A miniaturized power brick device

Abstract

The utility model provides a kind of miniaturization power brick device, including shell, capacitor component is installed in shell interior, the capacitor structure spare of connecting capacitor component, first power module, second power module, first brazing water channel, second brazing water channel, sealing module, heat-conducting gasket and three-phase copper bar, capacitor component is connected first power module, first brazing water channel, heat-conducting gasket and three-phase copper bar in turn on the side in the direction of device width, another side of capacitor component is connected second power module and second brazing water channel in turn, sealing module is located at the end of shell, sealing module is connected with water inlet and outlet pipeline inside, water inlet and outlet pipeline are connected with first brazing water channel, second brazing water channel, sealing module includes water gap sealing surface, first sealing area and second sealing area, water gap sealing surface is with shell side surface in the same plane, first sealing area is located in capacitor structure spare interior, so that sealing module and capacitor structure spare share first sealing area, the miniaturization configuration of power brick can be realized.

Description

Technical Field

[0001] This utility model relates to the field of new energy vehicles, and in particular to a miniaturized power brick device. Background Technology

[0002] In the field of new energy vehicles, integrated power devices (power bricks) connect the vehicle battery and drive motor to achieve efficient energy conversion and precise control. The power brick structure integrates multiple components, resulting in a large size. Furthermore, high power output generates significant heat, requiring a large heat dissipation structure for efficient cooling, which contradicts the trend towards miniaturization and lightweight devices. Currently, heat dissipation structures typically employ independent, bulky cooling channels, usually with only one side of the power module for cooling, leading to low cooling efficiency and further increasing the overall space required.

[0003] Furthermore, the cooling channels require a sealed structure. Traditional sealing structures consist of a sealing ring and a sealing groove, necessitating dedicated space within the power brick to accommodate the sealing ring. This approach results in a bulky frame structure and low space utilization. Therefore, there is an urgent need for a power brick device that significantly reduces size, offers superior heat dissipation performance, and boasts higher reliability. Utility Model Content

[0004] In order to overcome the above-mentioned technical defects, the purpose of this utility model is to provide a miniaturized power brick device, which reduces the structural size of the power brick by setting the frame sealing module and changing the fixing device, thereby improving heat dissipation efficiency and ensuring reliable sealing.

[0005] This utility model discloses a miniaturized power brick device, comprising: The housing contains a capacitor assembly, a capacitor structure connecting the capacitor assembly, a first power module, a second power module, a first brazing channel, a second brazing channel, a sealing module, a thermal pad, and a three-phase copper busbar. The capacitor assembly is sequentially connected to the first power module, the first brazing channel, the thermal pad, and the three-phase copper busbar on one side of the device's width direction, and to the second power module and the second brazing channel on the other side. The sealing module is located at the end of the housing and has inlet and outlet water pipes connected inside. Both the inlet and outlet water pipes are connected to the first and second brazing channels. The sealing module includes a water inlet sealing surface, a first sealing area, and a second sealing area. The water inlet sealing surface is on the same plane as the bottom surface of the housing. The first sealing area is located inside the capacitor structure, allowing the sealing module and the capacitor structure to share the first sealing area.

[0006] Preferably, the sealing module includes a skeleton sealing ring with an elliptical cross-section, and the sprue sealing surface is located at the point where the skeleton sealing ring coincides with the bottom surface of the housing. The sprue sealing surface is divided into a first sealing surface and a second sealing surface by the major axis. The first sealing surface and the second sealing surface correspond to the cross-sections of the first sealing area and the second sealing area, respectively. The first sealing surface coincides with the tangent of the capacitor structure in the length direction.

[0007] Preferably, a first sealing gap is provided between the first brazing water channel and the first power module, and a second sealing gap is provided between the second brazing water channel and the second power module. Two skeleton sealing rings are provided, which are respectively fixed to the first sealing gap and the second sealing gap.

[0008] Preferably, the device further includes multiple screw assemblies, wherein the first power module, the first brazing channel, the second power module, and the second brazing channel are each provided with screw holes that mate with the screw assemblies. The first power module and the first brazing channel are connected to one side of the capacitor assembly via the screw assemblies, and the second power module and the second brazing channel are connected to the other side of the capacitor assembly via the screw assemblies.

[0009] Preferably, the screw assembly includes a screw and a screw post connected to the screw. The screw post is fixed between the first brazing channel and the first power module. The screw post includes a cylindrical surface 82 and a through hole disposed in the middle of the cylindrical surface 82. The length and width of the cylindrical surface 82 are both smaller than the screw head diameter of the screw.

[0010] Preferably, the screw post is disposed between multiple waterway plates of the first brazed waterway / second brazed waterway, and the screw post includes a first sidewall and a second sidewall, both of which are in contact with the surface of the waterway plate.

[0011] Preferably, the distance from the center of the through hole to the first sidewall / second sidewall is less than or equal to 2.6 mm.

[0012] Preferably, the device further includes multiple sets of mounting feet, which are connected to the bottom surface of the housing and are connected to the housing by reverse screws.

[0013] Preferably, the length of the sealing module is less than or equal to 10.6 mm.

[0014] Preferably, the length of the device is less than or equal to 219 mm.

[0015] Compared with existing technologies, the above technical solution has the following advantages: 1. By setting a skeleton sealing ring, the sealing module and the capacitor assembly share a part of the area, which shortens the length of the device. At the same time, the skeleton sealing ring does not need to add additional sealing grooves and other support structures. It can directly and tightly fit with each integrated device and be fixed in the gap between each integrated device, which further reduces the width of the device. 2. By using screw posts with reduced length and placing the mounting feet at the bottom of the capacitor assembly, the length and width dimensions of the device are reduced. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of the power brick device disclosed in the embodiments of this utility model; Figure 2 This is a bottom view of the power brick device disclosed in an embodiment of this utility model; Figure 3 This is a side view of the power brick device disclosed in an embodiment of the present utility model; Figure 4 A schematic diagram of the structure of a traditional sealed power brick; Figure 5 This is a partial view of the sealing structure disclosed in an embodiment of the present utility model; Figure 6 This is another side view of the power brick device disclosed in an embodiment of the present utility model; Figure 7 This is another structural diagram of the power brick device disclosed in this utility model embodiment; Figure 8 This is another structural diagram of a traditional sealed power brick. Figure 9 An exploded view of a traditional sealed power brick structure; Figure 10 This is a structural diagram of the device for connecting a screw and a screw post disclosed in an embodiment of the present utility model; Figure 11 This is a structural diagram of the screw removal and screw post device disclosed in an embodiment of the present utility model.

[0017] Reference numerals: 1-Capacitor assembly; 2-Capacitor structural component; 31-First power module; 32-Second power module; 41-First brazing channel; 42-Second brazing channel; 5-Sealing module; 51-Water inlet sealing surface; 511-First sealing surface; 512-Second sealing surface; 6-Thermal conductive pad; 7-Three-phase copper busbar; 81-Through hole; 82-Cylindrical surface; 83-Screw; 821-First sidewall; 822-Second sidewall; 9-Mounting foot. Detailed Implementation

[0018] The advantages of this utility model are further illustrated below with reference to the accompanying drawings and specific embodiments.

[0019] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numerals in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this disclosure. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this disclosure as detailed in the appended claims.

[0020] The terminology used in this disclosure is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. The singular forms “a,” “the,” and “the” as used in this disclosure and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein refers to and includes any and all possible combinations of one or more of the associated listed items.

[0021] It should be understood that although the terms first, second, third, etc., may be used in this disclosure to describe various information, such information should not be limited to these terms. These terms are used only to distinguish information of the same type from one another. For example, without departing from the scope of this disclosure, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Depending on the context, the word "if" as used herein may be interpreted as "when," "when," or "in response to determination."

[0022] In the description of this utility model, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0023] In the description of this utility model, unless otherwise specified and limited, it should be noted that the terms "installation", "connection" and "linking" should be interpreted broadly. For example, they can refer to mechanical or electrical connections, or internal connections between two components. They can be direct connections or indirect connections through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms according to the specific circumstances.

[0024] In the following description, the use of suffixes such as "module," "part," or "unit" to denote elements is solely for the purpose of illustrating this invention and has no specific meaning in itself. Therefore, "module" and "part" can be used interchangeably.

[0025] like Figure 1 As shown, to achieve the above objectives, one embodiment of this utility model discloses a miniaturized power brick device, comprising: The housing contains a capacitor assembly 1, a capacitor structure 2 connecting the capacitor assembly 1, a first power module 31, a second power module 32, a first brazing channel 41, a second brazing channel 42, a sealing module 5, a thermal pad 6, and a three-phase copper busbar 7. The capacitor assembly 1 is connected to the first power module 31, the first brazing channel 41, the thermal pad 6, and the three-phase copper busbar 7 in sequence on one side of the device width direction, and to the second power module 32 and the second brazing channel 42 in sequence on the other side. The sealing module 5 is located at the end of the housing in the device width direction. The sealing module 5 has inlet and outlet water pipes connected inside, and both the inlet and outlet water pipes are connected to the first brazing channel 41 and the second brazing channel 42. The sealing module 5 includes a water inlet sealing surface 51, a first sealing area, and a second sealing area. The water inlet sealing surface 51 is on the same plane as the bottom surface of the housing. The first sealing area is located inside the capacitor structure 2, so that the sealing module 5 and the capacitor structure 2 share the first sealing area.

[0026] Specifically, traditional sealing structures require the use of sealing rings, sealing grooves, and additional support structures (such as O-rings). The power brick has internal space to accommodate the sealing groove and additional support structures. Furthermore, the traditional sealing structure and capacitor assembly 1 are completely independent modules; the sealing groove and the bottom surface of the capacitor assembly are not on the same plane, and the plane containing the sealing groove is above the bottom surface of the capacitor assembly. Based on these two points, the traditional sealing structure occupies a large volume. Figure 2 , Figure 3 , Figure 5 As shown, in one embodiment of this utility model, the sprue sealing surface 51 of the sealing module 5 is lowered to the same plane as the bottom surface of the housing, that is, the sprue sealing surface 51 is consistent with the height of the housing. Based on this, a part of the sealing module 5, namely the first sealing area, uses part of the area of ​​the capacitor structure component 2, thereby shortening the length of the device. In addition, the two power modules are respectively equipped with the first brazing water channel 41 and the second brazing water channel 42, realizing dual-sided heat dissipation of the power modules, resulting in better heat dissipation effect. Among them, the capacitor structure component 2 is the outer wall of the capacitor assembly 1, has a certain thickness, and provides structural support for the capacitor assembly 1.

[0027] Furthermore, such as Figure 2As shown, the sealing module 5 includes a skeleton sealing ring with an elliptical cross-section. The sprue sealing surface 51 is located at the point where the skeleton sealing ring coincides with the bottom surface of the housing. The sprue sealing surface 51 is divided into a first sealing surface 511 and a second sealing surface 512 along its major axis. The first sealing surface 511 and the second sealing surface 512 correspond to the cross-sections of the first sealing area and the second sealing area, respectively. The first sealing surface 511 coincides with the tangent in the length direction of the capacitor structure 2, thus shortening the length of the device and enabling the sealing module 5 to be sealed using the housing. Specifically, the skeleton sealing ring is divided into a first sealing area and a second sealing area according to the major axis of its elliptical cross-section. The area of ​​the first sealing area that coincides with the bottom surface of the housing is the first sealing surface 511. Similarly, the area of ​​the second sealing area that coincides with the bottom surface of the housing is the second sealing surface 512. The first sealing area is the area of ​​the skeleton sealing ring close to the capacitor assembly 1. Since the capacitor structure 2 is connected to the capacitor assembly 1, the first sealing area can be embedded inside the capacitor structure 2, occupying the area of ​​the capacitor structure 2 itself without increasing the volume.

[0028] refer to Figure 4 Because the water channel has a sealing surface, which occupies a large space, the thickness of the capacitor assembly's outer wall increases, typically to about 10mm. (Reference) Figure 3 The first sealing area of ​​the skeleton sealing ring is shared with the capacitor structural component 2, so there is no need to ensure 8mm of space for the sealing groove and support structure, thus reducing the size to at most 3mm.

[0029] Furthermore, a first sealing gap is provided between the first brazing water channel 41 and the first power module 31, and a second sealing gap is provided between the second brazing water channel 42 and the second power module 32. Two skeleton sealing rings are provided, which are respectively fixed to the first sealing gap and the second sealing gap. Specifically, as shown... Figures 8-9 As shown, the overall width of a traditional sealing structure is typically 18.8 mm, such as... Figures 6-7 As shown, this embodiment uses a skeleton sealing ring, eliminating the sealing groove and other supporting structures, saving at least 8.8mm of width and reducing the overall width of the sealing module 5 to a maximum of 10.6mm. The skeleton sealing ring ensures precise and stable installation gaps for each integrated component, eliminating the need for additional sealing grooves and complex supporting structures on the housing or module, simplifying parts processing, and minimizing width dimensions. Simultaneously, it meets the sealing requirements of the device, connecting the first brazed water channel 41 and the second brazed water channel 42 to achieve parallel water channel connection. It should also be noted that in this embodiment, the sealing module 5 can be located at one or both ends of the housing in the width direction, with two modules at each end corresponding to the first brazed water channel 41 and the two brazed water channels.

[0030] Furthermore, such as Figure 10-11As shown, the device also includes multiple screw assemblies. The first power module 31, the first brazing channel 41, the second power module 32, and the second brazing channel 42 are all provided with screw holes that mate with the screw assemblies. The first power module 31 and the first brazing channel 41 are connected to one side of the capacitor assembly 1 via the screw assemblies, and the second power module 32 and the second brazing channel 42 are connected to the other side of the capacitor assembly 1 via the screw assemblies. Furthermore, the screw assembly includes a screw 83 and a screw post connected to the screw 83. The screw post is fixed to the first brazing channel 42. Between the brazing channel 41 and the first power module, the screw post includes a cylindrical surface 82 and a through hole 81 located in the middle of the cylindrical surface 82. The length and width of the cylindrical surface 82 are both smaller than the screw head diameter of the screw 83. The screw post is located between multiple channel plates of the first brazing channel 41 / second brazing channel 42. The screw post includes a first sidewall 821 and a second sidewall 822. Both the first sidewall 821 and the second sidewall 822 are in contact with the channel plate surface. The distance from the center of the through hole 81 to the first sidewall 821 and the second sidewall 822 is less than or equal to 2.6 mm.

[0031] Specifically, traditional screw posts typically have an outward-expanding arc in the middle, which mates with the circular head of screw 83, and protruding square sidewalls on both sides. This type of screw post occupies a relatively large space, typically 7.6mm. The screw post used in this embodiment is a reduction of the traditional screw post structure. The square sidewalls on both sides of the traditional screw post are contracted, and the length of the post surface 82 is reduced to less than the screw head diameter. The distance from the center of the through hole 81 to the first sidewall 821 / second sidewall 822 is reduced by at least 1.2mm, and the length of each screw post is reduced by at least 2.4mm. After the reduction, the screw post length is at most 5.2mm. It should be noted that this embodiment has three waterway panels, and screw assemblies are provided between adjacent waterway panel surfaces.

[0032] Furthermore, the device also includes multiple sets of mounting feet 9, which are connected to the bottom surface of the housing. The mounting feet 9 are connected to the housing via reverse screws 83. Specifically, conventionally, the mounting feet 9 are located on the side of the capacitor assembly 1. Now, the mounting feet 9 are located on the bottom surface, and the reverse screws 83 are smaller, thus reducing the length and width dimensions of the device.

[0033] Furthermore, through optimization of the installation method of the power bricks, optimization of module assembly, and optimization of waterway structure, the overall length of the device can be less than or equal to 219mm, occupying a small area and facilitating miniaturization design.

[0034] In summary, this invention solves the contradiction between volume and heat dissipation in high power density applications. By fixing the mounting feet and optimizing the screw posts, it significantly reduces the space occupied by the power brick, meets the requirements of compact equipment, and breaks through size limitations. The skeleton sealing ring achieves reliable sealing in an extremely narrow space, balancing sealing and miniaturization, and solves the problem of excessive volume in traditional sealing methods.

[0035] It should be noted that the embodiments of this utility model have better implementability and are not intended to limit this utility model in any way. Any person skilled in the art may use the above-disclosed technical content to change or modify it into equivalent effective embodiments. However, any modifications or equivalent changes and modifications made to the above embodiments based on the technical essence of this utility model without departing from the content of the technical solution of this utility model shall still fall within the scope of the technical solution of this utility model.

Claims

1. A miniaturized power brick device, characterized in that, include: The housing contains a capacitor assembly, a capacitor structure connecting the capacitor assembly, a first power module, a second power module, a first brazing channel, a second brazing channel, a sealing module, a thermal pad, and a three-phase copper busbar. The capacitor assembly is sequentially connected to the first power module, the first brazing channel, the thermal pad, and the three-phase copper busbar on one side of the device's width direction, and to the second power module and the second brazing channel on the other side. The sealing module is located at the end of the housing and has inlet and outlet water pipes connected inside. Both the inlet and outlet water pipes are connected to the first and second brazing channels. The sealing module includes a water inlet sealing surface, a first sealing area, and a second sealing area. The water inlet sealing surface is on the same plane as the bottom surface of the housing. The first sealing area is located inside the capacitor structure, allowing the sealing module and the capacitor structure to share the first sealing area.

2. The miniaturized power brick device as described in claim 1, characterized in that, The sealing module includes a skeleton sealing ring with an elliptical cross-section. The sprue sealing surface is located at the point where the skeleton sealing ring coincides with the bottom surface of the housing. The sprue sealing surface is divided into a first sealing surface and a second sealing surface by the major axis. The first sealing surface and the second sealing surface correspond to the cross-sections of the first sealing area and the second sealing area, respectively. The first sealing surface coincides with the tangent of the capacitor structure in the length direction.

3. The miniaturized power brick device as described in claim 2, characterized in that, A first sealing gap is provided between the first brazing water channel and the first power module, and a second sealing gap is provided between the second brazing water channel and the second power module. Two skeleton sealing rings are provided, which are respectively fixed to the first sealing gap and the second sealing gap.

4. The miniaturized power brick device as described in claim 1, characterized in that, The device also includes multiple screw assemblies. The first power module, the first brazing channel, the second power module, and the second brazing channel are all provided with screw holes that cooperate with the screw assemblies. The first power module and the first brazing channel are connected to one side of the capacitor assembly through the screw assemblies, and the second power module and the second brazing channel are connected to the other side of the capacitor assembly through the screw assemblies.

5. A miniaturized power brick device as described in claim 4, characterized in that, The screw assembly includes a screw and a screw post connected to the screw. The screw post is fixed between the first brazing channel and the first power module. The screw post includes a cylindrical surface and a through hole in the middle of the cylindrical surface. The length and width of the cylindrical surface are both smaller than the screw head diameter of the screw.

6. The miniaturized power brick device as described in claim 5, characterized in that, The screw post is disposed between multiple waterway plates of the first brazed waterway / second brazed waterway. The screw post includes a first sidewall and a second sidewall, both of which are in contact with the surface of the waterway plate.

7. A miniaturized power brick device as described in claim 6, characterized in that, The distance from the center of the through hole to the first sidewall / second sidewall is less than or equal to 2.6 mm.

8. A miniaturized power brick device as described in claim 1, characterized in that, The device also includes multiple sets of mounting feet, which are connected to the bottom surface of the housing and are connected to the housing by reverse screws.

9. A miniaturized power brick device as described in claim 1, characterized in that, The length of the sealing module is less than or equal to 10.6 mm.

10. A miniaturized power brick device as described in claim 1, characterized in that, The length of the device is less than or equal to 219 mm.

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