Liquid-cooled power module and liquid-cooled current transformer

Abstract

The utility model discloses a liquid cooling power module and liquid cooling transformer, liquid cooling power module includes power pipe module, power inductance module and liquid cooling board, and power pipe module includes a plurality of power pipe unit along the Y axle direction arrangement, and its size in Y axle direction is greater than the size in X axle direction, power inductance module and power pipe module along X axle direction arrangement, the cooling liquid flow channel of liquid cooling board includes with the liquid inlet port intercommunication liquid inlet flow channel, with the liquid outlet port intercommunication liquid outlet flow channel and the liquid distribution flow channel of intercommunication liquid inlet flow channel and liquid outlet flow channel, liquid inlet flow channel and liquid outlet flow channel are respectively located in the two sides of liquid distribution flow channel along Y axle direction, and liquid distribution flow channel is equipped with a plurality of liquid distribution branch flow channel corresponding with power pipe unit, and liquid outlet flow channel corresponds with power inductance module, and liquid cooling transformer includes above -mentioned liquid cooling power module, and this application can reduce vibration isolation and improve differentiating heat dissipation under the premise of realizing module compact.

Description

Technical Field

[0001] This utility model relates to the field of electrical heat dissipation, specifically to a liquid-cooled power module and a liquid-cooled converter. Background Technology

[0002] In existing liquid cooling designs for power modules, high-power inductor modules and power transistor modules are typically integrated on the same liquid cooling plate. Both inductor and transistor modules are large components, and their layout directly determines the size of the liquid cooling plate and the entire module. Existing layout strategies often prioritize ease of wiring or structural symmetry, failing to optimally utilize space and resulting in excessively large liquid cooling plate dimensions in one or more dimensions, hindering device miniaturization. High-frequency inductors, such as power inductors, generate significant mechanical vibrations during operation. If the inductor is installed too close to the vibration-sensitive power transistor (whose internal chip is connected to the substrate via solder), the inductor's vibrations will be directly transmitted to the power transistor through the liquid cooling plate, easily causing fatal damage such as solder joint fatigue fracture and interface delamination, seriously threatening the long-term reliability of the product. Furthermore, power inductors and power transistor modules have drastically different heat dissipation characteristics. Power inductors generate a large amount of heat but can operate at higher temperatures, while power transistor modules generate relatively less heat but are extremely sensitive to temperature. Achieving an optimal balance through simple flow channel design in existing layouts is also a major challenge. Utility Model Content

[0003] The purpose of this utility model is to overcome the above-mentioned defects or problems in the background art and provide a liquid-cooled power module and a liquid-cooled converter, which can reduce vibration isolation and improve differentiated heat dissipation while achieving module compactness.

[0004] To achieve the above objectives, the present invention and its preferred embodiments adopt the following technical solutions, but the embodiments are not limited to the following solutions:

[0005] Technical Solution 1 and its preferred embodiments relate to a liquid-cooled power module, including a power transistor module comprising a plurality of power transistor units arranged along the Y-axis, the Y-axis dimension being larger than the X-axis dimension; a power inductor module arranged along the X-axis with the power transistor module; and a liquid cooling plate for supporting the power transistor module and the power inductor module and for dissipating heat from them, the plate having an inlet port and an outlet port, a coolant flow channel forming between the inlet port and the outlet port, the coolant flow channel including an inlet flow channel communicating with the inlet port, an outlet flow channel communicating with the outlet port, and a distribution flow channel connecting the inlet flow channel and the outlet flow channel; the inlet flow channel and the outlet flow channel are respectively located on both sides of the distribution flow channel along the Y-axis; the distribution flow channel has a plurality of distribution branches corresponding to the power transistor units, and the outlet flow channel corresponds to the power inductor module.

[0006] Based on technical solution one, there is also technical solution two. In technical solution two and its preferred embodiments, the liquid outlet channel extends along the Y-axis direction; the liquid distribution channel further includes a return channel connecting each liquid distribution branch channel and the liquid outlet channel. The return channel includes a return section extending along the Y-axis direction and several first return branches extending along the X-axis direction arranged along the Y-axis direction; each first return branch is connected in parallel between the return section and the liquid outlet channel; the return section connects each liquid distribution branch channel.

[0007] Based on technical solution two, technical solution three is also provided. In technical solution three and its preferred embodiments, the liquid distribution branch extends along the X-axis direction; the liquid return channel further includes several second liquid return branches extending along the Y-axis direction and spaced apart along the Y-axis direction, and third liquid return branches corresponding to the second liquid return branches and spaced apart along the Y-axis direction and extending along the X-axis direction; the second liquid return branches connect to the outlet ends of at least two adjacent liquid distribution branches; the two ends of each third liquid return branch are respectively connected to the corresponding second liquid return branch and the liquid return section.

[0008] Based on technical solution three, technical solution four is also provided. In technical solution four and its preferred embodiments, each power tube unit is provided with N liquid distribution branches, where N is an even number; the number of second liquid return branches is equal to the number of power tube units, and each second liquid return branch is provided in a one-to-one correspondence with each power tube unit and is respectively connected to the liquid outlet end of the liquid distribution branch corresponding to the power tube unit; the number of third liquid return branches is half of N, and each third liquid return branch is respectively connected to the middle of two adjacent liquid distribution branches and the second liquid return branch.

[0009] Based on technical solution three, there is also technical solution five. In technical solution five and its preferred embodiments, the projections of each third return liquid branch and each first return liquid branch on the projection plane perpendicular to the X-axis are staggered.

[0010] Based on any one of technical solutions two to five, a technical solution six is ​​also provided. In technical solution six and its preferred embodiments, the liquid outlet channel is provided with a number of first liquid outlet branches extending along the X-axis direction at intervals along the Y-axis direction, which are equal in number and correspond one-to-one with the number of first liquid return branches, and a number of second liquid outlet branches extending along the Y-axis direction at intervals along the X-axis direction. The first liquid outlet channels and the second liquid outlet branches are staggered. The first liquid outlet branches are connected to the first liquid return branches one-to-one.

[0011] Based on technical solution four, technical solution seven is also provided. In technical solution seven and its preferred embodiments, the inlet channel extends along the Y-axis direction; the distribution channel further includes a supply channel connecting each distribution branch channel and the inlet channel. The supply channel includes N first supply branches spaced apart along the Y-axis direction and extending along the Y-axis direction, and second supply branches corresponding to the first supply branches and extending along the X-axis direction. Each first supply branch corresponds to each power tube unit and is connected to the inlet end of the corresponding distribution branch channel of the corresponding power tube unit. The two ends of each second supply branch are connected to the corresponding first supply branch and the inlet channel. The number of second supply branches is half of N, and each second supply branch corresponds to the middle of two adjacent distribution branches and is connected to the first supply branch.

[0012] Based on technical solution seven, there is also technical solution eight. In technical solution eight and its preferred embodiments, the projections of the second liquid supply branch and the third liquid return branch on the projection plane perpendicular to the X-axis direction at least partially overlap.

[0013] Based on technical solution seven, there are also technical solutions nine, ten and their preferred embodiments, in which the liquid inlet port is located on the first side of the liquid cooling plate along the Y-axis direction; the liquid flow area of ​​the second liquid supply branch corresponding to the power tube unit that is further away from the liquid inlet port along the Y-axis direction is larger.

[0014] Technical solution ten relates to a liquid-cooled converter, including a housing and a liquid-cooled power module as described in any one of technical solutions one to nine, wherein the housing forms a cavity separately or in combination with a liquid cooling plate to form a cavity; when the housing forms a cavity separately, the liquid-cooled power module is placed in the cavity; when the housing and the liquid cooling plate form a cavity, both the power transistor module and the power inductor module are placed in the cavity.

[0015] As can be seen from the above description of the present invention and its preferred embodiments, compared with the prior art, the technical solution of the present invention and its preferred embodiments have the following beneficial effects due to the adoption of the following technical means:

[0016] The applicant discovered through research that the main reason for the technical problem in the existing technology of "difficulty in comprehensively solving vibration isolation and differentiated heat dissipation under the premise of achieving module compactness" is that the power inductor module and the power transistor module are usually arranged side by side along the length of the liquid cooling plate. Since both the power inductor module and the power transistor module require a large space in the Y-axis direction, the overall length of the liquid cooling plate in the Y-axis direction is relatively long, increasing the module volume and hindering the miniaturization and compact design of the equipment. To avoid excessive length of the liquid cooling plate, the power inductor module and the power transistor module are arranged in a compact layout, resulting in a small spacing between the power inductor and power transistor modules, and thus, the power inductor generates... Vibrations can be directly transmitted to power transistors that are sensitive to mechanical stress, easily leading to fatigue cracking of the power transistor solder joints and connection failure, severely affecting product reliability and service life. Furthermore, due to the relatively long length of the liquid cooling plate, existing layouts typically place the flow channel area corresponding to the power transistor module upstream of the flow channel area of ​​the power inductor module to facilitate heat dissipation for the temperature-sensitive power transistors. The coolant flow channel of the liquid cooling plate forms a serpentine path to dissipate heat from both the power transistor and power inductor modules. As the coolant flows through the liquid cooling plate, its temperature gradually increases. This temperature gradient results in the coolant temperature in contact with the power transistors downstream of the flow channel being significantly higher than that upstream, creating uneven heat dissipation. Differences in the operating temperature of power transistors at different locations can lead to inconsistent module performance, thereby affecting the overall reliability of the system.

[0017] In technical solution one and its preferred embodiment, by arranging several power transistor units of the power transistor module along the Y-axis and making its size along the Y-axis larger than its size in the X-axis, the power transistor module occupies less space in the X-axis, thus creating conditions for arranging the power inductor module alongside it in the X-axis. The arrangement of the power inductor module and the power transistor module along the X-axis changes the traditional practice of arranging two large modules side by side along the Y-axis, which results in an excessively long Y-axis dimension of the liquid cooling plate. It makes full use of the space of the liquid cooling plate in the X-axis direction and shortens the overall length of the liquid cooling plate in the Y-axis direction, thereby reducing the volume of the liquid cooling plate and the entire power module while ensuring functional integrity. Furthermore, the layout along the X-axis avoids the disadvantage of sacrificing lateral spacing in the traditional Y-axis parallel layout to reduce the length of the liquid cooling plate. This provides a key layout basis for actively setting a safe distance that meets vibration isolation requirements in the X-axis direction, increasing the vibration transmission path. The mechanical vibration generated when the power inductor is working will be significantly attenuated due to the increased distance when it is transmitted to the vibration-sensitive power transistor through the liquid cooling plate. This reduces the risk of failure such as fatigue fracture of the solder joints and interface delamination inside the power transistor, thereby improving the long-term operational reliability and service life of the power module. After the coolant enters the lowest-temperature inlet channel through the inlet port, it is distributed in parallel and simultaneously to each power transistor unit through several branch channels. This parallel cooling method ensures that all power transistor units can contact the low-temperature coolant at a basically uniform temperature, avoiding the problem of poor heat dissipation of downstream power transistor units caused by temperature rise in traditional serpentine serial channels. This ensures balanced heat dissipation and consistent performance of each power transistor unit. The outlet channel is set to correspond to the power inductor module. The coolant, whose temperature rises after flowing through the power transistor module, flows back to the outlet channel to dissipate heat for the power inductor module, which is not sensitive to temperature but generates a lot of heat. This design not only makes efficient use of the cooling capacity of the coolant, but also naturally achieves differentiated temperature management for the two types of components through a simple channel structure, thus optimizing the overall heat dissipation efficiency.

[0018] In Technical Solution 2 and its preferred embodiments, the inclusion of a return flow channel increases the X-axis distance between the coolant return area of ​​the power transistor module and the power inductor module, thereby further lengthening the vibration transmission path and reducing the risk of mechanical vibration transmission to the sensitive power transistor, adding another layer of protection for the long-term reliability of the product. Furthermore, the parallel design of the return flow channel (each first return branch is connected in parallel between the return section and the outlet flow channel) provides more flow branches compared to a single return flow channel. This effectively reduces the overall flow resistance during coolant return, allowing the coolant to quickly and evenly converge into the outlet flow channel after dissipating heat from the power transistor module through multiple parallel first return branches. This avoids high-temperature coolant stagnation or crossflow in the power transistor module area, ensuring the stability and consistency of the power transistor module's heat dissipation effect and laying a good foundation for subsequent uniform heat dissipation of the power inductor module.

[0019] In technical solution three and its preferred embodiments, the setting of the second and third liquid return branches further increases the distance between the liquid distribution branch channel and the liquid outlet channel in the X-axis direction, thereby further lengthening the vibration transmission path, reducing the risk of mechanical vibration being transmitted to the sensitive power tube, and adding another layer of protection for the long-term reliability of the product. Furthermore, the distribution branch channel extending along the X-axis, the second return branch channel extending along the Y-axis, the third return branch channel extending along the X-axis, and the return section extending along the Y-axis together constitute multiple closed and interconnected grid units. The fully connected gridded return network makes the path selection of coolant return extremely flexible, forming a highly redundant parallel flow path system. This structure ensures a high degree of self-balance of return fluid pressure, and local changes in flow resistance can be quickly distributed throughout the entire network. This ensures that the heated coolant flowing out from each distribution branch channel can smoothly and evenly flow into the return section and finally flow to the outlet channel. This avoids the risk of poor return flow, local eddies, and heat accumulation (local hot spots) caused by a single or excessively long flow path. From a fluid perspective, this improves the consistency and stability of the heat dissipation environment of the power tube unit.

[0020] In technical solution four and its preferred embodiments, each power transistor unit is provided with N distribution channels, where N is an even number; the number of second return channels is equal to the number of power transistor units, distributing the cooling task of one power transistor unit to N parallel distribution channels, which significantly increases the total number of flow channels in its heat dissipation area. This parallel design reduces the local flow resistance of the coolant when it flows through each power transistor unit, ensures sufficient coolant flow, and can more precisely control the temperature distribution at the bottom of the unit. The number of third return channels is half of N, and each third return channel corresponds to the middle of two adjacent distribution channels and is connected to the second return channel. Compared with connecting at the end, this is more conducive to ensuring that the shortest path length of each distribution channel is equal when the outlet end reaches the outlet channel, thereby helping to improve the flow uniformity of each distribution channel and thus improving the temperature uniformity of the power transistor module.

[0021] In technical solution five and its preferred embodiments, the projections of each third return liquid branch and each first return liquid branch on the projection plane perpendicular to the X-axis are staggered, which is more conducive to the coolant in the third return liquid branch mixing in the return liquid section first, and then flowing to each first return liquid branch. This helps to ensure that the coolant from each third return liquid branch through the return liquid section to the first return liquid branch forms a more uniform flow path, further improving the uniformity of the flow rate of each liquid distribution branch.

[0022] In technical solution six and its preferred embodiments, the outlet flow channel is designed as a grid structure including a first outlet branch channel and a second outlet branch channel. The grid design greatly increases the inlet area of ​​the coolant entering the outlet flow channel and provides a large number of parallel low flow resistance paths. This helps to quickly absorb the liquid flow from multiple first return branches and avoids local congestion and pressure concentration at the inlet that may occur in a traditional single outlet flow channel. It ensures that the pressure distribution along the entire length of the outlet flow channel is more balanced. The pressure-balanced outlet flow channel can ensure that the heated coolant flows more evenly across the entire bottom contact surface of the power inductor module, thereby improving the uniformity of its heat dissipation.

[0023] In technical solution seven and its preferred embodiments, compared to the solution where the inlet ends of each liquid distribution branch are directly connected in parallel to the liquid inlet channel, in the direct parallel connection solution, the liquid distribution branch closer to the liquid inlet channel has a shorter flow path and lower flow resistance, which will "steal" most of the flow; while the flow in the distant channel is insufficient, resulting in uneven cooling. The setting of the liquid supply channel is equivalent to adding a "buffer zone and balancer" between the liquid inlet channel and each liquid distribution branch. By adjusting the length and cross-sectional area of ​​these first liquid supply branches and second liquid supply branches, the flow resistance of each liquid distribution branch can be actively matched and balanced, thereby suppressing the phenomenon of uneven flow distribution. In addition, the above setting is also conducive to the liquid inlet channel dissipating heat from other electrical components. The number of second liquid supply branches is half of N. Each second liquid supply branch corresponds to the middle of two adjacent liquid distribution branches and is connected to the first liquid supply branch. Compared with connecting at the end, it is more conducive to making the shortest path length from the liquid inlet end of the liquid distribution branch to the liquid inlet channel equal, thereby helping to improve the flow uniformity of each liquid distribution branch and thus improve the temperature uniformity of the power tube module.

[0024] In technical solution eight and its preferred embodiments, the projections of the second liquid supply branch and the third liquid return branch on the projection plane perpendicular to the X-axis direction at least partially overlap, which helps to simplify the processing steps and makes the path length from the liquid inlet channel through the liquid distribution branch channel to the liquid outlet channel similar, thereby improving the uniformity of the flow rate of each liquid distribution branch channel.

[0025] In technical solution nine and its preferred embodiments, the liquid flow area of ​​the second liquid supply branch corresponding to the power tube unit further away from the liquid inlet port along the Y-axis is larger. This ensures that the second liquid supply branch corresponding to the power tube unit far from the liquid inlet port and the second liquid supply branch corresponding to the power tube unit close to the liquid inlet port have similar flow rates, which is more conducive to maintaining the flow uniformity of each liquid distribution branch channel and thus improving the temperature uniformity of the power tube module.

[0026] Technical solution ten and its preferred embodiments have the technical advantages of any one of technical solutions one to nine. When the liquid cooling plate and the shell cooperate to form an accommodating cavity, it means that the liquid cooling plate has a thicker thickness, which is more conducive to processing fine and deep flow channels corresponding to the power tube unit on the liquid cooling plate, thereby making it more conducive to heat dissipation of the power tube unit and improving heat dissipation efficiency. Attached Figure Description

[0027] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0028] Figure 1 This is an overall schematic diagram of the heat dissipation structure according to an embodiment of the present utility model;

[0029] Figure 2 for Figure 1 Top view;

[0030] Figure 3 This is a schematic diagram of the coolant flow channel of the liquid cooling plate in an embodiment of this utility model;

[0031] Figure 4 This is a top view of the liquid cooling plate in an embodiment of the present invention.

[0032] Explanation of key figure labels:

[0033] Power transistor module 10; power transistor unit 11; converter tube 111; power inductor module 20; liquid cooling plate 30; liquid inlet port 31; liquid outlet port 32; liquid inlet channel 33; liquid outlet channel 34; first liquid outlet branch channel 341; second liquid outlet branch channel 342; liquid distribution channel 35; liquid distribution branch channel 351; liquid supply channel 352; first liquid supply branch 3521; second liquid supply branch 3522; liquid return channel 353; liquid return section 3531; first liquid return branch 3532; second liquid return branch 3533; third liquid return branch 3534; first auxiliary channel 36; second auxiliary channel 37; first heat exchange section 41; second heat exchange section 42; third heat exchange section 43; first cooling fan 51; second cooling fan 52; third cooling fan 53. Detailed Implementation

[0034] 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 preferred embodiments of the present utility model and should not be considered as excluding other embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the scope of protection of the present utility model.

[0035] Unless otherwise expressly defined, the use of terms such as "first," "second," or "third" in the claims, description, and drawings of this utility model is for distinguishing different objects and not for describing a specific order.

[0036] Unless otherwise expressly defined, in the claims, description, and accompanying drawings of this utility model, the use of directional terms such as "center," "lateral," "longitudinal," "horizontal," "vertical," "top," "bottom," "inner," "outer," "upper," "lower," "front," "rear," "left," "right," "clockwise," and "counterclockwise" to indicate orientation or positional relationships is based on the orientation and positional relationships shown in the accompanying drawings and is only for the convenience of describing this utility model and simplifying the description. It does 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 limiting the specific protection scope of this utility model.

[0037] Unless otherwise expressly defined, the terms "fixed connection" or "fixed connection" used in the claims, description and drawings of this utility model shall be interpreted broadly to refer to any connection in which there is no displacement or relative rotation relationship between the two parties, including non-removable fixed connection, detachable fixed connection, integral connection and fixed connection through other devices or components.

[0038] In the claims, description and accompanying drawings of this utility model, the terms "comprising", "having", and variations thereof are used to mean "including but not limited to".

[0039] In the claims and the description other than the embodiments, the terms "Y-axis direction," "Y-axis direction," and "Z-axis direction" only refer to a feature having one of the aforementioned directions being perpendicular to a feature having another direction, and do not require that they be implemented according to the "Y-axis direction," "Y-axis direction," and "Z-axis direction" described in the embodiments. In the embodiments, the Y-axis direction is perpendicular to both the Y-axis direction and the Z-axis direction. The X-axis direction can be divided into left and right, the Y-axis direction into front and back, and the Z-axis direction into up and down.

[0040] See Figure 1 , Figure 1A liquid-cooled power module is shown, including a power transistor module 10, a power inductor module 20, a liquid cooling plate 30, at least one heat exchange section, and at least one cooling fan.

[0041] See Figure 2 The power transistor module 10 includes a plurality of power transistor units 11 arranged along the Y-axis, the size of which in the Y-axis direction is larger than its size in the X-axis direction. Exemplarily, each power transistor unit 11 includes multiple converter components 111 arranged along the X-axis. The converter components 111 are formed of semiconductor power devices. The types of converter components 111 include high-loss components and low-loss components. Exemplarily, a high-loss component includes an IGBT switching chip as a controllable switch and a diode chip as a freewheeling device, while a low-loss component includes only a diode chip as a freewheeling device. Multiple converter components 111 can be cooperated to form an IGBT module.

[0042] The power inductor module 20 and the power transistor module 10 are arranged along the X-axis. The power inductor module 20 may include multiple power inductors, which are high-frequency inductors used in power conversion circuits.

[0043] See Figure 2 The liquid cooling plate 30 is used to support the power transistor module 10 and the power inductor module 20 and to dissipate heat from them. It has a liquid inlet port 31 and a liquid outlet port 32, which are located on the first side of the liquid cooling plate 30 along the Y-axis and arranged along the X-axis. (See also...) Figure 3A coolant flow channel is formed between the inlet port 31 and the outlet port 32. The coolant flow channel includes an inlet flow channel 33 communicating with the inlet port 31, an outlet flow channel 34 communicating with the outlet port 32, and a distribution flow channel 35 connecting the inlet flow channel 33 and the outlet flow channel 34. The inlet flow channel 33 and the outlet flow channel 34 are respectively located on both sides of the distribution flow channel 35 along the Y-axis direction. The distribution flow channel 35 is provided with a plurality of distribution branch channels 351 corresponding to the power tube unit 11. The outlet flow channel 34 corresponds to the power inductor module 20. The inlet flow channel 33 extends along the Y-axis, the branch flow channel 351 extends along the X-axis, and the outlet flow channel 34 extends along the Y-axis. The inlet flow channel 33 contains multiple flow dividers extending along the Y-axis. These flow dividers combine to form several flow divider groups spaced apart along the Y-axis. Each flow divider group includes several flow dividers spaced apart along the X-axis. These flow dividers optimize the coolant flow path. In practical applications, multiple flow dividers spaced apart along the X-axis and extending along the X-axis can be installed in the branch flow channel 351 to further optimize the coolant flow path. The coolant flow channel also includes a first auxiliary flow channel 36 and a second auxiliary flow channel 37 connected in parallel between the inlet flow channel 33 and the outlet flow channel 34. The first auxiliary flow channel 36 and the second auxiliary flow channel 37 are located on both sides of the distribution flow channel 35 along the Y-axis direction, wherein the first auxiliary flow channel 36 is located on the front side of each distribution flow channel 35 along the Y-axis direction. In this embodiment, each power tube unit 11 is provided with N distribution branch channels 351, where N is an even number. In this embodiment, N is 4, but it should be understood that N can also be other values.

[0044] See also Figure 3 The liquid distribution channel 35 also includes a liquid supply channel 352 connecting each liquid distribution branch channel 351 and the liquid inlet channel 33. The liquid supply channel 352 includes N first liquid supply branches 3521 spaced apart along the Y-axis and extending along the Y-axis, and second liquid supply branches 3522 corresponding to the first liquid supply branches 3521 and extending along the X-axis. Each first liquid supply branch 3521 corresponds one-to-one with each power tube unit 11 and is connected to the liquid inlet end of the corresponding liquid distribution branch channel 351 of the corresponding power tube unit 11. The two ends of each second liquid supply branch 3522 are connected to the corresponding first liquid supply branch 3521 and the liquid inlet channel 33, respectively. The number of second liquid supply branches 3522 is half of N, and each second liquid supply branch 3522 corresponds to the middle of two adjacent liquid distribution branches 351 and is connected to the first liquid supply branch 3521. In this embodiment, the liquid flow area of ​​the second liquid supply branch 3522 corresponding to the power tube unit 11 that is further away from the liquid inlet port 31 along the Y-axis is larger.

[0045] The liquid distribution channel 35 also includes a return channel 353 connecting each liquid distribution branch channel 351 and the outlet channel 34. The return channel 353 includes a return section 3531 extending along the Y-axis and several first return branches 3532 extending along the X-axis and arranged along the Y-axis. Each first return branch 3532 is connected in parallel between the return section 3531 and the outlet channel 34. The return section 3531 connects each liquid distribution branch channel 351. In this embodiment, the return section 3531 is connected through a second return branch 3533 and a third return branch 3534. The return flow channel 353 further includes several second return flow branches 3533 extending along the Y-axis and spaced apart along the Y-axis, and third return flow branches 3534 corresponding to the second return flow branches 3533 and spaced apart along the Y-axis and extending along the X-axis. The second return flow branches 3533 are connected to the outlet ends of at least two adjacent distribution channels 351. The two ends of each third return flow branch 3534 are respectively connected to the corresponding second return flow branch 3533 and return flow branch 3531.

[0046] In this embodiment, the number of second return liquid branches 3533 is equal to the number of power tube units 11, and the number of third return liquid branches 3534 is half of N. Each second return liquid branch 3533 is correspondingly arranged with each power tube unit 11 and is connected to the outlet end of the corresponding liquid distribution channel 351 of the power tube unit 11. Each third return liquid branch 3534 is connected to the middle of two adjacent liquid distribution channels 351. The projections of each third return liquid branch 3534 and each first return liquid branch 3532 on the projection plane perpendicular to the X-axis direction are staggered.

[0047] In this embodiment, the projections of the second liquid supply section 3522 and the third liquid return section 3534 on the projection plane perpendicular to the X-axis direction at least partially overlap.

[0048] The liquid outlet channel 34 is provided with a first liquid outlet branch channel 341 extending along the X-axis direction at intervals along the Y-axis direction, which is equal in number to and corresponds one-to-one with the first liquid return branch section 3532, and a number of second liquid outlet branch channels 342 extending along the Y-axis direction at intervals along the X-axis direction. The first liquid outlet channel 34 and the second liquid outlet branch channel 342 are staggered. The first liquid outlet branch channel 341 is connected to the first liquid return branch section 3532 in a one-to-one correspondence.

[0049] See Figure 4 The liquid cooling plate 30 is provided with connection points A1 and A2 that connect to the liquid cooling pipes of the first heat exchange section 41 (hereinafter referred to as the first heat exchange section 41), connection points B1 and B2 that connect to the liquid cooling pipes of the second heat exchange section 42 (hereinafter referred to as the second heat exchange section 42), and connection points C1 and C2 that connect to the liquid cooling pipes of the third heat exchange section 43 (hereinafter referred to as the third heat exchange section 43).

[0050] See Figure 1-2 The heat exchange section protrudes from the liquid cooling plate 30 along the Z-axis and is connected in series or parallel with the cooling liquid flow channel of the liquid cooling plate 30. In this embodiment, each heat exchange section is in the form of an air-liquid heat exchanger, and the number of heat exchange sections is at least three, namely the first heat exchange section 41, the second heat exchange section 42, and the third heat exchange section 43. The liquid cooling pipe of the first heat exchange section 41 is connected in parallel or in series with the liquid inlet flow channel 33; the liquid cooling pipe of the second heat exchange section 42 is connected in series or in parallel with the first auxiliary flow channel 36; and the liquid cooling pipe of the third heat exchange section 43 is connected in series or in parallel with the second auxiliary flow channel 37. In a preferred embodiment, the first heat exchange section 41 and the second heat exchange section 42 are both connected in parallel with the coolant flow channel of the liquid cooling plate 30, and the third heat exchange section 43 is connected in series with the coolant flow channel of the liquid cooling plate 30. The number of first heat exchange sections 41 is at least two, and each first heat exchange section 41 is spaced apart along the Y-axis and communicates with the middle portion of the inlet flow channel 33 along the Y-axis and the portion away from the inlet port 31. The second heat exchange section 42 and the third heat exchange section 43 are both located near the second side of the liquid cooling plate 30 along the Y-axis.

[0051] See also Figure 1-2 The cooling fans are used to drive airflow through the heat exchange section for heat exchange. In this embodiment, the number of cooling fans is at least three, and each cooling fan includes at least three cooling fans 51, 52, and 53 respectively located near the first heat exchange section 41, the second heat exchange section 42, and the third heat exchange section 43. The first heat exchange section 41 is provided with a first air passage along the X-axis direction; the second heat exchange section 42 is provided with a second air passage along the first direction; and the third heat exchange section 43 is provided with a second air passage along the second direction. Both the first and second directions are inclined relative to the X-axis direction. The first cooling fan 51 passes through the air along the X-axis direction and its outlet side faces the first heat exchange section 41; the second cooling fan 52 passes through the air along the first direction and its outlet side faces the second heat exchange section 42; and the third cooling fan 53 passes through the air along the second direction and its outlet side faces the third heat exchange section 43.

[0052] In this embodiment, by arranging several power transistor units 11 of the power transistor module 10 along the Y-axis and making its size along the Y-axis larger than its size in the X-axis, the power transistor module 10 occupies less space in the X-axis, thus creating conditions for arranging the power inductor module 20 alongside it in the X-axis. The power inductor module 20 and the power transistor module 10 are arranged side by side along the X-axis. This layout changes the traditional practice of arranging two large modules side by side along the Y-axis, which results in an excessively long Y-axis dimension of the liquid cooling plate. It makes full use of the space of the liquid cooling plate 30 in the X-axis direction and shortens the overall length of the liquid cooling plate 30 in the Y-axis direction, thereby reducing the volume of the liquid cooling plate 30 and the entire power module while ensuring functional integrity. Furthermore, the layout along the X-axis avoids the disadvantage of sacrificing lateral spacing in the traditional Y-axis parallel layout to reduce the length of the liquid cooling plate 30. This provides a key layout basis for actively setting a safe distance that meets vibration isolation requirements in the X-axis direction, increasing the vibration transmission path. The mechanical vibration generated when the power inductor is working will be significantly attenuated due to the increased distance when it is transmitted to the vibration-sensitive power transistor through the liquid cooling plate 30. This reduces the risk of failure such as fatigue fracture of the solder joints inside the power transistor and interface delamination, thereby improving the long-term operational reliability and service life of the power module. After the coolant enters the lowest-temperature inlet channel 33 through the inlet port 31, it is distributed in parallel and simultaneously to each power transistor unit 11 through several branch channels 351. This parallel cooling method ensures that all power transistor units 11 can come into contact with low-temperature coolant at a basically uniform temperature, avoiding the problem of poor heat dissipation of downstream power transistor units 11 caused by temperature rise in traditional serpentine serial channels. This ensures balanced heat dissipation and consistent performance of each power transistor unit 11. The outlet channel 34 is set to correspond to the power inductor module 20. The coolant that has increased in temperature after flowing through the power transistor module 10 flows back to the outlet channel 34 to dissipate heat for the power inductor module 20, which is not sensitive to temperature but generates a lot of heat. This design not only makes efficient use of the cooling capacity of the coolant, but also naturally achieves differentiated temperature management for the two types of components through a simple channel structure, thus optimizing the overall heat dissipation efficiency.

[0053] In this embodiment, the arrangement of the return flow channel 353 increases the X-direction distance between the coolant return area of ​​the power transistor module 10 and the power inductor module 20, thereby further lengthening the vibration transmission path and reducing the risk of mechanical vibration being transmitted to the sensitive power transistor, adding another layer of protection for the long-term reliability of the product. Furthermore, the parallel design of the return flow channel 353 (each first return branch 3532 is connected in parallel between the return section 3531 and the outlet flow channel 34) provides more flow branches compared to a single return flow channel, effectively reducing the overall flow resistance during the coolant return process. This allows the coolant, after dissipating heat for the power transistor module 10, to quickly and evenly flow into the outlet flow channel 34 through multiple parallel first return branches 3532, preventing high-temperature coolant from stagnating or flowing across the power transistor module 10 area. This ensures the stability and consistency of the heat dissipation effect of the power transistor module 10 and lays a good foundation for the subsequent uniform heat dissipation of the power inductor module 20.

[0054] In this embodiment, the arrangement of the second return liquid branch 3533 and the third return liquid branch 3534 further increases the distance between the liquid distribution branch channel 351 and the liquid outlet channel 34 in the X-axis direction, thereby further lengthening the vibration transmission path, reducing the risk of mechanical vibration being transmitted to the sensitive power tube, and adding another layer of protection for the long-term reliability of the product. Furthermore, the liquid distribution branch channel 351 extending along the X-axis, the second return liquid branch 3533 extending along the Y-axis, the third return liquid branch 3534 extending along the X-axis, and the return liquid section 3531 extending along the Y-axis together constitute a series of closed and interconnected grid units. The fully connected gridded return network makes the path selection of coolant return highly flexible, forming a highly redundant parallel flow path system. This structure ensures a high degree of self-balancing of return liquid pressure, and local flow resistance changes can be quickly distributed to the entire network, thereby ensuring that the heated coolant flowing out from each liquid distribution branch channel 351 can smoothly and evenly flow into the return liquid section 3531 and finally flow to the outlet channel 34. This avoids the risk of poor return flow, local eddies, and heat accumulation (local hot spots) caused by a single or excessively long flow path, thereby improving the consistency and stability of the heat dissipation environment of the power tube unit 11 from a fluid perspective.

[0055] In this embodiment, each power tube unit 11 is provided with N distribution channels 351, where N is an even number. The number of second return channels 3533 is equal to the number of power tube units 11. The cooling task of one power tube unit 11 is distributed to N parallel distribution channels, which greatly increases the total number of flow channels in its heat dissipation area. This parallel design reduces the local flow resistance when the coolant flows through each power tube unit 11, ensures sufficient coolant flow, and can more precisely control the temperature distribution at the bottom of the unit. The number of third return channels 3534 is half of N. Each third return channel 3534 corresponds to the middle of two adjacent distribution channels 351 and is connected to the second return channel. Compared with connecting at the end, it is more conducive to ensuring that the shortest path length when the liquid outlet of each distribution channel 351 reaches the liquid outlet channel 34 is equal, thereby helping to improve the flow uniformity of each distribution channel 351 and thus improve the temperature uniformity of the power tube module 10.

[0056] In this embodiment, the projections of each third return liquid branch 3534 and each first return liquid branch 3532 on the projection plane perpendicular to the X-axis are staggered. This is more conducive to the coolant in the third return liquid branch 3534 mixing in the return liquid section 3531 before flowing to each first return liquid branch 3532. This helps to ensure that the coolant from each third return liquid branch 3534 through the return liquid section 3531 to the first return liquid branch 3532 forms a more uniform flow path, further improving the uniformity of the flow rate of each liquid distribution branch channel 351.

[0057] In this embodiment, the outlet channel 34 is designed as a grid structure including a first outlet branch channel 341 and a second outlet branch channel 342. The grid design greatly increases the inlet area of ​​the coolant entering the outlet channel 34 and provides a large number of parallel low flow resistance paths. This helps to quickly absorb the liquid flow from multiple first return branches 3532 and avoids local congestion and pressure concentration at the inlet that may occur in a traditional single outlet channel 34. This ensures that the pressure distribution along the entire length of the outlet channel 34 is more balanced. The pressure-balanced outlet channel 34 can ensure that the heated coolant flows more evenly across the entire bottom contact surface of the power inductor module 20, thereby improving the uniformity of its heat dissipation.

[0058] In this embodiment, in the direct parallel connection scheme, the flow path of the liquid distribution branch channel 351 that is close to the liquid inlet channel 33 is short and the flow resistance is small, which will "steal" most of the flow; while the flow of the channel that is far away is insufficient, resulting in uneven cooling. The setting of the liquid supply channel 352 is equivalent to adding a "buffer zone and balancer" between the liquid inlet channel 33 and each liquid distribution branch channel 351. By adjusting the length and cross-sectional area of ​​these first liquid supply branches 3521 and second liquid supply branches 3522, the flow resistance of each liquid distribution branch channel 351 can be actively matched and balanced, thereby suppressing the phenomenon of uneven flow distribution. In addition, the above setting is also conducive to the liquid inlet channel 33 to dissipate heat from other electrical components.

[0059] In this embodiment, the number of second liquid supply branches 3522 is half of N. Each second liquid supply branch 3522 corresponds to the middle of two adjacent liquid distribution branches 351 and is connected to the first liquid supply branch 3521. Compared with connecting at the end, it is more conducive to making the shortest path length from the liquid inlet end of the liquid distribution branch 351 to the liquid inlet channel 33 equal, thereby helping to improve the uniformity of the flow of each liquid distribution branch 351, thereby improving the temperature uniformity of the power tube module 10.

[0060] In this embodiment, the projections of the second liquid supply branch 3522 and the third liquid return branch 3534 on the projection plane perpendicular to the X-axis direction overlap at least partially, which helps to simplify the processing steps and makes the path length from the liquid inlet channel 33 through the liquid distribution branch channel 351 to the liquid outlet channel 34 similar, thereby improving the uniformity of the flow rate of each liquid distribution branch channel 351.

[0061] In this embodiment, the liquid flow area of ​​the second liquid supply branch 3522 corresponding to the power tube unit 11 further away from the liquid inlet port 31 along the Y-axis is larger, which can ensure that the second liquid supply branch 3522 corresponding to the power tube unit 11 further away from the liquid inlet port 31 and the second liquid supply branch 3522 corresponding to the power tube unit 11 closer to the liquid inlet port 31 have similar flow rates, which is more conducive to maintaining the flow uniformity of each liquid distribution branch channel 351, thereby improving the temperature uniformity of the power tube module 10.

[0062] This utility model also provides a liquid-cooled converter (not shown in the figure), including a housing and the above-mentioned liquid-cooled power module. The housing forms a cavity on its own or in combination with the liquid cooling plate 30 to form a cavity. When the housing forms a cavity on its own, the liquid-cooled power module is placed in the cavity. When the housing and the liquid cooling plate 30 form a cavity, both the power transistor module 10 and the power inductor module 20 are placed in the cavity.

[0063] The liquid-cooled converter has the above-mentioned technical advantages. In addition, when the liquid cooling plate 30 and the housing cooperate to form a cavity, it means that the liquid cooling plate 30 has a thicker thickness, which is more conducive to processing the fine and deep flow channels corresponding to the power tube unit 11 on the liquid cooling plate 30, thereby making it more conducive to heat dissipation of the power tube unit 11 and improving heat dissipation efficiency.

[0064] The foregoing description of the specifications and embodiments is intended to explain the scope of protection of this utility model, but does not constitute a limitation on the scope of protection of this utility model. Modifications, equivalent substitutions, or other improvements to the embodiments of this utility model or a portion thereof that can be obtained by those skilled in the art through logical analysis, reasoning, or limited experimentation, based on the teachings of this utility model or the foregoing embodiments, should all be included within the scope of protection of this utility model.

Claims

1. A liquid-cooled power module, characterized in that, include The power transistor module (10) includes a plurality of power transistor units (11) arranged along the Y-axis direction, the size of which in the Y-axis direction is larger than the size in the X-axis direction; The power inductor module (20) and the power transistor module (10) are arranged along the X-axis; and A liquid cooling plate (30) is used to support the power transistor module (10) and the power inductor module (20) and to dissipate heat for them. It is provided with an inlet port (31) and an outlet port (32). A coolant flow channel is formed between the inlet port (31) and the outlet port (32). The coolant flow channel includes an inlet flow channel (33) connected to the inlet port (31), an outlet flow channel (34) connected to the outlet port (32), and a branch flow channel (35) connecting the inlet flow channel (33) and the outlet flow channel (34). The inlet flow channel (33) and the outlet flow channel (34) are respectively located on both sides of the branch flow channel (35) along the Y-axis direction. The branch flow channel (35) is provided with a plurality of branch flow channels (351) corresponding to the power transistor unit (11). The outlet flow channel (34) corresponds to the power inductor module (20).

2. The liquid-cooled power module as described in claim 1, characterized in that, The outlet flow channel (34) extends along the Y-axis direction; the distribution flow channel (35) further includes a return flow channel (353) connecting each distribution branch channel (351) and the outlet flow channel (34). The return flow channel (353) includes a return section (3531) extending along the Y-axis direction and several first return branches (3532) arranged along the Y-axis direction and extending along the X-axis direction; each first return branch (3532) is connected in parallel between the return section (3531) and the outlet flow channel (34); the return section (3531) connects each distribution branch channel (351).

3. A liquid-cooled power module as described in claim 2, characterized in that, The liquid distribution branch channel (351) extends along the X-axis direction; the liquid return channel (353) further includes several second liquid return branches (3533) extending along the Y-axis direction and spaced apart along the Y-axis direction, and third liquid return branches (3534) corresponding to the second liquid return branches (3533) spaced apart along the Y-axis direction and extending along the X-axis direction; the second liquid return branches (3533) are connected to the liquid outlet of at least two adjacent liquid distribution branches (351); the two ends of each third liquid return branch (3534) are respectively connected to the corresponding second liquid return branch (3533) and liquid return section (3531).

4. A liquid-cooled power module as described in claim 3, characterized in that, Each power tube unit (11) is provided with N liquid distribution channels (351), where N is an even number; the number of second return liquid branches (3533) is equal to the number of power tube units (11), and each second return liquid branch (3533) is provided in a one-to-one correspondence with each power tube unit (11) and is respectively connected to the liquid outlet end of the corresponding liquid distribution channel (351) of the power tube unit (11); the number of third return liquid branches (3534) is half of N, and each third return liquid branch (3534) is respectively connected to the middle of two adjacent liquid distribution channels (351) and the second return liquid branch (3533).

5. A liquid-cooled power module as described in claim 3, characterized in that, The projections of each third return liquid branch (3534) and each first return liquid branch (3532) on the projection plane perpendicular to the X-axis are staggered.

6. A liquid-cooled power module as described in any one of claims 2-5, characterized in that, The liquid outlet channel (34) is provided with a first liquid outlet branch channel (341) extending along the X-axis direction at intervals along the Y-axis direction, which is equal in number to and corresponds one-to-one with the first liquid return branch (3532), and a number of second liquid outlet branch channels (342) extending along the Y-axis direction at intervals along the X-axis direction. Each first liquid outlet channel (34) and each second liquid outlet branch channel (342) is staggered. The first liquid outlet branch channel (341) is connected to the first liquid return branch (3532) in a one-to-one correspondence.

7. A liquid-cooled power module as described in claim 4, characterized in that, The inlet channel (33) extends along the Y-axis direction; the distribution channel (35) further includes a supply channel (352) connecting each distribution branch channel (351) and the inlet channel (33). The supply channel (352) includes N first supply branches (3521) spaced apart along the Y-axis direction and extending along the Y-axis direction, and second supply branches (3522) corresponding to the first supply branches (3521) spaced apart along the Y-axis direction and extending along the X-axis direction. Each first supply branch (3521) respectively Each power transistor unit (11) corresponds to one of the power transistor units (11) and is connected to the inlet end of the corresponding liquid distribution branch channel (351). The two ends of each second liquid supply branch (3522) are connected to the corresponding first liquid supply branch (3521) and the liquid inlet channel (33). The number of second liquid supply branches (3522) is half of N. Each second liquid supply branch (3522) corresponds to the middle of two adjacent liquid distribution branches (351) and is connected to the first liquid supply branch (3521).

8. A liquid-cooled power module as described in claim 7, characterized in that, The projections of the second liquid supply section (3522) and the third liquid return section (3534) on the projection plane perpendicular to the X-axis direction at least partially overlap.

9. A liquid-cooled power module as described in claim 7, characterized in that, The liquid inlet port (31) is located on the first side of the liquid cooling plate (30) along the Y-axis direction; the liquid flow area of ​​the second liquid supply branch (3522) corresponding to the power tube unit (11) further away from the liquid inlet port (31) along the Y-axis direction is larger.

10. A liquid-cooled converter, characterized in that, The device includes a housing and a liquid-cooled power module as described in any one of claims 1-9. The housing forms a cavity on its own or in combination with a liquid cooling plate (30) to form a cavity. When the housing forms a cavity on its own, the liquid-cooled power module is placed inside the cavity. When the housing forms a cavity in combination with a liquid cooling plate (30), both the power transistor module (10) and the power inductor module (20) are placed inside the cavity.

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