Cooling device for a vehicle battery charger

Abstract

Cooling device (10) for a charger (11) for a vehicle battery (30), comprising: at least one cooling unit (12) which is configured to be supplied with oil, wherein the at least one cooling unit (12) is configured to be connected to at least one electronic component (13) of the charger (11) for cooling.

Description

[0001] The invention relates to a cooling device for a charger for a vehicle battery, a charger with such a cooling device, and a vehicle with such a cooling device and / or such a charger.

[0002] Battery chargers for electric or hybrid vehicles generate heat during operation. For safety and performance reasons, this heat must be dissipated. Conventional cooling systems use air or water, among other methods. However, the cooling capacity of these systems is insufficient for current requirements.

[0003] In this context, it has now become apparent that there is a need to provide a cooling device for a vehicle battery charger. Specifically, there is a need to provide an improved cooling device for a vehicle battery charger.

[0004] Cooling devices are known from CN 221340229 U, DE 10 2008 012 645 A1, DE 3933956 A1 and DE 10 2021 207 645 A1.

[0005] The object of the present invention is to eliminate, or at least partially eliminate, the disadvantages described above in a cooling device for a vehicle battery charger. In particular, the object of the present invention is to provide an improved cooling device for a vehicle battery charger.

[0006] The aforementioned problem is solved by the claims. In particular, the problem is solved by a cooling device for a charger for a vehicle battery having the features of independent claim 1. Furthermore, the problem is solved by a charger having the features of independent claim 9 and by a vehicle having the features of independent claim 10.

[0007] Features described in connection with the cooling device according to the invention naturally also apply in connection with the charger according to the invention, the vehicle according to the invention and vice versa, so that with regard to the disclosure of the individual aspects of the invention, mutual reference is always made or can be made.

[0008] A first aspect of the present invention relates to a cooling device for a charger for a vehicle battery, comprising: at least one cooling unit which is arranged to be supplied with oil, wherein the at least one cooling unit is arranged to be connected to at least one electronic component of the charger for cooling purposes.

[0009] The term "charger" specifically refers to an integrated charger for electric vehicles, designed to convert alternating current (AC) to direct current (DC) for charging a vehicle battery. Furthermore, the charger may be configured to control the charging power. The charger may include one or more of the following components: semiconductor devices such as ICs, MOSFETs, and IGBTs, as well as capacitors and transformers. These components generate significant heat during operation and require cooling.

[0010] Within the scope of the invention, a cooling unit is understood to be a device configured to be actively supplied with oil and to extract heat from a component of the charger in order to cool it. The cooling unit may comprise a hollow body. The cooling unit may include an inlet. The cooling unit may include an outlet. The cooling unit may be made of metal, plastic, and / or ceramic. The cooling unit may include interfaces for attachment to the charger or a support structure of the charger. The interfaces may be monolithic with the cooling unit. The cooling unit may be configured to be indirectly connected to the component by means of a connecting unit. The cooling unit may be configured to be directly connected to the component via a holding unit.

[0011] The term "oil" in this context refers specifically to mineral and / or synthetic oils. The oil preferably has a viscosity in the range of 5 mm. 2 / s and 15 mm 2 exhibit / s.

[0012] In this context, the battery refers in particular to an energy storage device for an electric vehicle or a hybrid vehicle.

[0013] In this context, the term "vehicle" is preferably understood to mean an electric vehicle or a hybrid vehicle.

[0014] The term "connect" in this context refers in particular to indirect and direct connection in order to dissipate heat from the component to the cooling unit.

[0015] The invention is based on the understanding that installation space in vehicles is limited and that the market constantly demands increased performance, in this case charging capacity. Current cooling concepts for chargers are insufficient to meet these demands. Furthermore, air exchange between the interior of a charger and the ambient air, combined with temperature fluctuations, leads to corrosion and consequential damage to components such as circuit traces and contacts. Air cooling and water cooling are inadequate. Additionally, the use of water-based heat transfer fluids can lead to short circuits, and neglected maintenance can result in freezing.

[0016] The invention proposes equipping a vehicle-mounted high-voltage (HV) battery charger with oil cooling. Specifically, it proposes arranging an oil-cooled cooling unit on a component, for example, a semiconductor device within the charger, to cool that component. This increases the cooling capacity. The use of suitable oils prevents corrosion. The additional active cooling allows the components to be mounted closer together, enabling a compact arrangement within the charger. Compared to water-glycol mixtures, oil cooling allows for higher cooling medium temperatures. There is no risk of freezing due to inadequate maintenance (lack of antifreeze). Oil is better suited for use within HV components due to its dielectric properties.

[0017] According to the invention, the at least one cooling unit is indirectly connected to the at least one component of the charger via at least one connecting unit, wherein the connecting unit can be configured to transfer heat between the at least one component of the charger and the at least one cooling unit and to secure the at least one cooling unit.

[0018] The term "connecting unit" refers in particular to a structural component designed to establish an indirect connection between the cooling unit and the component. The connecting unit can be a single piece or multiple pieces. The connecting unit is preferably made of a metal characterized by high thermal conductivity. The connecting unit can also be made of formed sheet metal. It can include interfaces for attachment to a support structure of the charger. These interfaces can be plug-in and designed to compensate for tolerances. The connecting units can have flat interface areas for contact between the component and the connecting unit, as well as between the connecting unit and the cooling unit.The cooling unit can be connected to the connecting unit, for example, via a screw connection or a welded connection. The connecting unit can have openings or holes to promote airflow for cooling the component. These openings can also have a beneficial effect of reducing weight. The connecting unit can have geometric stiffeners in the form of raised areas and recesses, which enable a stable arrangement of the cooling unit. The connecting unit can have at least one interface for screwing it to a support structure of the charger. The cooling unit can comprise a large, flat component that is connected to the connecting unit on one side. On the other side of the connecting unit, a variety of components can be arranged and are in contact with it for heat dissipation. This can have a beneficial effect on manufacturing costs.

[0019] Preferably, the at least one cooling unit can be directly connected to the at least one component of the charger.

[0020] The direct connection can advantageously improve heat dissipation through thermal conduction. Alternatively, a so-called thermal interface material (TIM) can be placed between the cooling unit and the component to increase thermal conductivity. This can also have a positive effect on heat dissipation, as it can, for example, compensate for unevenness between the component and the cooling unit.

[0021] According to a preferred embodiment, the at least one cooling unit may comprise ceramic material, and / or wherein the cooling device may preferably comprise a holding unit that presses the cooling unit against the at least one component of the charger.

[0022] The term "holding unit" refers specifically to a structural component designed to establish a direct connection between the cooling unit and the component. The holding unit may be configured to press the cooling unit against or onto the component. The holding unit may also have interfaces for connection to a support structure of the charger.

[0023] This allows a contact force to be provided, thereby increasing heat transfer.

[0024] The use of ceramic for the cooling unit advantageously enables electrical insulation. This eliminates the need for additional materials such as TIM materials. The ceramic can be made of Al₂SO₃ or Al₂SO₃. Al₂SO₃ and Al₂SO₃ advantageously exhibit good thermal conductivity, meaning low thermal insulation properties combined with high electrical insulation. The ceramic cooling unit can be connected to the mounting unit via clamps or crimps. The mounting unit can have a recess, a shoulder, or a pocket for arranging or fixing the ceramic cooling unit. For example, several ceramic cooling elements can be arranged with the mounting unit. These multiple ceramic cooling elements can be individual or connected to each other, for example, via ceramic fins. This can have an advantage in terms of assembly.

[0025] According to a preferred embodiment, the at least one cooling unit can be arranged to be positioned above the at least one component.

[0026] Positioning the cooling unit above the component allows for the advantageous use of natural convection of warm air. The cooling unit can directly cool or dissipate the rising warm air. Furthermore, the cooling unit is easier to integrate into the system when positioned above the component.

[0027] Preferably, at least one cooling unit can be arranged to be positioned below at least one component.

[0028] This allows hot air to be forced upwards and more easily dissipated. This can advantageously prevent heat build-up above the component, as there is no cooling unit there.

[0029] Preferably, the cooling unit can be arranged in a support structure of the charger, wherein the support structure can be arranged vertically and / or horizontally within the charger.

[0030] The term "support structure" in this context refers to a structural component designed to hold parts of the charger. The support structure can be a single piece or multiple pieces. It can be made of metal and / or plastic. For example, the support structure may include one or more of the following: base plate, support plate, side wall, support flange, and / or freestanding support flange.

[0031] In this way, the functional density can be advantageously increased, thus enabling a compact design.

[0032] According to a preferred embodiment, the cooling device may further comprise the following components: a pump and at least one connecting line for the oil-communicating connection from the pump and the at least one cooling unit, wherein the at least one connecting line may comprise one or more of the following components: hose, pipe, flat tube with fin structure, and / or wherein the cooling device may further comprise an oil cooler and / or wherein the cooling device may comprise a control unit for regulating a cooling temperature for the oil and / or wherein the cooling device may comprise a control unit for controlling a volume flow of the oil.

[0033] The connecting line advantageously allows for flexible cooling circuits between the pump and the cooling unit. Using an oil cooler can further reduce the charger's temperature. A control unit for regulating the flow rate allows for effective temperature control. A control unit for regulating the cooling temperature ensures reliable responses to temperature fluctuations within the charger. The functionalities of the control unit and the regulation unit can be implemented in separate units or in a single, combined unit.

[0034] Another aspect of the present invention relates to a charger comprising a cooling device as described above and at least one electronic component, wherein the cooling unit is thermally connected to the at least one electronic component for cooling.

[0035] Another aspect of the present invention relates to a vehicle with a cooling device described in more detail above, wherein the cooling unit is thermally connected to the at least one electronic component of the charger for cooling, and / or to a charger described in more detail above.

[0036] All disclosures and embodiments described herein relate to the cooling device, charger, and vehicle described above, and vice versa. Advantageously, the advantages offered by one embodiment and example also apply to all other embodiments and examples, and vice versa.

[0037] Further advantages, features, and details of the invention will become apparent from the following description, in which several embodiments of the invention are described in detail with reference to the drawings. The features mentioned in the claims and in the description can be essential to the invention individually or in any combination. The following are shown schematically: Fig. 1 a charger according to the invention, Fig. 2 a cooling device according to the invention, Fig. 3 a detailed view of a cooling device according to the invention, Fig. 4 a connecting element, Fig. 5 a detailed view of a connecting element, Fig. 6 a further detailed view of a cooling device according to the invention, Fig. 7 a further cooling device according to the invention, Fig. 8 a further cooling device according to the invention, Fig. 9 a further cooling device according to the invention, Fig. 10 a further cooling device according to the invention and Fig. 11 a vehicle according to the invention.

[0038] Fig. Figure 1 shows a charger 11 according to the invention for a vehicle battery 30. The charger 11 comprises a cooling device 10. The cooling device 10 comprises three cooling units 12, each for cooling an electronic component 13. The cooling units 12 are connected to a pump 16 via connecting lines 17 and are circulated with oil. The pump 16 delivers oil for cooling. The cooling device 10 further comprises an oil cooler 18, which is integrated into the oil cooling circuit. The cooling device 10 also comprises a control unit 19 for regulating the cooling temperature and a control unit 20 for controlling the oil flow rate.

[0039] Fig. Figure 2 shows a cooling device 10 according to the invention. The cooling units 12 are arranged above the electronic components 13.

[0040] Fig. Figure 3 shows a detailed view of a cooling device 10 according to the invention. The electronic component 13 is arranged on a printed circuit board 23. The printed circuit board 23 is arranged on insulation 25. The insulation 25 is arranged on a support structure 15. The cooling unit 12 is attached to the insulation 25 by means of a connecting unit 14.

[0041] Fig. Figure 4 shows a connecting element 14. The connecting element 14 has screws as interfaces 22 for connection to the insulation 25. The connecting element 14 has flat areas on its top and bottom surfaces for connecting the cooling unit 12 and the electronic component 13, which enable the best possible heat transfer by conduction. Furthermore, the connecting element 14 has gaps in these areas that allow heat dissipation by convection.

[0042] Fig. Figure 5 shows a detailed view of a connecting element 14. The connecting element 14 has a further interface 22 for connection to a support structure 15, which is realized via a plug connection. The interface 22 can, in this case, enable tolerance compensation.

[0043] Fig. Figure 6 shows a further detailed view of a cooling device 10 according to the invention. The connecting device 14 is attached to an insulation 25. The connecting unit 14 connects the cooling unit 12 to the electronic components 13, which are arranged on a printed circuit board 23. The printed circuit board 23 is arranged on the insulation 25. The flat underside of the connecting unit 14 is in contact with the electronic components 13.

[0044] Fig. Figure 7 shows another cooling device 10 according to the invention. In contrast to Fig. 6. The cooling unit 12 and the connecting unit 14 are integrally manufactured as a single piece. This can have an advantageous effect on assembly.

[0045] Fig. Figure 8 shows another cooling device 10 according to the invention. The cooling unit 12 is made of ceramic and is pressed against the electronic component 13 by means of a holding unit 21. The cooling unit 12 is connected to the holding unit 21 by means of a clamp 24, which acts as an interface.

[0046] Fig. Figure 9 shows another cooling device 10 according to the invention. The electronic component 13 is arranged on a vertically oriented support structure 15. In this case, the electronic component 13 is cooled via a ceramic cooling unit 12, which is fixed by means of a holding unit 21.

[0047] Fig. Figure 10 shows another cooling device according to the invention. In contrast to Fig. In the present case, a cooling unit 12 is additionally integrated into the supporting structure 15 to enable cooling from two sides.

[0048] Fig.Figure 11 shows a vehicle 30 according to the invention with a charger 11 according to the invention and a cooling device 10 according to the invention. Reference symbol list 10 Cooling device 11 charger 12 cooling units 13-component charger 14 Connecting unit / connecting element 15 Supporting structure 16 pump 17 Connecting line 18 oil coolers 19 Control unit 20 Control unit 21 Holding unit 22 Interface Connection Unit 23 Circuit board 24 Interface Holding unit / clamp 25 Insulation 30 vehicles

Claims

[1] Cooling device (10) for a charger (11) for a vehicle battery (30), comprising: at least one cooling unit (12) which is designed to be supplied with oil, wherein at least one cooling unit (12) is arranged to be connected to at least one electronic component (13) of the charger (11) for cooling, characterized by , that which at least one cooling unit (12) is indirectly connected via at least one connecting unit (14) to at least one component (13) of the charger (11), wherein the connecting unit (14) is configured to transfer heat between the at least one component (13) of the charger (11) and the at least one cooling unit (12) and to secure the at least one cooling unit (12). [2] Cooling device (10) according to one of the preceding claims, wherein the at least one cooling unit (12) is arranged to be positioned above the at least one component (13). [3] Cooling device (10) according to one of the preceding claims, wherein the at least one cooling unit (12) is arranged to be located below the at least one component (13). [4] Cooling device (10) according to one of the preceding claims, wherein the cooling unit (12) is arranged to be arranged in a support structure (15) of the charger (11), wherein the support structure (15) is arranged vertically and / or horizontally within the charger (11). [5] Cooling device (10) according to any of the preceding claims, further comprising a pump (16) and at least one connecting line (17) to the oil-communicating connection from the pump (16) and the at least one cooling unit (12), wherein at least one connecting line (17) comprises one or more of the following components: hose, pipe and / or flat tube with ribbed structure and / or wherein the cooling device (10) further comprises an oil cooler (18) and / or a control unit (19) for controlling a cooling temperature for the oil and / or a control unit (20) for controlling a volume flow of the oil. [6] Charger (11) comprising a cooling device (10) according to any one of claims 1 to 5 and at least one electronic component (13), wherein the cooling unit (12) is thermally connected to the at least one electronic component (13) for cooling. [7] Vehicle (30) with a cooling device (10) according to one of claims 1 to 5, wherein the cooling unit (12) is thermally connected to the at least one electronic component of the charger (11) for cooling and / or to a charger (11) according to claim 6.

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