Voltage converter housing for electric vehicles

Abstract

The utility model discloses an electric car's voltage converter shell, including shell main part (1), the shell main part (1) is equipped with the installation cavity (2) for accommodating conversion circuit, still include the fin (3), the material of fin (3) is different with the material of shell main part (1), the fin (3) is installed on shell main part (1), and the shell main part (1) is provided with the opening (4) through, the fin (3) at least partial passes through opening (4) and extends into installation cavity (2) inside, is used to carry out heat exchange with the heating element on conversion circuit. The utility model not only can improve the heat dissipation performance, makes the stability of voltage converter better, and the service life is longer, and its production cost is lower, possesses stronger market competitiveness.

Description

Technical Field

[0001] This utility model relates to the field of voltage converter technology, and in particular to a voltage converter housing for a two-wheeled (three-wheeled) electric vehicle. Background Technology

[0002] An electric vehicle DC-DC voltage converter, also known as an electric vehicle voltage converter, is a device that converts the higher DC voltage of the onboard battery in a two-wheeled (or three-wheeled) electric vehicle into a 12V DC voltage. Since onboard accessories such as lights, horns, and various instruments use a standard 12V DC power supply, while the battery voltage of electric vehicles is generally higher (48V-90V), a DC-DC voltage converter is necessary to transform the higher DC voltage of the battery into a 12V DC output to meet the standard DC voltage supply requirements of these devices. Because electric vehicle voltage converters have a high output power, they generate a significant amount of heat. The longer the vehicle travels, the higher the temperature rise of the voltage converter. Without forced cooling, the voltage converter will inevitably overheat, affecting electrical performance and potentially causing the entire circuit to burn out. To reduce the temperature rise of the electric vehicle voltage converter and prevent damage to circuit components due to overheating, existing electric vehicle voltage converters employ an open-type heat dissipation structure.

[0003] For example, utility model patent application CN202222771453.7 discloses a high-efficiency heat dissipation structure for an electric vehicle converter, which includes an electric vehicle converter housing. The housing has an installation chamber containing an alignment component, and a side-mounted heat dissipation assembly corresponding to the installation chamber. The housing also has an outer reinforcing component. Currently, most electric vehicle converter housings on the market have a similar structure to that in this patent, using die-cast aluminum as the entire housing. Cooling is primarily achieved through heat conduction between the upper surface of the housing and the heating element. However, in actual use and production, it has been found that this housing has poor heat dissipation performance. Firstly, it cannot conduct heat for cooling; secondly, the thermal conductivity of the die-cast aluminum housing decreases when the temperature exceeds 90℃, leading to poor heat dissipation and a risk of short circuits. Furthermore, the die-cast aluminum structure results in high production costs, making it less competitive in mass production.

[0004] Therefore, it is necessary to improve the housing of existing voltage converters for electric vehicles to enhance the converter's heat dissipation performance while reducing its production cost. Utility Model Content

[0005] The purpose of this invention is to provide a housing for a voltage converter in an electric vehicle. This invention not only improves heat dissipation performance, making the voltage converter more stable and with a longer service life, but also has lower production costs and stronger market competitiveness.

[0006] To achieve the above objectives, this utility model provides the following technical solution: a voltage converter housing for an electric vehicle, comprising a housing body, wherein the housing body has an installation cavity for accommodating a conversion circuit, and also includes a heat sink, wherein the material of the heat sink is different from that of the housing body, the heat sink is installed on the housing body, and the housing body has a through opening, wherein the heat sink at least partially passes through the opening and extends into the installation cavity for heat exchange with the heating element on the conversion circuit.

[0007] By adopting the above technical solution, the voltage converter housing adopts a split structure, which consists of two parts: the housing body and the heat sink. The heat sink is the main heat dissipation component. The two parts are made of different materials. For example, the housing body can be made of a cheaper material, while the heat sink can be made of a material with better heat dissipation performance. This setting can better control costs. Compared with the existing technology where the entire housing is made of die-cast aluminum support, the production cost can be significantly reduced, giving it a price advantage in mass production and making it more competitive in the market.

[0008] The present invention is further configured such that the outer shell body is made of plastic material and the heat sink is made of aluminum alloy material.

[0009] By adopting the above technical solution, the main body of the casing is made of plastic, which is not only lightweight and malleable, making it easy to process different shapes, but also, most importantly, significantly reduces the processing cost. The heat sink is made of aluminum alloy, such as aluminum alloy 6060 or 6063, which can maintain stable thermal conductivity efficiency below 200℃ and has good stability. Thus, the voltage converter casing has the advantages of low cost and good heat dissipation performance.

[0010] The present invention is further configured such that the heat sink includes a contact plate and a plurality of heat dissipation fins disposed on the contact plate, the contact plate is connected to the opening of the outer shell body for contacting the heating element on the connection circuit, and the heat dissipation fins are disposed on the side of the contact plate away from the mounting cavity.

[0011] By adopting the above technical solution, firstly, setting heat dissipation fins can increase the heat dissipation area and achieve efficient heat exchange in a limited space. Secondly, the design of heat dissipation fins can disturb airflow and enhance convective heat transfer efficiency. In addition, heat dissipation fins also have the function of improving overall strength, which can effectively constrain the contact plate and prevent it from deforming due to thermal stress.

[0012] The present invention is further configured such that multiple heat dissipation fins are arranged in parallel to each other.

[0013] By adopting the above technical solutions, better airflow and cooling can be achieved, thus improving the heat dissipation effect.

[0014] The present invention is further configured such that the contact plate and the outer shell body are assembled together by ultrasonic welding, hot melt connection, glue fixation, interference fit or screw connection.

[0015] By adopting the above technical solutions, the connection between the contact plate and the main body of the shell is more diverse, which greatly improves the assembly flexibility and makes it easier to process and produce.

[0016] The present invention is further provided with a positioning structure for horizontally limiting the contact plate on the inner or outer side of the outer shell body.

[0017] By adopting the above technical solution, the installation and positioning of the contact plate are constrained by the positioning structure, which not only facilitates the initial operation of connecting the contact plate to the main body of the outer shell, but also makes the connection structure between the contact plate and the main body of the outer shell more stable.

[0018] The present invention is further configured such that the surface of the outer shell body is provided with multiple reinforcing ribs, and the lower end of the outer shell body is provided with a reinforcing flange extending along the edge contour.

[0019] By adopting the above technical solutions, the reinforcing ribs and flanges strengthen the structure of the outer shell, making it less prone to deformation.

[0020] The present invention is further provided that at least one mounting plate is provided on the side of the main body of the outer shell, and the mounting plate is provided with mounting holes for fasteners to pass through.

[0021] By adopting the above technical solution, the voltage converter housing can be easily connected to the target location using fasteners.

[0022] The present invention is further provided that the lower end surface of the mounting plate is provided with a plurality of anti-slip protrusions.

[0023] By adopting the above technical solution, the anti-slip protrusions can increase the friction between the mounting plate and the mounting position, thereby improving the stability of the voltage converter installation.

[0024] The present invention is further provided with a plurality of reinforcing ribs between the mounting plate and the outer shell body.

[0025] By adopting the above technical solution, the connection strength between the mounting plate and the main body of the casing can be improved, preventing breakage at the connection point due to external forces during use. Attached Figure Description Figure 1 A first-view structural diagram of the housing of a 6A voltage converter; Figure 2 A second-view structural diagram of the housing of a 6A voltage converter; Figure 3 An exploded view of the casing of a 6A voltage converter; Figure 4 A first-view structural diagram of the housing of an 8A voltage converter; Figure 5 A second-view structural diagram of the housing of an 8A voltage converter; Figure 6 A first-view structural diagram of the housing of a 10A voltage converter; Figure 7 This is a second-view structural diagram of the housing of a 10A voltage converter.

[0026] In the diagram: 1. Outer shell; 2. Mounting cavity; 3. Heat sink; 4. Opening; 5. Contact plate; 6. Heat sink fins; 7. Positioning structure; 8. Reinforcing rib; 9. Reinforcing flange; 10. Mounting plate; 11. Mounting hole; 12. Anti-slip protrusion; 13. Reinforcing rib. Detailed Implementation

[0027] 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 present utility model.

[0028] Example: As attached Figures 1-7 The voltage converter housing of the electric vehicle shown includes a housing body 1, within which a mounting cavity 2 for accommodating the conversion circuit is provided. It also includes a heat sink 3, made of a different material than the housing body 1. The heat sink 3 is mounted on the housing body 1, and an opening 4 is provided through the housing body 1. The heat sink 3 at least partially passes through the opening 4 and extends into the mounting cavity 2 for heat exchange with the heat-generating components on the conversion circuit. The voltage converter housing adopts a split structure, consisting of the housing body 1 and the heat sink 3. The heat sink 3 serves as the main heat dissipation component. The two components are made of different materials; for example, the housing body 1 can be made of a cheaper material, while the heat sink 3 can be made of a material with better heat dissipation performance. This design allows for better cost control. Compared to the existing technology where the entire housing is supported by die-cast aluminum, production costs are significantly reduced, giving it a price advantage in mass production and stronger market competitiveness.

[0029] In one embodiment, the housing body 1 can be made of plastic, and the heat sink 3 can be made of aluminum alloy. Making the housing body 1 of plastic is not only lightweight and malleable, facilitating the processing of different shapes, but most importantly, it significantly reduces processing costs. Making the heat sink 3 of aluminum alloy, such as aluminum alloy 6060 or 6063, maintains stable thermal conductivity below 200°C, exhibiting good stability. Therefore, the voltage converter housing combines the advantages of low cost and good heat dissipation performance.

[0030] In addition, the outer casing 1 and the heat sink 3 can also be made of other materials.

[0031] As attached Figures 1-3 As shown, the heat sink 3 includes a contact plate 5 and multiple heat dissipation fins 6 disposed on the contact plate 5. The heat dissipation fins 6 are vertically disposed on the surface of the contact plate 5. The contact plate 5 is connected to the opening 4 of the outer casing 1 for contacting the heating element on the connection circuit. Alternatively, a thermally conductive protrusion can be provided on the contact plate 5, which passes through the opening 4 and abuts against the heating element. Or, the entire contact plate 5 can be disposed at the opening 4, directly abutting against the heating element. The heat dissipation fins 6 are disposed on the side of the contact plate 5 away from the mounting cavity 2. First, the heat dissipation fins 6 increase the heat dissipation area, achieving efficient heat exchange within a limited space. Second, the design of the heat dissipation fins 6 can disturb airflow, enhancing convective heat transfer efficiency. Furthermore, the heat dissipation fins 6 also improve overall strength, effectively constraining the contact plate 5 and preventing deformation due to thermal stress.

[0032] As one implementation method, multiple heat dissipation fins 6 are arranged in parallel to each other, which can better achieve airflow and cooling, and improve the heat dissipation effect.

[0033] The contact plate 5 is assembled to the outer shell 1 via ultrasonic welding, hot-melt connection, adhesive fixing, interference fit, or screw connection. This versatility in the connection between the contact plate 5 and the outer shell 1 greatly enhances assembly flexibility and facilitates manufacturing.

[0034] As attached Figure 2 As shown, the inner or outer side of the outer shell body 1 is provided with a positioning structure 7 for horizontally limiting the contact plate 5. The positioning structure 7 can be configured as a protrusion or protrusion that abuts against the upper and lower sides or left and right sides of the contact plate 5, or a positioning groove can be directly provided on the inner or outer side of the outer shell body 1 for embedding and positioning of the edge of the contact plate 5. By constraining the installation and positioning of the contact plate 5 through the positioning structure 7, it is not only easier to connect the contact plate 5 to the outer shell body 1 in the early stage, but also to make the connection structure between the contact plate 5 and the outer shell body 1 more stable.

[0035] As attached Figure 1 As shown, the surface of the outer shell body 1 is provided with multiple reinforcing ribs 8, and the lower end of the outer shell body 1 is provided with a reinforcing flange 9 extending along the edge contour. The reinforcing ribs 8 and the reinforcing flange 9 play a role in strengthening the structure of the outer shell body 1, making its structure less prone to deformation.

[0036] As attached Figure 1 As shown, at least one mounting plate 10 is also provided on the side of the housing body 1. The mounting plate 10 has mounting holes 11 for fasteners (such as screws) to pass through. The mounting holes 11 can be designed to be circular or oblong. This design facilitates the connection of the voltage converter housing to the target location by fasteners.

[0037] As attached Figure 2 As shown, the lower end surface of the mounting plate 10 is provided with a plurality of anti-slip protrusions 12. That is, the anti-slip protrusions 12 can increase the friction between the mounting plate 10 and the mounting position, thereby improving the stability of the voltage converter installation.

[0038] As attached Figure 1 As shown, multiple reinforcing ribs 13 are provided between the mounting plate 10 and the outer shell body 1. This design can improve the connection strength between the mounting plate 10 and the outer shell body 1 and prevent the connection between the two from breaking due to external force during use.

[0039] Furthermore, the voltage converter housing provided in this embodiment takes 6A, 8A, and 10A voltage converters as examples. The structure of the 6A voltage converter housing can be referred to in the appendix. Figures 1-3 The housing structure of the 8A voltage converter can be found in the attached document. Figure 4 and attached Figure 5 The housing structure of the 10A voltage converter can be found in the attached diagram. Figure 6 and attached Figure 7 .

Claims

1. A voltage converter housing for an electric vehicle, comprising a housing body (1), wherein the housing body (1) has a mounting cavity (2) for accommodating a conversion circuit, characterized in that: It also includes a heat sink (3), the material of which is different from that of the outer shell body (1). The heat sink (3) is installed on the outer shell body (1), and an opening (4) is provided through the outer shell body (1). The heat sink (3) passes through the opening (4) at least partially and extends into the mounting cavity (2) for heat exchange with the heat-generating element on the conversion circuit.

2. The voltage converter housing for an electric vehicle according to claim 1, characterized in that: The outer shell (1) is made of plastic, and the heat sink (3) is made of aluminum alloy.

3. The voltage converter housing for an electric vehicle according to claim 1, characterized in that: The heat sink (3) includes a contact plate (5) and a plurality of heat dissipation fins (6) disposed on the contact plate (5). The contact plate (5) is connected to the opening (4) of the outer shell body (1) for contacting the heat-generating element on the connection circuit. The heat dissipation fins (6) are disposed on the side of the contact plate (5) away from the mounting cavity (2).

4. The voltage converter housing for an electric vehicle according to claim 3, characterized in that: Multiple heat dissipation fins (6) are arranged in parallel to each other.

5. The voltage converter housing for an electric vehicle according to claim 3, characterized in that: The contact plate (5) and the outer shell body (1) are assembled together by ultrasonic welding, hot melt connection, glue fixation, interference fit or screw connection.

6. The voltage converter housing for an electric vehicle according to claim 3, characterized in that: The outer shell body (1) is provided with a positioning structure (7) for horizontally limiting the contact plate (5) on its inner or outer side.

7. The voltage converter housing for an electric vehicle according to claim 1, characterized in that: The outer shell body (1) has multiple reinforcing ribs (8) on its surface, and a reinforcing flange (9) is provided at the lower end of the outer shell body (1) along the edge contour.

8. The voltage converter housing for an electric vehicle according to claim 1, characterized in that: The outer casing (1) is also provided with at least one mounting plate (10) on its side, and the mounting plate (10) is provided with mounting holes (11) for fasteners to pass through.

9. The voltage converter housing for an electric vehicle according to claim 8, characterized in that: The lower end face of the mounting plate (10) is provided with multiple anti-slip protrusions (12).

10. The voltage converter housing for an electric vehicle according to claim 8, characterized in that: Multiple reinforcing ribs (13) are provided between the mounting plate (10) and the outer shell body (1).

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