Liquid cooling components, range extenders, and vehicles

Abstract

This utility model discloses a liquid cooling component, a range extender, and a vehicle, relating to the field of liquid cooling technology. The liquid cooling component includes a first heat sink and a second heat sink of different heights, and a connector connecting the first and second heat sinks. The first heat sink has a first liquid cooling channel for cooling a first heat-generating component, and the second heat sink has a second liquid cooling channel for cooling a second heat-generating component. The connector has a connecting liquid cooling channel that connects the first and second liquid cooling channels. This utility model's technical solution reduces the complexity of the heat dissipation system for heat-generating components of different heights.

Description

Technical Field

[0001] This utility model relates to the field of heat dissipation technology, and in particular to a liquid cooling component, a range extender, and a vehicle. Background Technology

[0002] As the performance of electronic devices continues to improve, the power density of heat-generating components (such as CPUs, GPUs, and controllers) is also increasing, placing higher demands on heat dissipation systems. Liquid cooling, due to its high efficiency and reliability, has gradually become the core heat dissipation solution for high heat flux density devices. In traditional liquid cooling systems, when cooling heat-generating components at different heights is required, two or more independent water channels are often designed to correspond to the height of each heat-generating component, ensuring that the coolant can effectively cover all heat sources. However, this approach increases system complexity and leads to higher manufacturing costs. Utility Model Content

[0003] The main objective of this invention is to provide a liquid cooling component, a range extender, and a vehicle, which aims to reduce the complexity of the heat dissipation system for heat-generating elements at different heights.

[0004] To achieve the above objectives, this utility model provides a liquid cooling assembly, which includes a first heat sink and a second heat sink of different heights, and a connector connecting the first heat sink and the second heat sink. The first heat sink is provided with a first liquid cooling channel for cooling a first heat-generating element, the second heat sink is provided with a second liquid cooling channel for cooling a second heat-generating element, and the connector is provided with a connecting liquid cooling channel that connects the first liquid cooling channel and the second liquid cooling channel.

[0005] In one embodiment, the second heat sink includes a second heat sink substrate and a second flow channel cover plate. The surface of the second heat sink substrate facing away from the adapter forms a communicating second groove and a third groove. The second heat-generating element is sealed in the groove of the second groove to form a first sub-flow channel. The second flow channel cover plate is welded to the groove of the third groove to form a second sub-flow channel. The first sub-flow channel and the second sub-flow channel communicate to form a second liquid cooling channel. The adapter liquid cooling channel communicates with the second sub-flow channel.

[0006] In one embodiment, a spacer rib is formed between the second groove and the third groove. The end of the spacer rib facing the adapter has a through notch. One end of the through notch extends to the bottom of the second groove, and the other end of the through notch extends to the bottom of the third groove. A third flow channel cover is welded to the through notch. The third flow channel cover cooperates with the spacer rib to form a guiding flow channel, which connects the first sub-flow channel and the second sub-flow channel.

[0007] In one embodiment, the cross-sectional area of ​​the second sub-channel is larger than the cross-sectional area of ​​the through-channel.

[0008] In one embodiment, the surface of the second heat dissipation substrate facing the adapter is provided with a fourth groove. The fourth groove is located at one end of the second heat dissipation substrate away from the adapter. The groove opening of the fourth groove is provided with a fourth flow channel cover plate. The fourth flow channel cover plate and the second groove cooperate to form a liquid inlet flow channel. The liquid inlet flow channel is connected to the second sub-flow channel.

[0009] In one embodiment, the surface of the second heat dissipation substrate facing the adapter is provided with a recessed portion, the recessed portion is provided corresponding to the second groove, and the recessed portion is provided with reinforcing ribs.

[0010] In one embodiment, the first heat sink includes a first heat sink substrate and a first flow channel cover plate. A first groove is formed on the surface of the first heat sink substrate facing away from the adapter. The first flow channel cover plate is welded to the groove opening of the first groove to form the first liquid cooling channel.

[0011] In one embodiment, the first heat dissipation substrate, the adapter, and the second heat dissipation substrate are integrally die-cast.

[0012] To achieve the above objectives, this utility model provides a range extender, which includes a generator, a controller electrically connected to the generator, a capacitor element, and the liquid cooling assembly described above. The controller has an insulated gate bipolar transistor, the capacitor element forms the first heating element, and the insulated gate bipolar transistor forms the second heating element.

[0013] In one embodiment, the range extender further includes a housing disposed on the controller, the liquid cooling assembly forming the housing; and / or, the generator housing has a motor cooling channel communicating with the first liquid cooling channel.

[0014] To achieve the above objectives, this utility model provides a vehicle that includes the range extender described above.

[0015] The technical solution of this application, by setting a first heat dissipation plate and a second heat dissipation plate of different heights, can simultaneously cool and dissipate heat from the first and second heat-generating components of different heights. Furthermore, the first liquid cooling channel on the first heat dissipation plate and the second liquid cooling channel on the second heat dissipation plate are connected through a connecting liquid cooling channel on a transition plate, so that the first and second liquid cooling channels are connected in series to form an integrated water channel. In other words, heat-generating components of different heights can share a single water channel for heat dissipation. Compared with setting separate liquid cooling systems for heat-generating components of different heights, this saves the use of one set of liquid cooling systems and reduces the structural complexity of the heat dissipation system. Moreover, it reduces the space occupied by the vehicle, freeing up more installation space for other components such as the battery pack. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0017] Figure 1 This is a three-dimensional structural diagram of an embodiment of the liquid cooling component of this utility model;

[0018] Figure 2 This is a cross-sectional structural diagram of an embodiment of the liquid cooling component of this utility model;

[0019] Figure 3 This is another cross-sectional structural diagram of an embodiment of the liquid cooling component of this utility model;

[0020] Figure 4 This is an exploded view of an embodiment of the liquid cooling component of this utility model.

[0021] Figure 5 This is an exploded structural diagram of another embodiment of the liquid cooling component of this utility model.

[0022] Explanation of icon numbers:

[0023] 100, First heat sink; 110, First liquid cooling channel; 120, First heat sink substrate; 130, First flow channel cover; 121, First groove; 200, Second heat sink; 210, Second liquid cooling channel; 220, Second heat sink substrate; 221, Second groove; 222, Third groove; 223, Fourth groove; 224, Recess; 230, Second flow channel cover; 240, Spacer rib; 241, Through notch; 250, Third flow channel cover; 260, Fourth flow channel cover; 270, Reinforcing rib; 300, Adapter; 310, Adapter liquid cooling channel; 400, Controller; 410, Insulated gate bipolar transistor.

[0024] The realization of the purpose, functional features and advantages of this utility model will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0025] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the embodiments of the present utility model.

[0026] It should be noted that all directional indicators (such as up, down, left, right, front, back, etc.) in this utility model embodiment are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicator will also change accordingly.

[0027] Furthermore, in the embodiments of this utility model, descriptions involving "first," "second," etc., are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of the embodiments of this utility model, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0028] In this embodiment of the invention, unless otherwise explicitly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this embodiment of the invention according to the specific circumstances.

[0029] Furthermore, the technical solutions of the various embodiments of this utility model can be combined with each other, but only if they are based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the protection scope claimed by the embodiments of this utility model.

[0030] In traditional liquid-cooled heat dissipation systems, especially in range extenders, the electronic control unit (ECU) and generator are separate designs. The ECU's boundaries are limited by the overall vehicle space requirements, with no room for expansion in the plane. To meet the capacitor's capacity requirements, the capacitor needs to protrude rearward. This creates a height difference between the IGBT's cooling channels and the capacitor's cooling channels, often necessitating the design of two or more independent channels to correspond to the height of each heat-generating element, ensuring the coolant effectively covers all heat sources. However, this approach increases system complexity and leads to higher manufacturing costs.

[0031] In view of this, the present invention provides a liquid cooling component, a range extender, and a vehicle. The first liquid cooling channel on the first heat sink and the second liquid cooling channel on the second heat sink are connected through a connecting liquid cooling channel on the adapter plate, so that the first liquid cooling channel and the second liquid cooling channel are connected in series to form an integrated water channel. That is to say, heat-generating components of different heights can share a water channel for heat dissipation. Compared with setting independent liquid cooling systems for heat-generating components of different heights, the use of a set of liquid cooling systems is saved, and the structural complexity of the heat dissipation system is reduced.

[0032] To better understand the above technical solution, the following detailed explanation is provided in conjunction with the accompanying drawings.

[0033] like Figures 1 to 3As shown in the figure, this utility model embodiment proposes a liquid cooling assembly, which includes a first heat sink 100 and a second heat sink 200 of different heights, and a connector 300 connecting the first heat sink 100 and the second heat sink 200. The first heat sink 100 is provided with a first liquid cooling channel 110 for cooling a first heat-generating component, and the second heat sink 200 is provided with a second liquid cooling channel 210 for cooling a second heat-generating component. The connector 300 is provided with a connecting liquid cooling channel 310, which connects the first liquid cooling channel 110 and the second liquid cooling channel 210. It can be understood that the coolant in the first liquid cooling channel 110 and the second liquid cooling channel 210 are connected in series through the connecting liquid cooling channel 310, allowing the first heat-generating component and the second heat-generating component of different heights to share a single liquid cooling system for heat dissipation, simplifying the complexity of the heat dissipation structure. That is, during the cooling process, the coolant first enters the second liquid cooling channel 210, then flows into the first liquid cooling channel 110 through the connecting liquid cooling channel 310, thereby forming a liquid cooling circuit. Optionally, the adapter 300 can be integrally formed with the first heat sink 100 and the second heat sink 200, or it can be assembled by welding; this is not limited here. It should be noted that the height difference in this embodiment can be a radial distance difference or a lateral distance difference.

[0034] In this embodiment, by setting up a first heat sink 100 and a second heat sink 200 with different heights, simultaneous cooling of the first and second heat-generating components at different heights can be achieved. Furthermore, the first liquid cooling channel 110 on the first heat sink 100 and the second liquid cooling channel 210 on the second heat sink 200 are connected via a connecting liquid cooling channel 310 on a connecting plate, allowing the first and second liquid cooling channels 110 and 210 to be connected in series to form an integrated water channel. This means that heat-generating components at different heights can share a single water channel for cooling. Compared to using separate liquid cooling systems for heat-generating components at different heights, this saves the use of one set of liquid cooling systems and reduces the structural complexity of the cooling system. Moreover, it reduces the space occupied by the vehicle, freeing up more installation space for other components such as the battery pack.

[0035] In one embodiment of this utility model, the first heat dissipation substrate 120, the adapter 300, and the second heat dissipation substrate 220 are integrally die-cast. This achieves a seamless connection between the first heat dissipation substrate 120, the adapter 300, and the second heat dissipation substrate 220, improving the stability and reliability of the overall structure. It also eliminates the need for easily damaged connecting parts such as sealing rings and bolts, reducing the risk of leakage in the cooling system. Furthermore, compared to traditional injection molding processes, die-cast parts have higher strength, better corrosion resistance, and are lighter.

[0036] In one embodiment of this utility model, reference is made to Figures 2 to 5 The second heat sink 200 includes a second heat sink substrate 220 and a second flow channel cover plate 230. The surface of the second heat sink substrate 220 facing away from the adapter 300 forms a communicating second groove 221 and a third groove 222. The second heating element is sealed in the opening of the second groove 221 to form a first sub-flow channel. The second flow channel cover plate 230 is welded to the opening of the third groove 222 to form a second sub-flow channel. The first sub-flow channel and the second sub-flow channel communicate to form a second liquid cooling channel 210. The adapter liquid cooling channel 310 communicates with the second sub-flow channel. For the die-casting process, the second liquid cooling channel 210 cannot be directly formed during the molding process of the second heat sink 200. Therefore, in this embodiment, the second heat sink 200 includes a second heat sink substrate 220 and a second flow channel cover plate 230. The second heat dissipation substrate 220 is formed by die casting, which creates a second groove 221 and a third groove 222. A second flow channel cover 230 is welded to the opening of the third groove 222, thereby sealing the third groove 222 to form a second sub-flow channel. Optionally, the second flow channel cover 230 can be friction-welded to the opening of the third groove 222 to improve sealing performance and further prevent leakage. The opening of the second groove 221 is used to install the second heating element. It can be understood that the second heating element is sealed and installed at the opening of the second groove 221, thereby sealing the second groove 221 to form a first sub-flow channel. Using the second heating element as a sealing cover for the second groove 221 allows for simultaneous installation and sealing of the second groove 221, simplifying the assembly process.

[0037] In one embodiment of this utility model, reference is made to Figure 3 A spacer rib 240 is formed between the second groove 221 and the third groove 222. One end of the spacer rib 240 facing the adapter 300 has a through-hole 241. One end of the through-hole 241 extends to the bottom of the second groove 221, and the other end extends to the bottom of the third groove 222. A third flow channel cover plate 250 is welded to the through-hole 241. The third flow channel cover plate 250 cooperates with the spacer rib 240 to form a guiding flow channel, which connects the first sub-flow channel and the second sub-flow channel. It can be understood that the through-hole 241 is located at the top of the spacer rib 240 and extends laterally to the third groove 222 and the second groove 221. By welding the third flow channel cover plate 250, the second groove 221, the third groove 222, and the through-hole 241 are sealed to form the first sub-flow channel, the second sub-flow channel, and the guiding flow channel.

[0038] In one embodiment of this invention, the cross-sectional area of ​​the second sub-channel is larger than that of the through-channel. Thus, the coolant in the first sub-channel can first flow into the second sub-channel for buffering before entering the through-channel. Compared to the through-channel, the enlarged cross-sectional area of ​​the second sub-channel reduces the pressure loss of the coolant as it passes through, increases the flow rate of the coolant from the second sub-channel to the first liquid cooling channel 110, and ensures that the coolant can smoothly overcome the height difference and enter the first liquid cooling channel 110 under lower pressure.

[0039] In one embodiment of this utility model, reference is made to Figure 4 The second heat dissipation substrate 220 has a fourth groove 223 on its surface facing the adapter 300. The fourth groove 223 is located at the end of the second heat dissipation substrate 220 away from the adapter 300. A fourth flow channel cover plate 260 is provided at the opening of the fourth groove 223. The fourth flow channel cover plate 260 and the second groove 221 cooperate to form a liquid inlet flow channel, which is connected to the second sub-flow channel. In this way, the liquid inlet flow channel can be connected to an external cooling source to realize a liquid cooling circuit. Optionally, the fourth flow channel cover plate 260 is welded to the opening of the fourth groove 223 by friction welding. Moreover, the liquid inlet flow channel and the adapter liquid cooling channel 310 are located at both ends of the second heat dissipation substrate 220, which increases the flow path of the coolant, can absorb more heat from the surface of the second heat-generating element, and improve the heat dissipation effect of the second heat-generating element.

[0040] In one embodiment of this utility model, the surface of the second heat dissipation substrate 220 facing the adapter 300 is provided with a recessed portion 224, which corresponds to the second groove 221, and the recessed portion 224 is provided with a reinforcing rib 270. Since the second heat-generating element needs to be installed at the opening of the second groove 221, the strength requirement of the second heat dissipation substrate 220 is relatively high. Therefore, a reinforcing rib 270 is provided on the second heat dissipation substrate 220 at the position corresponding to the second groove 221. The reinforcing rib 270 can improve the structural strength of the second heat dissipation substrate 220 at the position of the second groove 221. Moreover, by providing the reinforcing rib 270 in the recessed portion 224, the height of the reinforcing rib 270 protruding from the surface of the second heat dissipation substrate 220 can be reduced, thereby reducing the space occupied.

[0041] In one embodiment of this utility model, reference is made to Figure 2 , Figure 4 as well as Figure 5The first heat sink 100 includes a first heat sink substrate 120 and a first flow channel cover 130. A first groove 121 is formed on the surface of the first heat sink substrate 120 facing away from the adapter 300. The first flow channel cover 130 is welded to the opening of the first groove 121 to form the first liquid cooling channel 110. Specifically, the first heat sink substrate 120 is die-cast, forming the first groove 121. The first flow channel cover 130 is welded to the opening of the first groove 121, thereby sealing the first groove 121 to form the first liquid cooling channel 110. Optionally, the first flow channel cover 130 is friction-welded to the opening of the first groove 121, which can improve the sealing performance and further prevent leakage.

[0042] In one embodiment of this utility model, the adapter 300 includes a connecting adapter section and a supporting section. The adapter section is provided with a connecting liquid cooling channel 310 and is connected to one end of the first heat sink 100 and the second heat sink 200. The supporting section is connected to the other end of the first heat sink 100 and the second heat sink 200. Specifically, the adapter section is provided with a connecting liquid cooling channel 310 to connect the first liquid cooling channel 110 and the second liquid cooling channel 210. The supporting section connects the first heat sink 100 and the second heat sink 200 and is used to improve the connection strength between the first heat sink 100 and the second heat sink 200. In other words, the adapter 300 has both coolant delivery and mechanical support functions, reducing the need for additional components, simplifying the installation steps and process, making the assembly of the entire heat dissipation system simpler and faster, and reducing installation difficulty and time costs.

[0043] To achieve the above objectives, this utility model provides a range extender, which includes a generator, a controller 400 electrically connected to the generator, a capacitor element, and the aforementioned liquid cooling assembly. The controller 400 has an insulated-gate bipolar transistor (IGBT) 410, the capacitor element forms the first heating element, and the IGBT 410 forms the second heating element. It is understood that to meet the capacitance requirements, the capacitor element needs to protrude, i.e., its length is extended, so that the capacitor element and the IGBT 410 are not on the same plane and have a height difference. Specifically, the specific structure of the liquid cooling assembly refers to the above embodiment. Since this range extender adopts all the technical solutions of the above embodiments, it possesses at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated further here.

[0044] In one embodiment of this utility model, the range extender further includes a housing disposed on the controller 400, and the liquid cooling assembly forms the housing. This reduces the number of components used, lowers structural complexity, and reduces space occupation. And / or, the generator housing is provided with a motor cooling channel, which is connected to the first liquid cooling channel 110. That is, the motor cooling channel and the first liquid cooling channel 110 are connected in series to form a whole, enabling simultaneous heat dissipation of the controller 400, capacitor components, and motor, further reducing structural complexity. In one embodiment, a connecting pipe is provided on the first heat dissipation substrate 120, connecting the first liquid cooling channel 110 and the motor cooling channel. In other embodiments, the generator housing is also provided with a liquid outlet pipe, through which the coolant in the motor cooling channel flows out.

[0045] To achieve the above objectives, this utility model provides a vehicle that includes the range extender described above. Specifically, the specific structure of the range extender is as described in the above embodiments. Since this vehicle adopts all the technical solutions of the above embodiments, it possesses at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated upon here.

[0046] The above description is merely an exemplary embodiment of the present utility model and does not limit the patent scope of the present utility model embodiments. Any equivalent structural transformations made under the technical concept of the present utility model using the description and drawings of the present utility model embodiments, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present utility model embodiments.

Claims

1. A liquid-cooled assembly, comprising: The liquid cooling assembly includes a first heat sink and a second heat sink of different heights, and a connector connecting the first heat sink and the second heat sink. The first heat sink is provided with a first liquid cooling channel for cooling a first heat-generating element, the second heat sink is provided with a second liquid cooling channel for cooling a second heat-generating element, and the connector is provided with a connecting liquid cooling channel that connects the first liquid cooling channel and the second liquid cooling channel.

2. The liquid-cooling assembly of claim 1, wherein, The second heat sink includes a second heat sink substrate and a second flow channel cover plate. The surface of the second heat sink substrate facing away from the adapter forms a second groove and a third groove that are connected. The second heat-generating element is sealed in the groove of the second groove to form a first sub-flow channel. The second flow channel cover plate is welded to the groove of the third groove to form a second sub-flow channel. The first sub-flow channel and the second sub-flow channel are connected to form a second liquid cooling channel. The adapter liquid cooling channel is connected to the second sub-flow channel.

3. The liquid-cooling assembly of claim 2, wherein, A spacer rib is formed between the second groove and the third groove. One end of the spacer rib facing the adapter has a through notch. One end of the through notch extends to the bottom of the second groove, and the other end of the through notch extends to the bottom of the third groove. A third flow channel cover is welded to the through notch. The third flow channel cover cooperates with the spacer rib to form a guide flow channel. The guide flow channel connects the first sub-flow channel and the second sub-flow channel.

4. The liquid-cooling assembly of claim 3, wherein, The cross-sectional area of ​​the second sub-channel is larger than the cross-sectional area of ​​the through channel.

5. The liquid-cooling assembly of claim 2, wherein, The second heat dissipation substrate has a fourth groove on the surface facing the adapter. The fourth groove is located at the end of the second heat dissipation substrate away from the adapter. The groove opening of the fourth groove is provided with a fourth flow channel cover plate. The fourth flow channel cover plate and the second groove cooperate to form a liquid inlet flow channel. The liquid inlet flow channel is connected to the second sub-flow channel.

6. The liquid-cooling assembly of claim 2, wherein, The second heat dissipation substrate has a recessed portion on the surface facing the adapter, the recessed portion is provided corresponding to the second groove, and the recessed portion is provided with reinforcing ribs.

7. The liquid-cooling assembly of claim 2, wherein, The first heat sink includes a first heat sink substrate and a first flow channel cover plate. A first groove is formed on the surface of the first heat sink substrate facing away from the adapter. The first flow channel cover plate is welded to the groove opening of the first groove to form the first liquid cooling channel.

8. The liquid-cooling assembly of claim 7, wherein, The first heat dissipation substrate, the adapter, and the second heat dissipation substrate are integrally die-cast.

9. A range extender, characterized in that, The range extender includes a generator, a controller electrically connected to the generator, a capacitor element, and a liquid-cooled assembly as described in any one of claims 1 to 8, wherein the controller has an insulated-gate bipolar transistor, the capacitor element forms the first heating element, and the insulated-gate bipolar transistor forms the second heating element.

10. The range extender of claim 9, characterized in that The range extender also includes a housing disposed on the controller, the liquid cooling assembly forming the housing; and / or, the generator housing is provided with a motor cooling channel, the motor cooling channel being connected to the first liquid cooling channel.

11. A vehicle characterized by comprising: The vehicle includes the range extender as described in claim 9 or 10.

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