DC / DC converters and electric vehicles

Abstract

This application relates to the field of DC / DC converter technology, and discloses a DC / DC converter and an electric vehicle. The DC / DC converter includes a first cover plate, a metal bottom shell, a vent valve, and electronic components. The metal bottom shell is covered by the first cover plate, which defines a first receiving cavity. The metal bottom shell includes a bottom wall, peripheral side walls, and a first isolation wall. The peripheral side walls are connected to the perimeter of the bottom wall, and the first isolation wall is connected to both the bottom wall and the peripheral side walls, forming a second receiving cavity. The peripheral side walls have a vent valve mounting hole communicating with the second receiving cavity, and the vent valve is located at the vent valve mounting hole. The electronic components are located within the first receiving cavity. Through the above configuration, this application can improve the technical problem of poor operational reliability of DC / DC converters in related technologies.

Description

Technical Field

[0001] This application relates to the field of DC-DC converter technology, and in particular to a DC / DC converter and an electric vehicle. Background Technology

[0002] DC / DC converters are primarily used in electric vehicles, converting high-voltage direct current (DC) into low-voltage DC to power various electronic devices within the vehicle. The vent valve, as a component ensuring the safe operation of the DC / DC converter, also maintains a relatively constant internal environment to prevent the ingress of external moisture. However, when there is a significant temperature difference between the internal and external environments of the DC / DC converter, especially when electric vehicles operate under high-temperature and high-humidity conditions, warm air entering the converter through the vent valve can easily condense moisture onto the surfaces of cold drive boards or control boards, forming conductive paths and potentially causing insulation failure in these electronic components, thus reducing the operational reliability of the DC / DC converter. Utility Model Content

[0003] The purpose of this application is to provide a DC / DC converter and an electric vehicle, aiming to improve the technical problem of poor operational reliability of DC / DC converters in related technologies.

[0004] According to a first aspect of this application, a DC / DC converter is provided, comprising: First cover plate; A metal bottom shell is covered with the first cover plate, which defines a first receiving cavity. The metal bottom shell includes a bottom wall, a peripheral side wall, and a first isolation wall. The peripheral side wall is connected to the four sides of the bottom wall. The first isolation wall is connected to the bottom wall and the peripheral side wall respectively, and together with the bottom wall and the peripheral side wall, forms a second receiving cavity. The peripheral side wall has a vent valve mounting hole that communicates with the second receiving cavity. A vent valve is provided at the vent valve mounting hole; and Electronic devices are disposed within the first receiving cavity.

[0005] Optionally, the surface of the bottom wall facing the first receiving cavity is in at least partial contact with the electronic device; The bottom wall surface facing away from the first receiving cavity forms a water-cooled section. The water-cooled section is provided with a flow guide groove. The DC / DC converter also includes a second cover plate, which covers the water-cooled section and forms a cooling channel with the flow guide groove. The cooling channel is used to flow a cooling medium to cool the electronic device.

[0006] Optionally, a thermally conductive insulating layer is filled between the bottom wall surface facing the first receiving cavity and the electronic device.

[0007] Optionally, the thermally conductive insulating layer includes a Mylar sheet and a thermally conductive filler layer, the Mylar sheet being attached to the surface of the bottom wall facing the first receiving cavity, and the thermally conductive filler layer at least partially filling the space between the Mylar sheet and the electronic device.

[0008] Optionally, the first cover plate and the metal bottom shell are sealed together with sealant; and / or, the second cover plate and the water cooling section are sealed together with sealant.

[0009] Optionally, a thermally conductive layer is at least partially filled between the electronic device and the first cover plate.

[0010] Optionally, the DC / DC converter includes a DC high-voltage input terminal, a DC low-voltage output positive terminal, and a signal control terminal fixed to the bottom wall; the DC high-voltage input terminal, the DC low-voltage output positive terminal, and the signal control terminal are all electrically connected to the electronic device; The metal base shell is provided with a grounding part, which is electrically connected to the electronic device.

[0011] Optionally, the metal bottom shell includes a second partition wall, a third partition wall, and a fourth partition wall; the second partition wall is connected to the bottom wall and is disposed opposite to a portion of the peripheral sidewall; the third partition wall is connected to the second partition wall and the first partition wall respectively; the fourth partition wall is connected to the second partition wall and the peripheral sidewall respectively; the second partition wall, the third partition wall, and the fourth partition wall together divide the first receiving cavity into a first sub-cavity, a second sub-cavity, a third sub-cavity, and a fourth sub-cavity, wherein the second sub-cavity, the third sub-cavity, and the fourth sub-cavity are arranged side by side; The electronic device is located in the first sub-cavity, a portion of the DC high-voltage input terminals are located in the second sub-cavity, a portion of the signal control terminals are located in the third sub-cavity, and a portion of the DC low-voltage output positive terminal is located in the fourth sub-cavity.

[0012] Optionally, the DC / DC converter includes a filter circuit board; the filter circuit board is disposed in the fourth sub-cavity, and the filter circuit board and the positive terminal of the DC low-voltage output are respectively electrically connected to the electronic device.

[0013] According to a second aspect of this application, an electric vehicle is provided, including the DC / DC converter described above.

[0014] The beneficial effects of the embodiments of this application are as follows: The DC / DC converter involved in this application, by setting a first isolation wall, allows water vapor to come into contact with it and condense into water droplets when there is a large temperature difference between the internal and external environments. This serves to prevent water vapor from directly entering the first receiving cavity through the vent valve. Moreover, the first isolation wall, the bottom wall, and the peripheral side wall together enclose the second receiving cavity. Even if water vapor condenses into water droplets, it will be confined within the second receiving cavity. This improves the technical problem that when water vapor encounters the surface of cold electronic devices such as drive boards or control boards, it easily condenses into water vapor and accumulates around these electronic devices, forming a conductive path. This improves the operational reliability of the DC / DC converter. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the specific embodiments of this application or the prior art, the accompanying drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn to scale.

[0016] Figure 1 An exploded view of the structure of a DC / DC converter provided in one embodiment of this application; Figure 2 for Figure 1 Another exploded view of the DC / DC converter structure is shown; Figure 3 for Figure 1 The diagram shows a top view of the DC / DC converter without the first cover plate. Figure 4 for Figure 1 The diagram shows the structure of the metal base of the DC / DC converter; Figure label: 1a, First receiving cavity; 1aa, First sub-cavity; 1ab, Second sub-cavity; 1ac, Third sub-cavity; 1ad, Fourth sub-cavity; 10. Metal base shell; 10a. Second receiving cavity; 101. Vent valve mounting hole; 102. Grounding part; 110. Bottom wall; 1101. Water cooling part; 11011. Flow guide groove; 120. Peripheral side wall; 1201. Front side wall; 130. First isolation wall; 140. Second isolation wall; 150. Third isolation wall; 160. Fourth isolation wall; 20. First cover plate; 30. Electronic components; 40. Vent valve; 50. Second cover plate; 501. Inlet; 502. Outlet; 61. Thermally conductive layer; 62. Thermally conductive insulating layer; 621. Mylar sheet; 622. Thermally conductive filler layer; 71. DC high voltage input terminal; 72. Signal control terminal; 73. DC low voltage output positive terminal; 74. Filter circuit board; Detailed Implementation The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit this application or its application or use. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0017] Techniques, methods, and equipment known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and equipment should be considered part of the specification.

[0018] In the description of this application, it should be noted that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is usually based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this application and simplifying the description. Unless otherwise stated, these directional terms 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, and therefore should not be construed as a limitation on the scope of protection of this application; the directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0019] In the description of this application, it should be noted that the use of terms such as "first" and "second" to define the components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this application.

[0020] The technical features involved in the different embodiments of this application described below can be combined with each other as long as they do not conflict with each other.

[0021] Please see Figures 1 to 4According to one embodiment of this application, a DC / DC converter includes a metal base 10, a first cover plate 20, electronic components 30, and a vent valve 40. The first cover plate 20 covers the metal base 10 and defines a first receiving cavity 1a. The internal shape of the first receiving cavity 1a is determined by the shape and requirements of the electronic components 30 to be placed inside the cavity. The electronic components 30 are disposed in the first receiving cavity 1a and include, but are not limited to, drive circuit boards, control circuit boards, transformers, inductors, power devices, magnetic devices, etc. The metal base 10 has a vent valve mounting hole 101, and the vent valve 40 is disposed at the vent valve mounting hole 101 to maintain a relatively constant internal environment inside the first receiving cavity 1a.

[0022] For the metal base shell 10 and the first cover plate 20, such as Figure 1 As shown, in some embodiments, the metal base shell 10 has a receiving groove with an open top, and a first cover plate 20 covers the opening of the receiving groove, thereby defining the aforementioned first receiving cavity 1a by the first cover plate 20 and the metal base shell 10. Exemplarily, both the metal base shell 10 and the first cover plate 20 are generally rectangular, and both are made of aluminum, which ensures strength while allowing for rapid heat transfer and low weight. The first cover plate 20 and the metal shell are fixed together by fasteners, such as screws and bolts.

[0023] like Figure 4 As shown, in some embodiments, the metal base shell 10 includes a bottom wall 110, a peripheral side wall 120, and a first partition wall 130. The bottom wall 110 is located at the bottom of the first receiving cavity 1a, and the peripheral side wall 120 surrounds and connects to the bottom wall 110, forming together with the bottom wall 110 to enclose the aforementioned top-opening receiving groove. The first partition wall 130 is located inside the first receiving cavity 1a, and the first partition wall 130 is connected to both the bottom wall 110 and the peripheral side wall 120, forming a second receiving cavity 10a together with the bottom wall 110 and the peripheral side wall 120. The peripheral side wall 120 has the aforementioned vent valve mounting hole 101, which communicates with the second receiving cavity 10a. Exemplarily, the peripheral side wall 120 has the following... Figure 3 or Figure 4 The front sidewall 1201 shown has a cross-section of the first partition wall 130 that is approximately U-shaped. Its bottom end is integrally formed to the bottom wall 110 and the front sidewall 1201, respectively. The opposite ends of the first partition wall 130 are integrally formed to the front sidewall 1201. Thus, the first partition wall 130, the bottom wall 110 and the peripheral sidewall 120 together form the aforementioned second receiving cavity 10a.

[0024] The DC / DC converter involved in this application, by setting a first isolation wall 130, allows water vapor to come into contact with it and condense into water droplets when there is a large temperature difference between the internal and external environments. This effectively prevents water vapor passing through the vent valve 40 from directly entering the first receiving cavity 1a. Moreover, the first isolation wall 130, the bottom wall 110, and the peripheral side wall 120 together enclose the second receiving cavity 10a. Even if water vapor condenses into water droplets, it will be confined within the second receiving cavity 10a. This improves the technical problem that when water vapor encounters the surface of cold electronic devices such as drive boards or control boards, it easily condenses into water vapor and accumulates around these electronic devices 30, forming a conductive path. This, in turn, improves the operational reliability of the DC / DC converter.

[0025] To reduce the entry of external moisture into the cavity through the assembly gap between the first cover plate 20 and the metal base shell 10, the first cover plate 20 and the metal base shell 10 are further sealed together with sealant. In specific implementation, sealant can be evenly applied to the upper surface of the peripheral sidewall 120, the first cover plate 20 is covered and fasteners are inserted and screwed to fix it to the metal base shell 10. Under the tightening action of the fasteners, the sealant cures, thus completing the sealed connection between the two.

[0026] Of course, the metal base 10 is not limited to the specific shape or structure mentioned above; it only needs to meet the application requirement of preventing water vapor from the vent valve 40 from directly entering the first receiving cavity 1a. For example, as Figure 2 As shown, in some embodiments, the construction of the metal base 10 can be adjusted to enhance the heat dissipation of the DC / DC converter.

[0027] Specifically, the surface of the bottom wall 110 facing the first receiving cavity 1a is at least partially in contact with the electronic device 30.

[0028] A water-cooling section 1101 is formed on the surface of the bottom wall 110 facing away from the first receiving cavity 1a. The water-cooling section 1101 is provided with a guide channel 11011, the shape of which can be designed according to heat dissipation requirements. Preferably, the coverage area of ​​the guide channel 11011 is maximized to enhance the water-cooling effect. The DC / DC converter also includes a second cover plate 50, which is fixedly installed on the water-cooling section 1101. Exemplarily, the second cover plate 50 covers the opening of the guide channel 11011, thereby forming a cooling channel between the second cover plate 50 and the guide channel 11011. The cooling channel is used to flow a cooling medium to cool the electronic device 30. The cooling medium can be water or other liquids that easily absorb heat. In addition, the cooling medium can be at room temperature or a liquid below room temperature. Exemplarily, the second cover plate 50 and the water-cooling section 1101 are fixed together by fasteners, such as screws and bolts.

[0029] The advantage of adopting the above technical solution is that the heat generated by the electronic device 30 fixed in the first receiving cavity 1a during operation is transferred to the metal base shell 10. Part of the heat is dissipated through the outer surface of the metal base shell 10 by air heat dissipation, and the other part of the heat is carried away by the cooling medium flowing through the cooling channel, which can simultaneously meet the small size design and heat dissipation requirements of the DC / DC converter.

[0030] like Figure 2 As shown, in some embodiments, the surface of the second cover plate 50 facing away from the metal base shell 10 is provided with an inlet 501 and an outlet 502, both of which are connected to the cooling channel. In specific implementation, the chiller is connected to the inlet 501 and the outlet 502 respectively through water pipes. The cooling medium enters the cooling channel from the inlet 501, absorbs heat during the flow of the cooling channel, and flows out from the outlet 502 and back to the chiller.

[0031] To enhance the heat dissipation of the DC / DC converter, a thermally conductive layer 61 is further provided at least partially between the electronic device 30 and the first cover plate 20. The thermally conductive layer 61 may include thermally conductive grease, thermally conductive adhesive, thermally conductive silicone, thermally conductive graphite, etc. The electronic device 30 also includes a transformer and inductor integrated module, and the thermally conductive layer 61 is filled between the transformer and inductor integrated module and the inner surface of the first cover plate 20.

[0032] To reduce the risk of water vapor entering the first receiving cavity 1a condensing into water droplets upon contact with the cold inner surface of the bottom wall 110 and directly contacting the electronic device 30, a thermally conductive insulating layer 62 is further provided between the surface of the bottom wall 110 facing the first receiving cavity 1a and the electronic device 30. Specifically, the thermally conductive insulating layer 62 includes a Mylar sheet 621 and a thermally conductive filler layer 622. The Mylar sheet 621 is attached to the surface of the bottom wall 110 facing the first receiving cavity 1a, and the thermally conductive filler layer 622 at least partially fills the space between the Mylar sheet 621 and the electronic device 30. This arrangement isolates the surface of the bottom wall 110 facing the first receiving cavity 1a from the electronic device 30, ensuring effective heat dissipation between the electronic device 30 and the water-cooled section 1101 while reducing the risk of the electronic device 30 being damaged by short circuits due to contact with water droplets. Examples of the thermally conductive filler layer 622 include thermally conductive grease, thermally conductive adhesive, thermally conductive silicone, and thermally conductive graphite.

[0033] To reduce leakage of the cooling medium from the assembly gap between the second cover plate 50 and the water-cooled part 1101, the second cover plate 50 and the water-cooled part 1101 are further sealed together with sealant. In specific implementation, the sealant can be evenly applied to the inner surface edge of the second cover plate 50, the second cover plate 50 is covered and fasteners are inserted and screwed to fix it to the metal base shell 10. Under the tightening action of the fasteners, the sealant cures to complete the sealed connection between the two.

[0034] Please continue reading Figure 1 or Figure 3 In some embodiments, the DC / DC converter includes a DC high-voltage input terminal 71, a signal control terminal 72, and a DC low-voltage output positive terminal 73 fixed to a metal housing 10. The DC high-voltage input terminal 71, the DC low-voltage output positive terminal 73, and the signal control terminal 72 are electrically connected to an electronic device 30 inside the cavity to enable the electronic device 30 to operate. Preferably, a grounding portion 102 is provided outside the metal housing 10, and the grounding portion 102 is electrically connected to the electronic device 30 to serve as the DC low-voltage output negative terminal of the DC / DC converter.

[0035] Further, the metal base shell 10 includes a second partition wall 140, a third partition wall 150, and a fourth partition wall 160. The second partition wall 140 is connected to the bottom wall 110 and is disposed opposite to a portion of the peripheral side wall 120. The third partition wall 150 is connected to the second partition wall 140 and the first partition wall 130. The fourth partition wall 160 is connected to the second partition wall 140 and the peripheral side wall 120. Exemplarily, the second partition wall 140 is integrally formed to the bottom wall 110, is generally L-shaped, and is disposed opposite to the front side wall 1201 and its adjacent side walls. The third partition wall 150 is integrally formed to the bottom wall 110, the first partition wall 130, and the second partition wall 140, respectively. The fourth partition wall 160 is disposed side by side with the third partition wall 150 and is integrally formed to the bottom wall 110, the second partition wall 140, and the front side wall 1201. The second isolation wall 140, the third isolation wall 150, and the fourth isolation wall 160 together divide the first receiving cavity 1a into a first sub-cavity 1aa, a second sub-cavity 1ab, a third self-contained cavity, and a fourth sub-cavity 1ad, wherein the second sub-cavity 1ab, the third sub-cavity 1ac, and the fourth sub-cavity 1ad are arranged side by side. Electronic devices 30 are disposed in the first sub-cavity 1aa, some DC high-voltage input terminals 71 are disposed in the second self-contained cavity, some signal control terminals 72 are disposed in the third sub-cavity 1ac, and some DC low-voltage output positive terminals 73 are disposed in the fourth sub-cavity 1ad.

[0036] The advantage of adopting the above technical solution is that a second isolation wall 140 is provided between the first sub-cavity 1aa and the second sub-cavity 1ab, the third sub-cavity 1ac, and the fourth sub-cavity 1ad. The second isolation wall 140 electrically isolates the electronic device 30 and the input / output terminals. A third isolation wall 150 is provided between the second sub-cavity 1ab and the third sub-cavity 1ac. The third isolation wall 150 and the first isolation wall 130 jointly electrically isolate the DC high-voltage input terminal 71 and the signal control terminal 72. A fourth isolation wall 160 is provided between the third sub-cavity 1ac and the fourth sub-cavity 1ad. The fourth isolation wall 160 electrically isolates the signal control terminal 72 and the DC low-voltage output positive terminal 73. That is, the anti-interference capability of the DC / DC converter is strengthened from the structure, and the EMC performance of the whole machine is improved.

[0037] Furthermore, the DC / DC converter includes a filter circuit board 74. The filter circuit board 74 is located within the fourth sub-cavity 1ad, and the filter circuit board 74 and the positive terminal 73 of the low-voltage DC output are respectively connected to the electronic device 30. The filter circuit board 74 is used to reduce electromagnetic interference from external electrical equipment to the DC / DC converter.

[0038] Based on the DC / DC converter in the above embodiments, this application also proposes an electric vehicle that includes the aforementioned DC / DC converter.

[0039] The above description is merely an embodiment of this application and does not limit the patent scope of this application. Any equivalent structural or procedural transformations made using the content of this application's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this application.

Claims

1. A DC / DC converter, characterized in that, include: First cover plate; A metal bottom shell is covered with the first cover plate, and the first cover plate defines a first receiving cavity; The metal base shell includes a bottom wall, a peripheral side wall, and a first isolation wall. The peripheral side wall is connected to the four sides of the bottom wall. The first isolation wall is connected to the bottom wall and the peripheral side wall respectively, and together with the bottom wall and the peripheral side wall, they form a second receiving cavity. The peripheral side wall has a vent valve mounting hole that communicates with the second receiving cavity. A vent valve is provided at the vent valve mounting hole; and Electronic devices are disposed within the first receiving cavity.

2. The DC / DC converter according to claim 1, characterized in that, The bottom wall surface facing the first receiving cavity is in at least partial contact with the electronic device; The bottom wall surface facing away from the first receiving cavity forms a water-cooled section. The water-cooled section is provided with a flow guide groove. The DC / DC converter also includes a second cover plate, which covers the water-cooled section and forms a cooling channel with the flow guide groove. The cooling channel is used to flow a cooling medium to cool the electronic device.

3. The DC / DC converter according to claim 2, characterized in that, A thermally conductive insulating layer is filled between the bottom wall surface facing the first receiving cavity and the electronic device.

4. The DC / DC converter according to claim 3, characterized in that, The thermally conductive insulating layer includes a Mylar sheet and a thermally conductive filler layer. The Mylar sheet is attached to the surface of the bottom wall facing the first receiving cavity, and the thermally conductive filler layer at least partially fills the space between the Mylar sheet and the electronic device.

5. The DC / DC converter according to claim 2, characterized in that, The first cover plate and the metal bottom shell are sealed together by sealant; and / or, the second cover plate and the water cooling part are sealed together by sealant.

6. The DC / DC converter according to claim 1, characterized in that, At least a thermally conductive layer is partially filled between the electronic device and the first cover plate.

7. The DC / DC converter according to any one of claims 1-6, characterized in that, The DC / DC converter includes a DC high-voltage input terminal, a DC low-voltage output positive terminal, and a signal control terminal fixed to the bottom wall; the DC high-voltage input terminal, the DC low-voltage output positive terminal, and the signal control terminal are all electrically connected to the electronic device; The metal base shell is provided with a grounding part, which is electrically connected to the electronic device.

8. The DC / DC converter according to claim 7, characterized in that, The metal bottom shell includes a second partition wall, a third partition wall, and a fourth partition wall; the second partition wall is connected to the bottom wall and is disposed opposite to a portion of the peripheral sidewall; the third partition wall is connected to the second partition wall and the first partition wall respectively; the fourth partition wall is connected to the second partition wall and the peripheral sidewall respectively; the second partition wall, the third partition wall, and the fourth partition wall together divide the first receiving cavity into a first sub-cavity, a second sub-cavity, a third sub-cavity, and a fourth sub-cavity, wherein the second sub-cavity, the third sub-cavity, and the fourth sub-cavity are arranged side by side; The electronic device is located in the first sub-cavity, a portion of the DC high-voltage input terminals are located in the second sub-cavity, a portion of the signal control terminals are located in the third sub-cavity, and a portion of the DC low-voltage output positive terminal is located in the fourth sub-cavity.

9. The DC / DC converter according to claim 8, characterized in that, The DC / DC converter includes a filter circuit board; the filter circuit board is disposed in the fourth sub-cavity, and the filter circuit board and the positive terminal of the DC low-voltage output are respectively electrically connected to the electronic device.

10. An electric vehicle, characterized in that, Includes the DC / DC converter as described in any one of claims 1-9.

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