Parallel Air Duct Layout for EV Charging Module Heat Dissipation
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Solution Overview
Problem
Conventional electric vehicle charging module designs suffer from high electromagnetic interference, poor heat dissipation, and increased costs due to large current and voltage spikes, leading to reduced reliability and increased noise levels.
Innovation Solution
The charging module design features a parallel air duct layout between the rectifying and direct current conversion plates, with power switching transistors and capacitors strategically positioned to absorb spikes and improve airflow, along with heat sinks and electromagnetic devices to enhance heat dissipation and reduce electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If power switching transistors and magnetic devices are arranged in series in a straight line in an air duct, then the layout is compact, but air resistance increases and heat dissipation effect deteriorates
Solution Approach 1:
The patent divides the air duct into multiple parallel channels instead of using a single straight-line arrangement. Power switching transistors and magnetic devices are distributed across different parallel air ducts, segmenting the airflow path and reducing air resistance while maintaining compact layout.
Solution Approach 2:
The patent transitions from a one-dimensional straight-line arrangement to a multi-dimensional parallel duct configuration. By arranging air ducts in parallel along different spatial dimensions, the system achieves both compactness and improved heat dissipation.
2Device complexity
If the distance between power switching transistor and capacitor is increased, then layout flexibility improves, but voltage and current spike absorption capability deteriorates
Solution Approach 1:
The patent segments the power conversion circuit into modular units, each containing power switching transistors and their corresponding capacitors. This modular segmentation allows flexible layout arrangement while maintaining the close proximity needed for effective spike absorption within each module.
Solution Approach 2:
The patent introduces carefully designed circuit traces and grounding structures as intermediaries between power switching transistors and capacitors. These intermediaries enable flexible physical layout while maintaining effective electrical coupling for spike absorption.
3Area of stationary object
If heat sinks are connected in series in the air duct, then space utilization improves, but air resistance increases and heat dissipation performance deteriorates
Solution Approach 1:
The patent segments the heat dissipation system into multiple independent parallel air ducts, each with its own heat sink. This segmentation allows air to flow through multiple parallel paths, reducing overall air resistance while effectively utilizing available space through vertical stacking or lateral arrangement of the parallel ducts.
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 results in reduced electromagnetic interference, improved heat dissipation, lower noise levels, and increased reliability, while minimizing air resistance and manufacturing costs.
Implementation Method 1
The capacitor has a poor absorption effect on voltage and current spikes generated when the power switching transistor works
Implementation Method 2
A heat sink of the power switching transistor and the magnetic device of a DCDC plate are connected in series in a straight line in the air duct
Implementation Method 3
This further causes an increase in air resistance and directly affects an actual heat dissipation effect of the heat sink
Data Source
Figure 1~2
Figure 3~4
AI summary
A charging module includes: a housing, a rectifying plate, and a direct current conversion plate. The housing includes an upper housing and a lower housing that are fitted to each other. An air inlet and an air outlet are disposed on two sides of the housing. The rectifying plate is fixedly disposed on the upper housing. The direct current conversion plate is fixedly disposed on the lower housing. A plurality of power switching transistors are disposed on both the rectifying plate and the direct current conversion plate. There is a gap between the plurality of power switching transistors. The plurality of power switching transistors are disposed at a first end portion or a second end portion of the rectifying plate. The plurality of power switching transistors on the direct current conversion plate are disposed at one end portion of the direct current conversion plate. An air duct is disposed between the rectifying plate and the direct current conversion plate. The air duct is parallel to the rectifying plate and the direct current conversion plate. Two ends of the air duct are respectively connected to the air inlet and the air outlet. A flow path of an airflow in the air duct is in a straight line. According to embodiments of this application, in a working process, air resistance of the air duct in the charging module is small, a heat dissipation effect is good, noise is low, reliability is high, and costs can be reduced.