrusion (421). A second output copper busbar (423) is connected to one end of the second conductive plate (422) away from the first protrusion (421). Both the first output copper busbar (35) and the second output copper busbar (423) extend outside the chassis (1) as output electrodes.

6. The low-power water-cooled rectifier power supply according to claim 4, characterized in that, Each of the second output elements (43) includes a flat plate base (431), and a second protrusion (432) is provided on the side of each of the two flat plate bases (431) that is far apart from each other. The first circuit board (32) is mounted on the two second protrusions (432).

7. The low-power water-cooled rectifier power supply according to claim 4, characterized in that, An insulating layer (7) is attached to the surface of both the first output element (42) and the second output element (43), and the other side of the insulating layer (7) is attached to the heat sink (2).

8. The low-power water-cooled rectifier power supply according to claim 1, characterized in that, The radiator (2) has a fluid channel inside, which is connected to an inlet (21) and an outlet (22) respectively. The inlet (21) and outlet (22) extend out of the casing (1).

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