Onboard Charger Casing with Integrated Liquid Cooling Channel
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Solution Overview
Problem
Electric vehicle onboard chargers (OBCs) face heat dissipation challenges, leading to potential failure when temperature thresholds are reached, and existing liquid-cooling solutions increase the overall size and height of OBCs, which is a concern for manufacturers.
Innovation Solution
A casing design for OBCs incorporating a liquid channel with an inlet and outlet for heat-dissipating liquid, where heat-dissipating components are arranged to contact the channel directly or through a heat-transferring medium, and potting chambers enhance heat transfer to the liquid coolant, allowing for efficient cooling while reducing the overall size and height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid-cooling solutions are used for heat dissipation, then heat dissipation effectiveness is improved, but the overall size and height of OBCs increase
Solution Approach 1:
The cooling channels are integrated directly into the casing structure itself, merging the structural support function with the heat dissipation function. The casing walls serve dual purposes as both structural elements and heat transfer surfaces, eliminating the need for separate cooling components that would increase size.
Solution Approach 2:
The casing is designed to perform multiple functions simultaneously: providing structural support, electrical insulation, and heat dissipation. The same casing walls that enclose the OBC components also serve as cooling channels through which coolant flows, maximizing space utilization and reducing overall dimensions.
2Device complexity
If cooling channels are integrated into the casing, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The cooling channels are formed as integral parts of the casing during the molding process, combining what would otherwise be separate components. This integration reduces assembly steps and overall device complexity while the molding process inherently provides sufficient precision for the channel dimensions.
Solution Approach 2:
The cooling channels are designed to work with liquid coolant flow, utilizing fluid dynamics principles to achieve effective heat dissipation. The channel geometry is optimized for coolant flow patterns that maximize heat transfer while maintaining manufacturable dimensions through standard molding capabilities.
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
The design effectively dissipates heat generated by OBC components, preventing overheating and reducing the size of OBCs, thus addressing the heat dissipation challenges and meeting the size constraints of electric vehicle manufacturers.
Implementation Method 1
A heat dissipating liquid can flow into the channel through the inlet and out of the channel through the outlet
Implementation Method 2
A heat dissipating liquid can flow into the channel through the inlet and out of the channel through the outlet
Data Source
AI summary
A casing for an onboard charger includes a sidewall having a first height and an internal wall having a second height less than the first height. A channel is defined by the internal wall and the sidewall. An inlet connects to a first end of the channel and an outlet connects to a second end of the channel. A heat dissipating liquid can flow into the channel through the inlet and out of the channel through the outlet.