Patent Publication Number: US-2022225540-A1

Title: Box type cooling structure for controller

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of International Application No. PCT/CN2021/132296, filed on Nov. 23, 2021, which claims priority to Chinese Patent Application No. 202011330020.7, filed on Nov. 24, 2020. The disclosures of the above-mentioned applications are incorporated herein by reference in their entireties. 
    
    
     TECHNICAL FIELD 
     The present application relates to the field of cooling controllers, in particular to a box type cooling structure for a controller. 
     BACKGROUND 
     At present, the water cooling mode is the main cooling mode of the controllers, and for high heating components such as modules, capacitors and inductors, the mode of only cooling one side is adopted and the cooling effect is poor. 
     In the related art, the high-voltage portion is installed with the low-voltage portion in the controller, and the internal cavity of the controller has not been separated, and the high-pressure portion interferes with the low-voltage portion, and the EMC (Electro Magnetic Compatibility) performance of the whole machine is poor. 
     In the related art, when a vehicle adopts multiple controllers, a split structure is adopted, the occupied space is relatively large, and it is also not good for disassembly and repairing. 
     SUMMARY 
     The present application aims to provide a box type cooling structure for a controller. High-voltage portion and low-voltage portion are separated by adopting a box type design, mutual interference is reduced, performance of the vehicle is improved, cooling water channels are arranged around the high heating components, and the cooling effect is improved. 
     The technical solutions of the present application are as follows. 
     A box type cooling structure of a controller, the controller includes a driving and controlling board, an IGBT module and a film capacitor, the box type cooling structure includes an upper water channel substrate, a front water channel substrate, a left water channel substrate, a rear water channel substrate, a right water channel substrate and a lower water channel substrate sequentially enclosed in six directions of the controller, water channel structures are arranged in the upper water channel substrate, the front water channel substrate, the left water channel substrate, the rear water channel substrate, the right water channel substrate and the lower water channel substrate. 
     In an embodiment, a water inlet is provided at a top of the upper water channel substrate, a first water outlet, a second water outlet, a third water outlet and a fourth water outlet are arranged in four corners of a bottom of the upper water channel substrate; 
     a second water inlet communicating with the first water outlet is provided at a top of the front water channel substrate, and a fifth water outlet is provided at a bottom of the front water channel substrate; 
     a third water inlet communicating with the second water outlet is provided at a top of the left water channel substrate, and a sixth water outlet is provided at a bottom of the left water channel substrate; 
     a fourth water inlet communicating with the third water outlet is provided at a top of the rear water channel substrate, and a seventh water outlet is provided at a bottom of the rear water channel substrate; 
     a fifth water inlet communicating with the fourth water outlet is provided at a top of the right water channel substrate, and an eighth water outlet is provided at a bottom of the right water channel substrate; 
     a sixth water inlet communicating with the fifth water outlet, a seventh water inlet communicating with the sixth water outlet, an eighth water inlet communicating with the seventh water outlet and a ninth water inlet communicating with the eighth water outlet are provided at a top of the lower water channel substrate, and a ninth water outlet is provided at a bottom of the lower water channel substrate. 
     In an embodiment, the box type cooling structure further includes an intermediate water channel substrate; wherein a front supporting slide block is provided at a middle part of an inner side of the front water channel substrate and a rear supporting slide block is provided at a middle part of an inner side of the rear water channel substrate, a front end of the intermediate water channel substrate is fixed on the front supporting slide block, and a rear end of the intermediate water channel substrate is fixed on the rear supporting slide block; 
     a tenth water outlet and a tenth water inlet are provided in a middle part of an inner side of the left water channel substrate or the right water channel substrate; an eleventh water inlet communicating with the tenth water outlet and an eleventh water outlet communicating with the tenth water inlet are provided at a left end or a right end of the intermediate water channel substrate. 
     In an embodiment, a first cavity is formed between the intermediate water channel substrate and the upper water channel substrate, and the driving and controlling board and the IGBT module are arranged inside the first cavity; and a second cavity is formed between the intermediate water channel substrate and the lower water channel substrate, and the film capacitor is arranged inside the second cavity. 
     In an embodiment, one side of the intermediate water channel substrate is provided with a notch, two connection terminals of the film capacitor are connected to the IGBT module via a first copper bar and a second copper bar passing through the notch respectively, 
     In an embodiment, the rear water channel substrate is further provided with a three-phase output port, and a three-phase output copper bar of the IGBT module is extended out from the three-phase output port. 
     In an embodiment, a first cavity is formed between the intermediate water channel substrate and the upper water channel substrate, and the driving and controlling board and the film capacitor are arranged inside the first cavity; 
     a second cavity is formed between the intermediate water channel substrate and the lower water channel substrate, and the IGBT module is arranged inside the second cavity. 
     In an embodiment, the film capacitor is arranged on one of the upper water channel substrate, the front water channel substrate, the left water channel substrate, the rear water channel substrate, the right water channel substrate and the lower water channel substrate, and a plurality of IGBT modules are arranged on the other of the upper water channel substrate, the front water channel substrate, the left water channel substrate, the rear water channel substrate, the right water channel substrate and the lower water channel substrate. 
     In an embodiment, the six water channel substrates are connected by fasteners, and joints of the water channel substrate are sealed by sealant or seal rings; and insertion positions of each water inlet and each water outlet are sealed by seal rings. 
     The present application has the advantages as follows. 
     1. The cooling structure adopts seven water channel substrates to be assembled in an assembled mode, which is good for disassembling and repairing. 
     2. Internal water channels are arranged in the seven water channel substrates, so that to cool the four sides of each of the IGBT modules, the capacitors, the copper bars and the inductors in the controller, and the cooling effect is better. 
     3. Cavities are formed in the controller, high-voltage components can be separated from the low-voltage components in the controller, and mutual interference is reduced. 
     4. The intermediate water channel substrate is amounted in a plug-in mode, which is good for the installation and disassembling of the intermediate water channel substrate. 
     5. The water channels in the seven water channel substrates can be communicated with each other, so that circulating cooling of the components in the controller is realized. 
     6. The high heating components such as the IGBT modules, the capacitors or the inductors in the controller can be freely arranged on each water channel substrate, and the structural arrangement is relatively simple. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present application is further described below with reference to the accompanying drawings and the embodiments. 
         FIG. 1  is an isometric view of a box type cooling structure of a controller of the present application. 
         FIG. 2  is another isometric view of the box type cooling structure of the controller of the present application, viewed from another angle. 
         FIG. 3  is a cross-sectional view of an interior of the cooling structure of the controller of a first embodiment. 
         FIG. 4  is a schematic view of a first cavity inside the cooling structure of the controller of the first embodiment. 
         FIG. 5  is a schematic view of a second cavity inside the cooling structure of the controller of the first embodiment. 
         FIG. 6  is a structural view of an upper water channel substrate. 
         FIG. 7  is a view showing distribution of internal water channels of the upper water channel substrate. 
         FIG. 8  is a structural view of a front water channel substrate. 
         FIG. 9  is a view showing distribution of internal water channels of a front water channel substrate. 
         FIG. 10  is a view showing distribution of internal water channels of a left water channel substrate. 
         FIG. 11  is a structural view of a rear water channel substrate. 
         FIG. 12  is a view showing distribution of internal water channels of the rear water channel substrate. 
         FIG. 13  is a structural view of a right water channel substrate. 
         FIG. 14  is a view showing distribution of internal water channels of a right water channel substrate. 
         FIG. 15  is a view showing distribution of internal water channels of an intermediate water channel substrate. 
         FIG. 16  is a structural view of a lower substrate. 
         FIG. 17  is a view showing distribution of internal water channels of the lower substrate. 
         FIG. 18  is a cross-sectional view of the interior of the cooling structure of the controller of a second embodiment. 
         FIGS. 19 and 20  are cross-sectional views of the interior of the cooling structure of the controller of a third embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     First Embodiment 
     As shown in  FIGS. 1 and 2 , a box type cooling structure of a controller of the present application includes an upper water channel substrate  1 , a front water channel substrate  2 , a left water channel substrate  3 , a rear water channel substrate  8 , a right water channel substrate  39  and a lower water channel substrate  40  which sequentially surround in six directions of the controller to form a box structure. Water channel structures are provided in the six water channel substrates. The controller includes a driving and controlling board  11 , an Insulated Gate Bipolar Translator (IGBT) module  12 , and a film capacitor  19 . The front water channel substrate  2  is provided with outlet ports for a positive busbar, a negative busbar  5 , and a low-voltage plug  6  of the controller. A three-phase output port  31  is provided on the rear water channel substrate  8 , and a three-phase output copper bar  9  of the IGBT module  12  is extended out from the three-phase output port  31 . 
     As shown in  FIGS. 3-5 , the box structure further includes an intermediate water channel substrate  20 . A first cavity  41  is formed between the intermediate water channel substrate  20  and the upper water channel substrate  1 . The driving and controlling board  11  and the IGBT module  12  are arranged inside the first cavity  41 . A second cavity  42  is formed between the intermediate water channel substrate  20  and the lower water channel substrate  40 , the film capacitor  19  is arranged inside the second cavity  42 , a notch is formed in one side of the intermediate water channel substrate  20 , and two connection terminals of the film capacitor  19  are connected to the IGBT module  12  by the first copper bar  13  and the second copper bar  14  correspondingly through the notch. 
     As shown in  FIGS. 6 and 7 , a top of the upper water channel substrate  1  is provided with a water inlet  4 , and four corners at a bottom of the upper water channel substrate  1  are provided with a first water outlet  21 , a second water outlet  22 , a third water outlet  23  and a fourth water outlet  24  correspondingly. 
     As shown in  FIGS. 8 and 9 , a top of the front water channel substrate  2  is provided with a second water inlet  16  communicating with the first water outlet  21 , and a bottom of the front water channel substrate  2  is provided with a fifth water outlet  26 . A middle part of an inner side of the front water channel substrate  2  is provided with a front supporting slide block  25 . 
     As shown in  FIG. 10 , a top of the left water channel substrate  3  is provided with a third water inlet  15  communicating with the second water outlet  22 , and a bottom of the left water channel substrate  3  is provided with a sixth water outlet  27 . 
     As shown in  FIGS. 11 and 12 , a top of the rear water channel substrate  8  is provided with a fourth water inlet  18  communicating with the third water outlet  23 , and a bottom of the rear water channel substrate  8  is provided with a seventh water outlet  28 . A middle part of an inner side of the rear water channel substrate  8  is provided with a rear supporting slide block  30 . 
     As shown in  FIGS. 13 and 14 , a top of the right water channel substrate  39  is provided with a fifth water inlet  17  communicating with the fourth water outlet  24 , a bottom of the right water channel substrate  39  is provided with an eighth water outlet  29 . A middle part of an inner side of the right water channel substrate  39  is provided with a tenth water outlet  31  and a tenth water inlet  32 . In another embodiment, a middle part of an inner side of the left water channel substrate  3  is provided with the tenth water outlet  31  and the tenth water inlet  32 . 
     As shown in  FIG. 15 , a front end and a rear end of the intermediate water channel substrate  20  are fixed on the box structure by the front support slide block  25  and the rear support slide block  30  correspondingly. A left end or a right end of the intermediate water channel substrate  20  is provided with an eleventh water inlet  33  communicating with the tenth water outlet  31  and an eleventh water outlet  34  communicating with the tenth water inlet  32 , and a water channel is arranged inside the intermediate water channel substrate  20 . 
     As shown in  FIGS. 16 and 17 , a top of the lower water channel substrate  40  is provided with a sixth water inlet  35  communicating with the fifth water outlet  26 , a seventh water inlet  36  communicating with the sixth water outlet  27 , an eighth water inlet  37  communicating with the seventh water outlet  28  and a ninth water inlet  38  communicating with the eighth water outlet  29 . A bottom of the lower water channel substrate  40  is provided with a ninth water outlet  7 . 
     According to the box type cooling structure of the controller, cooling liquid enters via the first water inlet  4  of the upper water channel substrate  1 , and enters each water channel substrate via the first water outlet  21 , the second water outlet  22 , the third water outlet  23 , the fourth water outlet  24 , the second water inlet  16  of the front water channel substrate  2 , the third water inlet  15  of the left water channel substrate  3 , the fourth water inlet  18  of the rear water channel substrate  8  and the fifth water inlet  17  of the right water channel substrate  39  respectively. The intermediate water channel substrate  20  is provided in the middle of the controller, the cooling liquid in the right water channel  39  substrate can enter the intermediate water channel substrate  20  through the eleventh water inlet  33  of the intermediate water channel substrate  20 , and then flows back into the right water channel substrate  39  from the eleventh water outlet  34 . the cooling liquid in the front water channel substrate  2  flows out via the fifth water outlet  26 , the cooling liquid in the left water channel substrate  3  flows out via the sixth water outlet  27 , the cooling liquid in the rear water channel substrate  8  flows out via the seventh water outlet  28  and the cooling liquid in the right water channel substrate  39  flows out via the eighth water outlet  29 , and finally all the cooling liquid flows into the lower water channel substrate  40  via the sixth water inlet  35 , the seventh water inlet  36 , the eighth water inlet  37  and the ninth water inlet  38  on the lower water channel substrate  40 , and flows out via the nine water outlet  7 . the IGBT module, the capacitor and the inductor are located in the controller, and the cooling liquid passes through water channels in the water substrates and cools the IGBT module, the capacitor and the inductor. The three-phase output copper bar  9  is extended out from the three-phase output port  31  on the rear water channel substrate  8 , and the cooling liquid in the rear water channel substrate  8  cools the three-phase output copper bar  9 . 
     The six water channel substrates are connected through fasteners  10 , and the joints of the water channel substrates are sealed by sealant or seal rings. Insertion positions of each water inlet and each water outlet are sealed by seal rings. 
     Second Embodiment 
     As shown in  FIG. 18 , in a second arrangement manner of the controller, a first cavity  41  is formed between the intermediate water channel substrate  20  and the upper water channel substrate  1 , and the driving and controlling panel  11  and the film capacitor  19  are arranged inside the first cavity  41 . The intermediate water channel substrate  20  and the lower water channel substrate  40  form a second cavity  42 , and the IGBT module  12  is arranged inside the second cavity  42 . 
     Third Embodiment 
     In a third arrangement manner of the controller, among the six water channel substrates, the film capacitor  19  is arranged on one water channel substrate, and a plurality of IGBT modules  12  are arranged on the other water channel substrates. 
     As shown in  FIG. 19 , the film capacitor  19  is arranged on the front water channel substrate  2 , and the plurality of IGBT modules  12  are arranged on the lower water channel substrate. 
     As shown in  FIG. 20 , the film capacitor  19  is arranged on the front water channel substrate  2 , and the plurality of IGBT modules  12  are arranged on the upper water channel substrate  1 , the rear water channel substrate  8  and the lower water channel substrate  40 . 
     The above embodiments are only for illustrating the technical concept and features of the present application, and the purpose thereof is to enable a person skilled in the art to understand the contents of the present application and to implement the present application, and not to limit the scope of the present application. All modifications made according to the spirit of the main technical solution of the present application shall fall within the claimed scope of the present application.