A DC / DC power converter

Abstract

This utility model discloses a DC / DC power converter, belonging to the field of power electronics technology for thermal management of new energy commercial vehicles. It includes a top cover and a main housing. The main housing houses a DC / DC module and a PDU module. Symmetrical cable outlet holes are provided on the left and right sides of the main housing. The PDU module is located on top of the DC / DC module and is integrated on the PCBA board through a low-impedance connection interface. By adopting a high-low distribution layout for the PDU module and the DC / DC module, the reliability of the connection is improved, and the electromagnetic interference between the modules is reduced.

Description

Technical Field

[0001] This utility model belongs to the field of power electronics technology for thermal management of new energy commercial vehicles, and specifically relates to a DC / DC power converter. Background Technology

[0002] Although existing PDU-in-one electrical control boxes have achieved modular integration, they still have shortcomings in terms of heat dissipation performance, electromagnetic compatibility, and safety.

[0003] Chinese patent CN216752521U discloses a novel highly integrated energy conversion device for new energy vehicles, comprising a housing, a cover mounted on the upper side of the housing, a DC / DC and OBC combined module and a PDU module installed in the inner cavity of the housing; the cover has a first mounting hole on its side, through which the device is mounted on the housing by fastening bolts; the bottom side of the housing has a mounting seat, which is integrally formed with the housing; the inner bottom surface of the housing has the DC / DC and OBC combined module installed; the side of the DC / DC and OBC combined module has a second mounting hole for mounting on the inner bottom surface of the housing; and the inner side of the housing has a mounting protrusion. This novel highly integrated energy conversion device for new energy vehicles integrates the PDU module and the DC / DC and OBC combined module into one housing, resulting in a more compact structure, improved space utilization, and the ability to be pre-installed according to production schedule and material arrival progress, thus saving time and improving production efficiency.

[0004] The above technical solution has the following drawbacks:

[0005] Although the PDU module and the DC / DC and OBC combo module are integrated into a single enclosure, its heat dissipation structure is relatively simple, making it prone to overheating and system failure under high loads. Furthermore, the electromagnetic compatibility of the existing technology is not ideal, and electromagnetic interference can easily occur between modules, affecting system stability. Utility Model Content

[0006] To address the above deficiencies, this utility model provides a DC / DC power converter, including an upper cover and a main housing. The main housing houses a DC / DC module and a PDU module, and symmetrical cable outlets are provided on the left and right sides of the main housing.

[0007] The outer edge of the upper cover plate has recesses and protrusions from the outside to the inside. The outer edges of the main box and the upper cover plate are integrally formed with several flange protrusions. The main box and the upper cover plate are fixed by bolts through which several flange protrusions are threaded through.

[0008] The bottom of the main housing is provided with an integrally formed heat sink;

[0009] The PDU module is located on top of the DC / DC module and is integrated onto the PCBA board via a low-impedance connection interface.

[0010] The main enclosure is also equipped with an intelligent monitoring module for monitoring the location of the PDU module within the DC / DC module.

[0011] Furthermore, a sealing groove is provided on the top of the main housing, and a silicone rubber sealing ring is provided in the sealing groove.

[0012] Furthermore, the connection lines between the PDU module and the DC / DC module and the PCBA board are separated into high and low sections.

[0013] Furthermore, a mesh grille is installed on the mounting side of the main housing.

[0014] Compared with the prior art, the present invention has the following advantages:

[0015] 1. By adopting a high-low distribution layout for PDU modules and DC / DC modules, not only is the reliability of the connection improved, but electromagnetic interference between modules is also reduced;

[0016] 2. Multiple independent heat dissipation channels enable the heat generated by each module during operation to be dissipated quickly. Attached Figure Description

[0017] Figure 1 This is a perspective view of the present invention.

[0018] Figure 2 This is an exploded view of the present invention.

[0019] In the diagram: 1. Top cover; 2. Main housing; 3. DC / DC module; 4. PDU module; 5. Cable outlet; 6. Flanged protrusion; 7. Heat sink; 8. PCBA board; 9. Silicone rubber sealing ring; 10. Mesh grille. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] Example

[0022] like Figures 1 to 2As shown, this embodiment provides a DC / DC power converter, including an upper cover plate 1 and a main housing 2. A grid-like grille plate 10 is added to the mounting side of the main housing 2 to increase the strength of the plates at the connection. The main housing 2 is made of high-strength aluminum alloy material, which has good heat dissipation performance and electromagnetic shielding effect. A sealing groove is opened on the top of the main housing 2, and a silicone rubber sealing ring 9 is set in the sealing groove, which has the characteristics of high and low temperature resistance, compression set deformation, resilience and waterproof performance.

[0023] The main enclosure 2 houses a DC / DC module 3 and a PDU module 4. The PDU module 4 is located on top of the DC / DC module 3 and is integrated onto the PCBA board 8 via a low-impedance connection interface (for electrical connection with the DC / DC module 3). Internal wiring is separated into high and low impedance sections (e.g.,...). Figure 2 As shown, the four feet at the bottom of the PCBA board 8 fix the DC / DC module 3 and PDU module 4 to the inner bottom wall of the main box 2 with screws, which not only improves the reliability of the connection, but also reduces the electromagnetic interference between the modules;

[0024] In detail, PCBA board 8 is a thickened PCB board that integrates high and low voltage circuit modules, including high voltage control module, high voltage precharge module, high voltage fuse module, PTC high voltage DC contactor, etc. At the same time, it is integrated with DC / DC module 3 in a single enclosure, thereby optimizing the space layout, reducing the space occupied by independent components, and making it suitable for space-constrained scenarios. Internal integration reduces the complexity of external cables, reduces the risk of connection point failures, and improves assembly efficiency.

[0025] The main housing 2 has symmetrical cable outlet holes 5 on the left and right sides, which can symmetrically exit the cable at both ends (different cable exit methods can be adopted according to the actual use scenario), which greatly improves the utilization rate and convenience of this electronic control.

[0026] The outer edge of the top cover plate 1 has recesses and protrusions from the outside to the inside. The outer edges of the main body 2 and the top cover plate 1 are integrally formed with several flange protrusions 6. The main body 2 and the top cover plate 1 are fixed by bolts through which several flange protrusions 6 are threaded. When sealing, the bolts press the main body 2 and the top cover plate 1 together. At this time, the silicone rubber sealing ring 9 in the sealing groove is squeezed and deformed to seal the connection and achieve a good waterproof effect.

[0027] The bottom of the main housing 2 is equipped with an integrated heat sink 7. The main housing 2 can also be equipped with several micro fans, which can automatically adjust their speed according to the internal temperature of the housing (controlled by the intelligent monitoring module), so that the heat generated by each module during operation can be quickly dissipated, achieving good heat dissipation function.

[0028] The main enclosure 2 also houses an intelligent monitoring module for monitoring the PDU module 4 located within the DC / DC module 3. This module can monitor the real-time operating status of each module, including parameters such as temperature, voltage, and current. When an abnormality is detected, the system can promptly issue an alarm and take corresponding protective measures, such as automatically cutting off the power supply, thereby improving the system's safety and reliability.

[0029] It should be noted that the structure described in this utility model can be implemented in many different forms and is not limited to the embodiments described. Any equivalent transformations made by those skilled in the art based on the content of this utility model specification and drawings, or direct or indirect applications in other related technical fields, such as the loading and unloading of other items, are included within the protection scope of this utility model.

Claims

1. A DC / DC power converter, comprising a top cover (1) and a main housing (2), wherein a DC / DC module (3) and a PDU module (4) are installed inside the main housing (2), characterized in that: The main housing (2) has symmetrical cable outlet holes (5) on its left and right sides; The outer edge of the upper cover plate (1) is provided with recesses and protrusions from the outside to the inside. The outer edges of the main box (2) and the upper cover plate (1) are integrally formed with several flange protrusions (6). The main box (2) and the upper cover plate (1) are fixed by bolts through which several flange protrusions (6) are threaded through. The bottom of the main housing (2) is provided with an integrally formed heat sink (7); The PDU module (4) is located on top of the DC / DC module (3) and is integrated on the PCBA board (8) through a low-impedance connection interface; The main housing (2) is also equipped with an intelligent monitoring module for monitoring the location of the PDU module (4) in the DC / DC module (3).

2. The DC / DC power converter as described in claim 1, characterized in that: The top of the main housing (2) is provided with a sealing groove, and a silicone rubber sealing ring (9) is provided in the sealing groove.

3. A DC / DC power converter as described in claim 1, characterized in that: The connection lines between the PDU module (4) and the DC / DC module (3) and the PCBA board (8) are separated at different heights.

4. A DC / DC power converter as described in claim 1, characterized in that: The main housing (2) is fitted with a grid-like grating plate (10) on the mounting side.

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