EV Charging Unit Chamber Layout for Thermal Interference Control
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Solution Overview
Problem
Charging devices for electrified vehicles generate significant heat, leading to thermal interference between integrated circuits and components, which is exacerbated by size reduction efforts.
Innovation Solution
The charging device is designed with separate chambers for components that operate simultaneously, such as the second charger and DC-to-DC converter, and independent cooling channels for these components, along with a common cooling medium for components that do not operate simultaneously, like the first charger and relay, to manage thermal interference while reducing device size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If multiple circuits and devices related to charging are integrated to reduce the size of the charging device, then the device size is reduced, but thermal interference occurs between the circuits or devices
Solution Approach 1:
The housing is divided into multiple chambers (first chamber, second chamber, third chamber) that spatially separate different circuits and devices. The first charger and relay are placed in the second chamber, while the second charger is in the first chamber and the DC-to-DC converter is in the third chamber. This segmentation allows simultaneous operation of multiple components without thermal interference, while still maintaining a compact overall structure.
2Temperature
If components are disposed in separate chambers to avoid thermal interference, then thermal interference is reduced, but device complexity increases
Solution Approach 1:
The first charger and relay are combined in the same second chamber since they are not expected to operate simultaneously. This merging reduces the number of chambers needed and simplifies the overall structure while still preventing thermal interference between components that do operate simultaneously (first charger with second charger, relay with DC-to-DC converter).
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 configuration effectively cools the components, reduces thermal interference, and extends the service life of the charging device by equalizing cumulative usage time and thermal load across components.
Implementation Method 1
a first cooling medium channel configured to cool the second charger
Implementation Method 2
a first cooling medium channel configured to cool the second charger
Implementation Method 3
a second cooling medium channel configured to cool the DC-to-DC converter
Implementation Method 4
a second cooling medium channel configured to cool the DC-to-DC converter
Data Source
AI summary
The charging device mounted on electrified vehicle includes: a first charger capable of converting AC power supplied from the outside to DC power supplied to the battery; a second charger capable of converting AC power supplied from the outside to DC power supplied to the battery, and capable of converting DC power supplied from the battery to AC power supplied to the outside; a DC-to-DC converter capable of converting DC power supplied from the battery to low-voltage DC power supplied to the auxiliary battery; a relay for electrically connecting and disconnecting the DC charging inlet to the battery; and a housing including a first chamber for accommodating the second charger, a second chamber for accommodating the first charger and the relay, and a third chamber for accommodating DC-to-DC converter.