On-board Charger Longitudinal Coolant Flow Heat Dissipation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing on-board chargers for electric vehicles have inadequate heat dissipation due to the horizontal flow of coolant away from heat-generating components, leading to inefficient heat removal and potential damage to the charger.
Innovation Solution
A longitudinal coolant flow channel within the casing is implemented, in direct contact with heat-generating components, using heat conducting sheets and encapsulants to enhance heat exchange, and through holes with heat conducting glue to facilitate heat transfer from SMD switch tubes to the coolant channel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a coolant flow channel is disposed at the bottom of the casing with horizontal flow away from heat-generating elements, then the structure is simple, but the heat dissipation capability is insufficient
Solution Approach 1:
The patent transitions from horizontal coolant flow (parallel to heat-generating components) to longitudinal coolant flow (perpendicular to and through the components). The coolant flow channel is designed to extend along the length of heat-generating components like the transformer, enabling heat removal from multiple surfaces including top, bottom, and side surfaces, thereby significantly improving heat dissipation capability
Solution Approach 2:
The longitudinal coolant flow channel serves multiple functions simultaneously: it cools multiple heat-generating components (transformer, rectifier, inductor), removes heat from multiple surfaces of each component, and maintains a compact structural design. This multi-functional approach resolves the contradiction by achieving comprehensive heat dissipation without proportionally increasing structural complexity
2Reliability
If heat generating components are cooled effectively, then operational reliability improves, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent integrates the coolant flow channel directly with the heat-generating components by making the channel walls form part of the component structures themselves. The transformer winding support structure, rectifier housing, and inductor housing all incorporate coolant flow channels as integral parts, eliminating the need for separate cooling attachments and simplifying assembly while ensuring effective heat cooling
Solution Approach 2:
The patent introduces coolant flow channel walls as intermediary thermal conduction structures between heat-generating components and the cooling medium. These channel walls act as heat transfer mediators that conduct heat from component surfaces to the flowing coolant, enabling effective cooling while maintaining straightforward component design and assembly procedures
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design significantly improves heat dissipation, resulting in a more efficient, compact, cost-effective, and lightweight on-board charger with enhanced operational reliability.
Implementation Method 1
heat is dissipated from the heat generating components by using respective surfaces of the coolant flow channel
Implementation Method 2
a heat conducting sheet is arranged between the coolant flow channel and the male tab switch tube
Implementation Method 3
the heat conducting glue is in contact with the SMD switch tube through the through holes in the PCB; the SMD switch tube exchanges heat with the coolant flow channel through the heat conducting glue
Implementation Method 4
a space between each of the heat generating components and the mounting chamber is encapsulated with a heat conducting encapsulant
Data Source
AI summary
The present invention discloses an on-board charger with a heat dissipation structure. The on-board charger comprises a casing, and heat generating components, a PCB and a heat dissipation structure which are arranged inside the casing, and is characterized in that the heat dissipation structure is a coolant flow channel; the coolant flow channel is arranged longitudinally with respect to the heat generating components, and is in full contact with each heat generating component; heat is dissipated from the heat generating components by using respective surfaces of the coolant flow channel. The on-board charger with the heat dissipation structure provided by the present invention has the advantages of small size, excellent heat dissipation effect, simple assembly, low cost and light weight.