Cooler assembly

Abstract

The invention relates to a cooler assembly, in particular for cooling power electronics of a converter, comprising: a cooler which is made of aluminum and has a trough-shaped cross-section, having a first wall region, a second wall region, and a base region connecting the first wall region to the second wall region. The cooler has a first sheet metal component, a second sheet metal component, and a turbulator. The first wall region has a first cooling region, and the second wall region has a second cooling region. The first and second sheet metal components are spaced apart from one another at the first cooling region and at the second cooling region in order to form an intermediate space through which a cooling medium flows, and the turbulator is at least partly provided in the intermediate space for the cooling medium flowing therethrough, soldered connections being formed between the first sheet metal component and the second sheet metal component and the turbulator.

Description

[0001] Description

[0002] title

[0003] Cooler arrangement

[0004] State of the art

[0005] The present invention relates to a cooler arrangement, in particular for cooling power electronics of a converter, with a simplified design and excellent cooling performance.

[0006] For cooling converters, a coolant flow is typically routed through a channel between an aluminum casting and a friction stir welded aluminum casting. While the use of cast components is generally efficient, it necessitates thick walls, draft angles, and demoldable geometries. In addition to these geometric limitations, the increased wall thickness of the cast components requires additional installation space and material, and also complicates heat transfer for dissipation. A major problem with cast components, however, is their partially porous structure, which can lead to leaks. Therefore, quality tests, which are time-consuming and expensive, must be performed before installing such coolers.

[0007] Disclosure of the invention

[0008] The cooling arrangement according to the invention, particularly for cooling electronic components of converters, with the features of claim 1, has the advantage that simple and cost-effective manufacturing is possible. In particular, manufacturing can be carried out using proven methods for cooling arrangements. Furthermore, the cooling arrangement according to the invention has significantly thinner walls than cast components, resulting in advantages in terms of installation space, reduced weight, and reduced costs. In particular, the components of the cooling arrangement can be provided as extruded aluminum profiles, which further reduces manufacturing costs.

[0009] According to the invention, this is achieved by the cooler assembly comprising an aluminum cooler with a trough-shaped or U-shaped cross-section. The cooler includes a first and a second wall section, as well as a base section connecting the two wall sections. A space for electronic components requiring cooling is formed between the wall sections. The cooler comprises a first and a second sheet metal component, as well as a turbulator. The sheet metal components and the turbulator are made of aluminum. The first and second wall sections each have a first and second cooling zone, enabling cooling along both wall sections. The first and second sheet metal components are spaced apart at the cooling zones to create an intermediate space through which a cooling fluid can flow. The turbulator is at least partially located within this intermediate space.Solder joints are formed between the first and second sheet metal components and the turbulator. This allows for the preferably single manufacturing step of producing both solder joints between the two sheet metal components and solder joints to the turbulator. Since the sheet metal components do not have porous structures, there are no issues regarding leakage paths due to existing porosity. Furthermore, a high degree of freedom is achieved with regard to the design of subassemblies and electronic components, which can be accommodated in trough-shaped coolers. The turbulators are preferably formed along the entire length of the first and second cooling zones in the first and second wall regions, thereby ensuring very high cooling performance. Additional functions can also be integrated into the cooler arrangement according to the invention, such as...An integrated electromagnetic shield or mounting points for additional components. Thus, the cooler arrangement according to the invention can enable higher power density with reduced material consumption and reduced costs, with a minimal risk of leakage.

[0010] The dependent claims describe preferred embodiments of the invention. Preferably, the first cooling area of ​​the first wall area is connected to the second cooling area of ​​the second wall area by means of a connecting area. The connecting area is preferably formed on an outer surface of the base area, preferably by providing a feature in the base area.

[0011] Alternatively or additionally, the connection area between the first and second cooling zones is located on an inside side of the floor area.

[0012] Preferably, a third cooling area is formed in the base of the cooler assembly. This allows the cooler assembly to cool components from three sides.

[0013] Preferably, the third cooling zone in the base area is divided into at least two sub-zones by means of a partition. The partition preferably runs longitudinally along the cooler assembly. The first sub-zone of the third cooling zone is preferably connected to the first cooling zone, and the second sub-zone of the third cooling zone is connected to the second cooling zone. This allows the volume of both the first and second cooling zones to be increased.

[0014] Preferably, the first sheet metal component and / or the second sheet metal component has wing sections, which are preferably manufactured integrally with the sheet metal components. Preferably, the wing sections are arranged laterally outwards at an angle of approximately 90° from the first and / or second wall section.

[0015] For particularly cost-effective manufacturing, brazed joints of the cooler assembly are preferably hard-soldered. Preferably, all brazed areas of the cooler assembly are hard-soldered. The sheet metal components preferably have a uniform thickness of approximately 1.5 mm.

[0016] Particularly cost-effective manufacturing is achieved if the solder joint is pre-formed by an inward-facing solder layer on the first and / or second sheet metal component. Then, the components simply need to be loosely assembled as a temporary sub-assembly before the soldering step is performed.

[0017] Preferably, the first and second sheet metal components are directly connected and sealed at the connection points using a solder joint. This eliminates the need for additional components; the two sheet metal components provide both the space for the turbulator and the seal through a direct solder joint between them.

[0018] Furthermore, the cooler arrangement preferably comprises an inlet nozzle on the first wall area, which is preferably also connected by means of a soldered connection, and an outlet nozzle on the second wall area, which is also preferably connected to the second wall area by means of a soldered connection.

[0019] The inlet and / or outlet nozzles are cylindrical or, alternatively, oval-shaped. Preferably, recesses are provided in the first and second wall sections, in which the inlet and outlet nozzles are at least partially received.

[0020] Furthermore, the present invention relates to an electronic component, in particular a converter, with a cooling arrangement according to the invention.

[0021] drawing

[0022] Preferred embodiments of the invention are described in detail below with reference to the accompanying drawing. The drawing shows...

[0023] Figure 1 is a schematic, perspective view of a

[0024] Cooler arrangement according to a first embodiment of the invention from a first perspective,

[0025] Figure 2 is a perspective view of the cooler arrangement from Figure 1 from a second perspective; Figure 3 is a schematic side view of the cooler arrangement from Figure 1.

[0026] Figure 1 ,

[0027] Figure 4 shows a schematic view of an electronic assembly with a cooler arrangement of the first embodiment,

[0028] Figure 5 is a schematic, perspective view of a

[0029] Cooler arrangement according to a second embodiment of the invention,

[0030] Figures 6 to 8 show detailed views of the cooler arrangement of the second

[0031] Example of implementation,

[0032] Figure 9 shows a schematic sectional view of the cooler arrangement of the second embodiment.

[0033] Figure 10 shows a schematic representation of a fixing of partition walls of the cooler arrangement of the second embodiment, and

[0034] Figure 11 shows a schematic representation of a cooler arrangement according to a third embodiment of the invention.

[0035] Preferred embodiments of the invention

[0036] Below, with reference to Figures 1 to 4, a cooler arrangement 1 and a converter 100 with a cooler arrangement 1 according to the invention are described in detail.

[0037] As can be seen from Figures 1 to 3, the cooler arrangement 1 comprises a cooler 2, which in cross-section has a trough-shaped or a flattened U-shaped form. This trough-shaped form creates a receiving chamber 13, which is designed to receive electronic components or the like. Dividing plates 103 can also be provided in the receiving chamber 13, as shown in Figure 1, which subdivide the receiving chamber 13 into different sub-chambers. The cooler 2 comprises a first wall section 21, a second wall section 22, and a bottom section 23. The bottom section 23 connects the first and second wall sections 21 and 22. The wall sections 21 and 22 and the bottom section 23 comprise a first sheet metal component 3 and a second sheet metal component 4.

[0038] The cooler 2 thus comprises the two sheet metal components 3 and 4, as well as a turbulator 5, which is arranged in a space for the cooling medium, the space being formed between the two sheet metal components. The turbulator 5 is therefore at least partially located in the space between the two sheet metal components and significantly improves the cooling effect when the cooling medium flows through the cooler 2.

[0039] Thus, in this embodiment, a first cooling area 6 is formed on the first wall area 21 and a second cooling area 7 is formed on the second wall area 22.

[0040] Several solder joints 9, in particular hard solder joints, are formed between the first sheet metal component 3 and the second sheet metal component 4, as well as between the sheet metal components and the turbulator. These solder joints 9 serve, on the one hand, to fix the turbulator in the space between the two sheet metal components 3 and 4, and on the other hand, to connect the two sheet metal components 3 and 4 to each other in order to form a fluid-tight cooling channel in the cooler 2, particularly in the first and second wall regions. Figure 2 schematically illustrates the flow through the cooler 2, indicated by arrows. An inlet nozzle 11 is provided on the first wall region 21, into which the cooling medium flows, as indicated by arrow A. The cooling medium flows into the first wall region 21, into the space between the first and second sheet metal components 3. The turbulator 5 is arranged in this space, which is schematically represented in Figure 2 by the cutout.

[0041] The flow through the first wall section 21 occurs in the longitudinal direction XX of the cooler assembly, and the cooling channel is routed from the first wall section 21 to the second wall section 22 via a connecting section 24. A return flow then occurs towards the inlet side along the space at the second wall section between the first and second sheet metal components 3, 4, so that the cooling medium, which absorbs heat as it flows through, exits again at an outlet nozzle 12. This is indicated by arrow B in Figure 2.

[0042] A turbulator 5 is arranged in both wall areas 21 and 22. The floor area 23 is designed without a cooling zone.

[0043] The connection area 24 is formed by a protrusion in the base area of ​​the first sheet metal component 3 and is located on an outside of the cooler.

[0044] The solder joint 9 can be formed by applying solder material to the mutually facing inner surfaces of the first and second sheet metal components 3, 4. This also allows the inlet nozzle 11 and the outlet nozzle 12 to be fixed to the components in a single joining step by means of solder joints.

[0045] In this embodiment, the second sheet metal component 4 additionally has two wing sections 10. The wing sections 10 are each arranged on the sides of the cooler assembly 1 and at an angle of approximately 90° to the first wall section 21 and the second wall section 22, respectively (see Figures 1 and 2).

[0046] Figure 4 shows the converter 100 with integrated cooler arrangement 1. The wing sections 10 of the cooler arrangement 1 can perform additional functions in the converter; for example, in this embodiment, the wing sections 10 have openings to which further components of the converter 100 can be screwed or electrically connected.

[0047] As can be seen in Figure 2, the inflow and outflow thus occur on the same side of the cooler 2. The cooler 2 is therefore permeated with cooling medium in the longitudinal direction XX, starting from the inlet nozzle 11 and continuing to the opposite end. There is then a 90° deflection perpendicular to the longitudinal direction, another 90° deflection into the connection area 24, from there another 90° deflection into the second wall area 22, and then another 90° deflection and flow through the wall area 22 to the outlet nozzle 12. In the installed state of the cooler assembly 1 in the converter 100, as shown in Figure 4, power electronics 101, for example, are arranged in the receiving space 13 of the trough-shaped cooler 2. The fin sections 10, which are positioned laterally on the cooler 2, serve to fix further components.

[0048] The first and second sheet metal components 3, 4, and the turbulator 5 are made of aluminum. The wall thickness of the sheet metal components 3 and 4 is preferably 1.5 mm. Thus, the cooler 2 has a relatively low overall mass, and the manufacturing process is particularly simple and cost-effective, achieved through a brazing process that joins the sheet metal components 3, 4 to seal the cooling path and fixes the turbulator 5 between the two sheet metal components 3, 4. The aluminum sheets are non-porous, ensuring the cooler assembly 1 is leak-proof.

[0049] The wing sections 10, which are integrally formed with the second sheet metal component 4, can perform additional functions, such as further securing of components or providing electromagnetic shielding for other components. The trough-like shape of the cooler assembly 1 offers numerous surfaces for mounting heat sources of the converter 100, such as transistors, transformers, coils, and / or capacitors. A cooling medium can be routed very close to the heat sources, resulting in an extremely short heat transfer path.

[0050] Furthermore, the wing areas 10 can also be used for heat transfer and to dissipate heat laterally from the trough-shaped cooler 2.

[0051] Figures 5 to 10 show a cooler arrangement 1 according to a second embodiment of the invention, wherein identical or functionally identical parts are designated with the same reference numerals as in the first embodiment.

[0052] In contrast to the first embodiment, the second embodiment features a third cooling zone 8 in the base region 23 of the cooler 2. As can be seen particularly in Figures 5 and 9, a partition 80 is formed in the base region 23, so that the third cooling zone 8 in the base region 23 is divided into a first sub-zone 81 and a second sub-zone 82. As can be seen in Figure 9, the first sub-zone 81 is connected to the first cooling zone 6 via a fluid flow. The second sub-zone 82 is connected to the second cooling zone 7 via a fluid flow. Turbulators 5 are arranged in both the first sub-zone 81 and the second sub-zone 82 of the third cooling zone 8, as well as in the first and second cooling zones 6 and 7 (not shown in Figure 9). Furthermore, the fin sections 10 are formed by both sheet metal components 3 and 4. This allows, for example, improved electromagnetic shielding.To securely fix the divider plates 103, the divider plates 103 have three lugs 103a which are received in recesses 104 (see Figures 9 and 10).

[0053] Figures 6, 7, and 8 again show the direct connection of the two sheet metal parts 3 and 4 by means of a solder joint 9 at the opposite ends of the inlet and outlet nozzles. Figure 7 is a section along line AA, and Figure 8 is a section along line BB of Figure 6. This further illustrates that all seals of the cooling channel are achieved by directly connecting the first sheet metal part 3 to the second sheet metal part 4 by means of a solder joint.

[0054] The inlet port 11 and the outlet port 12 each have a cylindrical shape.

[0055] Figure 11 schematically shows an alternative to the inlet nozzles 11, 12 of the preceding claims, wherein Figure 11 shows an oval cross-section of the inlet nozzle 11. The outlet nozzle 12 can be configured in the same way. For connection to a pipeline or the like, the inlet nozzle 11 can have an insert 11a.

Claims

Claims 1. Cooling arrangement, in particular for cooling the power electronics of a converter, comprising: a cooler (2) made of aluminium with a trough-shaped cross-section, having a first wall region (21), a second wall region (22), and a bottom region (23) connecting the first wall region (21) to the second wall region (22), wherein the cooler (2) comprises a first sheet metal component (3), a second sheet metal component (4), and a turbulator (5), wherein the first wall region (21) has a first cooling region (6), and the second wall region (22) has a second cooling region (7), wherein the first and second sheet metal components (3, 4) are spaced apart from each other at the first cooling region (6) and at the second cooling region (7) to form a space for the flow of cooling medium, and the turbulator (5) is arranged at least partially in the space for the flow of cooling medium.and wherein solder joints (9) are formed between the first sheet metal component (3) and the second sheet metal component (4) and the turbulator (5).

2. Cooler arrangement according to claim 1, wherein the first cooling area (6) is connected to the second cooling area (7) by means of a connecting area (24).

3. Cooler arrangement according to claim 2, wherein the connecting area (24) extends along an outside of the bottom area (23) and / or along an inside of the bottom area (23).

4. Cooler arrangement according to one of the preceding claims, wherein a third cooling area (8) is formed in the bottom area (23).

5. Cooler arrangement according to claim 4, wherein the third cooling area (8) in the bottom area (23) is divided into a first sub-area (81) and a second sub-area (82) by means of a partition (80).

6. Cooler arrangement according to claim 5, wherein the first part (81) of the third cooling area (8) is connected to the first cooling area (6) and the second part (82) of the third cooling area (8) is connected to the second cooling area (7).

7. Cooler arrangement according to one of the preceding claims, wherein the first sheet metal component (3) and / or the second sheet metal component (4) has a wing area (10).

8. Cooler arrangement according to one of the preceding claims, wherein the solder joint (9) is a brazing joint, wherein in particular the solder joint (9) is formed by an inwardly directed solder layer on the first and / or second sheet metal component (3, 4).

9. Cooler arrangement according to one of the preceding claims, wherein the space for flow with cooling medium is sealed by directly connected sections on the first sheet metal part (3) and on the second sheet metal part (4).

10. Cooler arrangement according to one of the preceding claims, further comprising an inlet nozzle and an outlet nozzle, wherein the inlet nozzle (11) is connected to the first wall region (21) by means of a solder connection (9) and the outlet nozzle (12) is connected to the second wall region (22) by means of a solder connection (9).

11. Cooler arrangement according to claim 10, wherein the inlet nozzle (11) and the outlet nozzle (12) are arranged on the same side of the cooler (2) and / or wherein the inlet nozzle (11) and the outlet nozzle (12) are cylindrical or oval in shape.

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