Aluminum shell charger with good heat dissipation effect

Abstract

The utility model discloses an aluminium shell charger with good heat dissipation effect, including shell and install in the circuit board of shell inside, be provided with the heat conduction sheet for delaying heat conduction in the shell, and the power device on the circuit board is set close to the side of heat conduction sheet, so that the heat of circuit board first passes through heat conduction sheet conduction, the utility model discloses, through the cooperation of aluminium material shell and heat conduction sheet, when power device generates heat, first heat transfer to heat conduction sheet, then transfer to shell heat dissipation, make shell surface temperature lower than human body temperature, realized the delay heat transfer, thoroughly solved the situation of plastic combustion, cracking and shell overheating scalding palm.

Description

Technical Field

[0001] This utility model relates to the field of chargers for electric bicycles, and in particular to an aluminum-cased charger with good heat dissipation. Background Technology

[0002] Household electric bicycles have made great strides in the past decade, and their applicability has been continuously improved. They have basically replaced fuel-powered motor vehicles and become an indispensable means of public transportation for daily life and work.

[0003] Traditional home electric bicycle charger designs suffer from the following problems: ① The outer casing is mostly made of engineering plastic, which is prone to cracking, breakage, and serious damage, posing numerous safety hazards; ② Multiple power devices require individual heat sinks mounted on the PCB board, occupying a large space and increasing the PCB area, resulting in material waste and inconvenience for carrying; ③ Some existing chargers also use aluminum casings, with similar installation methods to plastic casings. The transformers on their drive boards, as well as multiple high-capacity filter electrolytic capacitors, generate heat during operation, causing the internal power devices to generate heat from each other. The lack of aluminum casing for heat dissipation is a significant waste! Utility Model Content

[0004] The purpose of this utility model is to solve the problems in the existing technology where "the outer shell is mostly made of engineering plastic, which is prone to cracking, breakage and serious damage, and there are many safety hazards; multiple power devices need to be equipped with heat sinks and installed on the PCB board, which occupies a lot of space, resulting in an increase in the PCB area, wasting materials and being inconvenient to carry; some chargers use aluminum shells, and the transformer on the drive board and multiple high-capacity filter electrolytic components generate heat when working, resulting in mutual heating of internal power devices, and aluminum shells have good thermal conductivity", so this invention proposes an aluminum shell charger that utilizes the good heat dissipation effect of aluminum shells.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: A charger with good heat dissipation in an aluminum shell includes: a shell and a circuit board installed inside the shell. The shell is provided with a heat-conducting sheet for delayed heat conduction. The power devices on the circuit board are arranged close to the heat-conducting sheet, so that the heat of the circuit board is first conducted through the heat-conducting sheet and then delayed to the aluminum shell for heat dissipation through the thickness of the aluminum material.

[0006] As a preferred embodiment of the aluminum shell charger with good heat dissipation of the present invention, the shell includes an upper end cover and a lower end cover, the upper end cover and the lower end cover are provided with slots for interlocking, a fan end cover is installed on one side of the upper end cover and the cable outlet end cover is installed on the other side, and the fan end cover is used in conjunction with the heat conduction plate.

[0007] As a preferred embodiment of the aluminum-cased charger with good heat dissipation of this utility model, wherein: a potting plastic box is installed inside the lower end cover, a PCB board is provided in the potting plastic box, a small signal output power management module is provided at the DC output end of the PCB board, a small signal excitation input module and a transformer are provided at the AC input end.

[0008] As a preferred embodiment of the aluminum-cased charger with good heat dissipation of the present invention, the PCB board DC output terminal is provided with a control circuit for real-time feedback of the output voltage signal to the AC input terminal to realize closed-loop constant voltage and constant current control, and heat-conducting sheets are provided at both the upper and lower ends of the transformer.

[0009] As a preferred embodiment of the aluminum-cased charger with good heat dissipation of this utility model, the PCB board is encapsulated in a plastic box by insulating potting compound, and the flame retardancy of both the plastic box and the potting compound material meets the UL-V0 level requirements.

[0010] As a preferred embodiment of the aluminum-cased charger with good heat dissipation of this utility model, the upper end cover, lower end cover, fan end cover and cable outlet end cover are all made of aluminum.

[0011] Compared with the prior art, the beneficial effects of this utility model are: On the one hand, the small signal excitation input module and small signal output power management module of the drive circuit adopt a separate surface-mount modular design and are connected to the matching circuit in a plug-in manner, which greatly reduces the area of ​​the PCB board and ensures that the power devices of the circuit can be installed close to one side. On the other hand, through the use of aluminum shell and heat sink, when the power device on one side heats up, the heat is first transferred to the heat sink for heat dissipation, and then transferred to the shell. This makes the surface temperature of the aluminum shell suitable and controllable, realizes delayed heat transfer, and completely solves the problems of plastic burning, cracking and uncontrollable shell temperature. Attached Figure Description

[0012] Figure 1 This is a perspective view of an aluminum-cased charger with good heat dissipation proposed in this utility model. Figure 2 This is a schematic diagram of the split structure of an aluminum shell charger with good heat dissipation proposed in this utility model. Figure 3 This is a schematic diagram of the internal structure of an aluminum-cased charger with good heat dissipation proposed in this utility model. Figure 4 This is a schematic diagram of the PCB board mounting structure for an aluminum-cased charger with good heat dissipation proposed in this utility model. Figure 5 This is a schematic diagram of the chip circuit of an aluminum-cased charger with good heat dissipation proposed in this utility model.

[0013] In the diagram: 101, upper end cover; 102, lower end cover; 103, fan end cover; 104, cable outlet end cover; 105, heat-conducting sheet; 201, PCB board; 202, small signal output power management module; 203, small signal excitation input module; 204, transformer; 205, potting plastic box; 206, heat-conducting sheet. Detailed Implementation

[0014] The embodiments of this utility model will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and should not be construed as limiting the scope of this utility model.

[0015] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "set up," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0016] Reference Figures 1-2 A charger with good heat dissipation in an aluminum shell includes a shell and a circuit board installed inside the shell. A heat-conducting plate 105 for delayed heat conduction is provided inside the shell. Power devices on the circuit board are positioned close to the heat-conducting plate 105, allowing heat from the circuit board to be delayed and conducted to the aluminum shell first through a heat sink and then through the thickness of the aluminum material, thus controlling the appropriate temperature of the aluminum shell surface. The heat-conducting plate 105 also contains heat dissipation fins for coordinated use. The shell includes an upper end cover 101 and a lower end cover 102, with mutual... The spliced ​​slot has a fan end cover 103 installed on one side of the upper end cover 101 and the lower end cover 102, and a cable outlet end cover 104 installed on the other side. The fan end cover 103 is used in conjunction with the heat conduction plate 105. When in use, the power devices on the PCB board 201 dissipate heat, which is initially dissipated through the heat conduction plate 105 and the internal heat dissipation fins to avoid the power devices from generating heat from each other. It also has a delayed heat conduction function. When the maximum current is working, it ensures that the surface temperature of the shell does not exceed the human body temperature. Due to the large area and long path of the heat conduction layer, delayed heat transfer is achieved, so that the shell does not feel hot to the touch.

[0017] In addition, the upper end cover 101, lower end cover 102, fan end cover 103 and cable outlet end cover 104 are all made of aluminum, which has a large heat dissipation area, low temperature rise and saves the use of dedicated heat conduction sheets. Due to the use of aluminum shell, the problems of plastic burning and cracking are completely solved, and the total area of ​​PCB is reduced again.

[0018] Reference Figures 3-4 The lower end cover 102 houses a potting plastic box 205, which contains a PCB board 201. The PCB board 201 has a small signal output power management module 202 at its DC output end and a small signal excitation input module 203 and a transformer 204 at its AC input end. The small signal output power management module 202, the small signal excitation input module 203, and the transformer 204 are placed on one side of the heat-conducting plate 105. The transformer 204 has heat-conducting plates 206 at both its upper and lower ends. When the transformer 204 is under full load, it will generate some temperature. A heat-conducting plate 206 is attached to the upper and lower ends of the transformer 204 core. The excess heat is discharged by pressing the upper and lower aluminum shells together. The circuit is also equipped with an over-temperature protection component. The remaining temperature inside the shell can be resolved by natural convection between the hidden windows at both ends of the shell and the outside air. The small signal output power management module 202 and the small signal excitation input module 203 adopt a separate surface-mount modular design and are connected to the matching circuits by plugging and unplugging.

[0019] Secondly, the PCB board 201 DC output terminal is equipped with a control circuit for real-time feedback of the output voltage signal to the AC input terminal to achieve closed-loop constant voltage and constant current. The transformer 204 is equipped with heat-conducting plates 206 at both the upper and lower ends. The PCB board 201 is encapsulated in a potting plastic box 205 with insulating potting glue, and the flame retardancy of both the potting plastic box 205 and the glue meets the UL-V0 level requirements. The PCB board 201 is individually packaged and insulated inside. The flame retardancy of the box and the glue meets the UL-V0 level requirements. At the same time, the safety distance between all high and low power devices on the PCB board 201 and the metal shell is greater than 5mm, which can meet the testing requirements of all safety indicators.

[0020] In addition, the chip works as follows: Input power processing: AC power is input through the live wire (L) and neutral wire (N), first passing through fuse F2 for overcurrent protection, then passing through filter UU10.5 to remove high-frequency noise, then passing through rectifier bridge D2 to convert it into pulsating DC power, and finally being filtered and smoothed by capacitor C50 to output a stable DC voltage.

[0021] The main switching circuit operates as follows: a smooth DC input is sent to the field-effect transistor Q1, which is turned on / off at high frequency under the control signal, driving the primary winding of transformer T1. Transformer T1 achieves voltage transformation and electrical isolation, and the secondary winding outputs AC power.

[0022] Output rectification and filtering: The secondary AC power of the transformer is rectified into pulsating DC power by diodes D3 and D5, and then filtered by capacitor C49 to obtain a preliminary stable DC voltage.

[0023] Constant voltage, constant current and output: The initial DC voltage is controlled by diode D7 to maintain constant voltage and current, and then further filtered by capacitor C45 to output a stable DC voltage that meets the load requirements.

[0024] Control and protection mechanisms: Optocoupler U20 adjusts the stability of output voltage and current through feedback signals; resistors R10, R50 and R42 are used to set the operating point and current limit; G-LED3 (green) and R-LED4 (red) monitor the power supply operating status.

[0025] It is worth noting that the entire device is controlled by a controller. Since the controller (power management module 202 and excitation input module 203) is a common circuit and belongs to existing mature technology, its electrical connection relationship and specific circuit structure will not be described in detail here.

[0026] The above description is merely a preferred embodiment of this utility model, but the protection scope of this utility model is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the technical scope disclosed in this utility model, based on the technical solution and inventive concept of this utility model, should be included within the protection scope of this utility model. In the description of this utility model, it should be noted that the terms "upper," "lower," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and 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, and therefore should not be construed as a limitation of this utility model. Furthermore, the terms "first," "second," or "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

Claims

1. A charger with a good heat dissipation aluminum shell, comprising: The housing and the circuit board mounted inside the housing are characterized in that: The housing is provided with a heat-conducting plate (105) for delayed heat conduction. The power devices on the circuit board are positioned on the side closest to the heat-conducting sheet (105); The heat from the power devices on the circuit board is preferentially conducted to the aluminum shell for heat dissipation through the heat-conducting sheet (105).

2. The aluminum-cased charger with good heat dissipation according to claim 1, characterized in that: The housing includes an upper end cover (101) and a lower end cover (102). The upper end cover (101) and the lower end cover (102) are provided with slots for splicing each other. A fan end cover (103) is installed on one side of the housing, and a cable outlet end cover (104) is installed on the other side. The fan end cover (103) is used in conjunction with the heat-conducting plate (105).

3. The aluminum-cased charger with good heat dissipation according to claim 2, characterized in that: The lower end cover (102) is fitted with a potting plastic box (205), and a PCB board (201) is installed in the potting plastic box (205). The PCB board (201) has a small signal output power management module (202) at the DC output end, a small signal excitation input module (203) at the AC input end, and a transformer (204).

4. The aluminum-cased charger with good heat dissipation according to claim 3, characterized in that: The PCB board (201) has a DC output terminal equipped with a control circuit for real-time feedback of the output voltage signal to the AC input terminal to achieve closed-loop constant voltage and constant current control. The transformer (204) has heat-conducting plates (206) at both the upper and lower ends.

5. The aluminum-cased charger with good heat dissipation according to claim 4, characterized in that: The PCB board (201) is encapsulated in a plastic box (205) by insulating potting compound, and the flame retardancy of both the plastic box (205) and the potting compound material meets the UL-V0 level requirements.

6. The aluminum-cased charger with good heat dissipation according to claim 5, characterized in that: The upper end cover (101), lower end cover (102), fan end cover (103), and cable outlet end cover (104) are all made of aluminum.

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