On board power device and thermal management system
The present disclosure discloses an onboard power device and a thermal management system, wherein the thermal management system comprises the onboard power device which comprises a power assembly comprising a plurality of electronic components and a shell comprising an inner cavity and a coolant passage that are isolated from each other, wherein the power assembly is disposed in the inner cavity which is filled with insulating heat conductive fluid, the power assembly being immersed in the insulating heat conductive fluid, and wherein a coolant flows through the coolant passage. The present disclosure allows the power assembly to be sufficiently and uniformly cooled by immersing in insulating heat conductive fluid, and by circulating coolant in the coolant passage of the onboard power device.
1 . An onboard power device, comprising:
a power assembly comprising a plurality of electronic components;
a shell comprising an inner cavity and a coolant passage that are isolated from each other, wherein the power assembly is disposed in the inner cavity which is filled with insulating heat conductive fluid, the power assembly is immersed in the insulating heat conductive fluid, and a coolant flows through the coolant passage; and
an expandable air cushion,
wherein the shell comprises an inner cavity cover plate and a housing, and
wherein the expandable air cushion is mounted between the inner cavity cover plate and the housing and adjacent to the inner cavity cover plate, enabling to adjust a volume change caused by thermal expansion and contraction of the insulating heat conductive fluid.
2 . The onboard power device according to claim 1 , wherein
the shell comprises passage cover plate, wherein the inner cavity cover plate is assembled with the housing to form the inner cavity, and the housing is assembled with the passage cover plate to form the coolant passage, and
the coolant passage is formed in a bottom of the housing, and the inner cavity is formed above the coolant passage.
3 . The onboard power device according to claim 2 , wherein
the passage cover plate is connected to the bottom of the housing via a friction stir welding (FSW); and/or,
the inner cavity cover plate is detachably connected to the housing via a detachable connector.
4 . The onboard power device according to claim 2 , wherein
a circumferential edge of the expandable air cushion is fitted to and sealed with an air cushion groove provided correspondingly on at least one of the housing and the inner cavity cover plate.
5 . The onboard power device according to claim 1 , further comprising:
a liquid injection hole disposed at a side of the shell and communicated with the inner cavity,
wherein a top surface of the liquid injection hole is higher than a top surface of the inner cavity.
6 . The onboard power device according to claim 1 , further comprising at least one of:
a coolant inlet and a coolant outlet that are communicated with the coolant passage, wherein the coolant inlet and the coolant outlet are provided on the same side or on the opposite sides of the shell; and,
a heat conductive fluid inlet and a heat conductive fluid outlet that are communicated with the inner cavity, wherein the heat conductive fluid inlet and the heat conductive fluid outlet are disposed on opposite sides of the shell.
7 . The onboard power device according to claim 2 , wherein
the power assembly comprises an onboard charger module which comprises a main circuit board on which a transformer is provided, and
wherein a portion of the coolant passage extends toward the inner cavity to form a transformer groove in the inner cavity, the transformer on the main circuit board being disposed in the transformer groove, a first portion of the coolant passage passing through a bottom of the transformer, and a second portion of the coolant passage passing through a side of the transformer.
8 . The onboard power device according to claim 7 , wherein
a power switch is further provided on the main circuit board,
wherein the onboard charger module further comprises a PFC circuit board on which an inductor is provided,
wherein the power switch is erectly fixed on a side wall of the coolant passage and connected to the coolant passage through a heat conductive interface material, and
wherein a portion of the housing extends toward the inner cavity to form an inductive groove in the inner cavity, the inductor on the PFC circuit board is disposed in the inductive groove.
9 . The onboard power device according to claim 8 , wherein
the transformer is encapsulated in the transformer groove through a potting glue and the outer wall of the transformer groove and an exposed portion of the transformer are naturally cooled through the insulating heat conductive fluid; and/or,
the inductor is encapsulated in the inductive groove through the potting glue, and the outer wall of the inductive groove and an exposed portion of the inductor are naturally cooled through the insulating heat conductive fluid.
10 . The onboard power device according to claim 8 , wherein
the onboard charger module further comprises a control circuit board, an EMI circuit board and a shielding plate, and the main circuit board and the PFC circuit board are mounted under the control circuit board;
the EMI circuit board and the shielding plate are mounted under the control circuit board, and the shielding plate is disposed between the EMI circuit board and the control circuit board;
the EMI circuit board, the shielding plate, and the control circuit board are stacked from bottom to top to form a stacked structure, and in a width direction of the shell, the main circuit board is disposed adjacent to one side wall of the housing, the stacked structure is disposed adjacent to another side wall of the housing, and the PFC circuit board is disposed between the main circuit board and the stacked structure.
11 . The onboard power device according to claim 1 , wherein
the insulating heat conductive fluid is oil or a fluorinated liquid, and the coolant is an ethylene glycol solution; and
the inner cavity is filled with the insulating heat conductive fluid, and the power assembly is completely immersed in the insulating heat conductive fluid.
12 . The onboard power device according to claim 1 , wherein
the power assembly comprises at least one of an onboard charger module, a battery module, an inverter module, and a DCDC power conversion module.
13 . A thermal management system, comprising:
a plurality of onboard power devices according to claim 1 ;
the inner cavity of each of the plurality of onboard power devices is communicated with each other to form a first cooling loop, and the insulating heat conductive fluid flows through the first cooling loop via a driving of a first pump; and/or,
the coolant passage of each of the plurality of onboard power device is communicated with each other to form a second cooling loop, and the coolant flows through the second cooling loop via a driving of a second pump.
14 . The thermal management system according to claim 13 , wherein
in the first cooling loop, each of the plurality of onboard power devices is connected to a flow branch in parallel, and the heat conductive fluid inlet of each of the plurality of onboard power devices is connected to a corresponding flow branch through a controllable branching valve which is used for adjusting a flow rate of the insulating heat conductive fluid flowing through the inner cavity of each of the plurality of onboard power devices according to a load condition of each of the plurality of onboard power devices.
15 . The thermal management system according to claim 13 , further comprising at least one of:
a first cooler communicated with the first cooling loop; and,
a second cooler communicated with the second cooling loop;
wherein in a case where the thermal management system comprises both the first cooler and the second cooler, the first cooler and the second cooler are separated individual coolers; or, the first cooler and the second cooler are integrated together.
16 . The thermal management system according to claim 13 , wherein a plurality of the onboard power devices are provided, wherein the power assembly of each of the plurality of onboard power devices comprises at least one of a battery module, an inverter module, an onboard charger module, and a DCDC power conversion module.
17 . The onboard power device according to claim 2 , wherein
the power assembly comprises an onboard charger module which comprises a main circuit board on which a transformer is provided,
wherein a bottom surface of the inner cavity is planar, and
wherein the transformer is directly immersed in the insulating heat conductive fluid, so that a direct contact cooling is performed through a natural convection of the insulating heat conductive fluid.
18 . The onboard power device according to claim 17 , wherein
a power switch is further provided on the main circuit board,
wherein the onboard charger module further comprises a PFC circuit board on which an inductor is provided,
wherein the power switch is directly immersed in the insulating heat conductive fluid, so that the direct contact cooling is performed through a natural convection of the insulating heat conductive fluid, and
wherein the inductor on the PFC circuit board is directly immersed in the insulating heat conductive fluid, so that a direct contact cooling is performed through a natural convection of the insulating heat conductive fluid.
19 . The thermal management system according to claim 13 , wherein the second cooling loop further comprises a solenoid valve for adjusting a flow rate of the coolant flowing through the second cooling loop.
20 . A thermal management system, comprising:
a plurality of onboard power devices, each of which comprises a power assembly comprising a plurality of electronic components, and a shell comprising an inner cavity and a coolant passage that are isolated from each other, wherein the power assembly is disposed in the inner cavity which is filled with insulating heat conductive fluid, and the power assembly is immersed in the insulating heat conductive fluid,
wherein a power assembly of each of the plurality of onboard power devices comprises at least one of a battery module, an inverter module, an onboard charger module, and a DCDC power conversion module, and
wherein the inner cavity of each of the plurality of onboard power devices is in fluid communication with the inner cavity of other onboard power devices to form a first cooling loop, and the insulating heat conductive fluid flows through the first cooling loop via a driving of a first pump,
wherein the power assembly comprises an onboard charger module which comprises a main circuit board on which a transformer is provided,
wherein a portion of the coolant passage extends toward the inner cavity, or a bottom surface of the inner cavity is planar, and
wherein a portion of the coolant passage extends toward the inner cavity to form a transformer groove in the inner cavity, the transformer on the main circuit board being disposed in the transformer groove, a first portion of the coolant passage passing through a bottom of the transformer, and a second portion of the coolant passage passing through a side of the transformer; or, the transformer being directly immersed in the insulating heat conductive fluid, so that a direct contact cooling is performed through a natural convection of the insulating heat conductive fluid.