This application claims the benefit under 35 U.S.C. § 119(a) of Chinese Patent Application No. CN 202111664490.1, filed on Dec. 30, 2021, which application is incorporated herein by reference in its entirety.
When being charged, high-power chargers applied in the field of power tools generate a considerable amount of heat inside. If the generated heat cannot be dissipated in time, some important electronic elements in the high-power chargers will fail, thereby damaging the chargers and even battery packs.
A charger includes a housing formed with an air inlet and an air outlet; a fan disposed in the housing and used for generating a heat dissipation airflow entering from the air inlet and flowing out from the air outlet; and a circuit board assembly including at least heating elements which generate heat when energized. A heat dissipation channel for the heat dissipation airflow to flow through is provided in the housing and includes at least a first channel and a second channel which sequentially communicate with each other, at least part of the heating elements are disposed in the second channel, and a cross-sectional area of a first port of the first channel facing the air inlet is larger than a cross-sectional area of a second channel so that the heat dissipation airflow flowing through the first channel is capable of accelerating through the second channel.
In some examples, the first channel further includes a second port facing away from the air inlet, where the first port has a larger cross-sectional area than the second port.
In some examples, the fan is disposed between the air inlet and the second port of the first channel.
In some examples, the heat dissipation channel further includes a third channel communicating with the second channel, where the heat dissipation airflow sequentially flows through the first channel, the second channel, and the third channel.
In some examples, the third channel includes a third port away from the air outlet and a fourth port close to the air outlet, and the fourth port is disposed opposite to the air outlet.
In some examples, the fourth port of the third channel has a larger cross-sectional area than the third port of the third channel.
In some examples, the cross-sectional area of the first port of the first channel is larger than or equal to a cross-sectional area of the fourth port of the third channel.
In some examples, the charger further includes a deflector disposed in the housing and detachably connected to the housing.
In some examples, the deflector and the housing form the heat dissipation channel for guiding a flow direction of the heat dissipation airflow flowing into the housing.
In some examples, the fan has a fan air inlet facing the air inlet and a fan air outlet facing away from the air inlet, and approximately all of the heat dissipation airflow flowing out from the fan air outlet flows out of the heat dissipation channel.
In some examples, the fan includes an outer fan frame for fixedly mounting the fan to the housing and a shock-absorbing material is wrapped on an outer side of the outer fan frame.
In some examples, a ratio of a diameter of a blade of the fan to a distance between the fan air inlet and the air inlet is greater than or equal to 6.
In some examples, the circuit board assembly includes a circuit board and a heat dissipation member, where the circuit board is provided with a printed circuit, and the heat dissipation member is connected to the heating elements in a thermally conductive manner and used for dissipating the heat generated by the heating elements.
In some examples, the heating elements are power semiconductor devices or transformers, and the heat generated by the heating elements in a working process of the charger is greater than 0.1 kWh.
In some examples, output power of the charger is higher than or equal to 1200 W and lower than or equal to 1600 W.
In some examples, the charger further includes a charging device, and the charging device includes a charging gun for connection with tool interface of a riding mower and a charging cable for connecting the charging gun to a body of the charger.
In some examples, a combination includes a riding mower and a charger. The charger includes: a housing formed with an air inlet and an air outlet; a fan disposed in the housing and used for generating a heat dissipation airflow entering from the air inlet and flowing out from the air outlet; and a circuit board assembly including at least heating elements which generate heat when energized. A heat dissipation channel for the heat dissipation airflow to flow through is provided in the housing and includes at least a first channel and a second channel which sequentially communicate with each other, at least part of the heating elements are disposed in the second channel, and a cross-sectional area of a first port of the first channel facing the air inlet is larger than a cross-sectional area of a second channel so that the heat dissipation airflow flowing through the first channel is capable of accelerating through the second channel.
In some examples, output power of the charger is higher than or equal to 1200 W and lower than or equal to 1600 W.
In some examples, a combination includes a UTV and a charger. The charger includes: a housing formed with an air inlet and an air outlet; a fan disposed in the housing and used for generating a heat dissipation airflow entering from the air inlet and flowing out from the air outlet; and a circuit board assembly including at least heating elements which generate heat when energized. A heat dissipation channel for the heat dissipation airflow to flow through is provided in the housing and includes at least a first channel and a second channel which sequentially communicate with each other, at least part of the heating elements are disposed in the second channel, and a cross-sectional area of a first port of the first channel facing the air inlet is larger than a cross-sectional area of a second channel so that the heat dissipation airflow flowing through the first channel is capable of accelerating through the second channel.
In some examples, output power of the charger is higher than or equal to 1200 W and lower than or equal to 1600 W.
FIG.4 is a schematic diagram of a cross-sectional area of a first port of a first channel along a line A-A, and a schematic diagram of a cross-sectional area of a second channel along a line B-B;
The present application is described below in detail in conjunction with drawings and examples.
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The housing 10 is formed with an accommodation space 10a in which a fan 20 for generating a cooling airflow and a circuit board assembly 30 for implementing a charging function of the charger 100 are disposed. The fan 20 is disposed near the air inlet 15 and used for drawing air outside the housing 10 into the housing 10 via the air inlet 15 to generate the cooling airflow. The circuit board assembly 30 includes a circuit board 31, heating elements 32 disposed on the circuit board 31, and a heat dissipation member 33 connected to the heating elements 32 in a thermally conductive manner.
A printed circuit is disposed on the circuit board 31 and used for connecting, for example, resistors, capacitors, and corresponding semiconductor elements to implement the function of the charger 100. When energized, the heating elements 32 generate heat. Specifically, the heat generated by the heating elements 32 is greater than or equal to 0.1 kWh. The heating elements 32 are electrically connected to the circuit board 31. Multiple heating elements 32 of different types and different specifications may be disposed in the charger 100. In some examples, the heating elements 32 may be power semiconductor devices or transformers such as field-effect transistors and may be provided with weld legs to be welded onto the circuit board 31.
The heat dissipation member 33 is connected to the heating elements 32 in the thermally conductive manner to transfer out the heat generated by the heating elements 32 when energized. In some examples, the heat dissipation member 33 may be implemented in the form of a heat sink which may be a whole plate or multiple separate plates. Thermal conduction among the separate plates is cut off, and an optimal heat dissipation effect cannot be achieved. At least a part of the heat dissipation member 33 is in contact with surfaces of the multiple heating elements 32, and the heat generated by the multiple heating elements 32 is conducted to the heat dissipation member 33 according to the principle of thermal conduction and then dissipated under the action of the cooling airflow. In general, to enhance the heat dissipation effect of the heat dissipation member 33, a surface of the heat dissipation member 33 in contact with the multiple heating elements 32 is designed to have a plate structure so that a maximum contact area between the heat dissipation member 33 and the multiple heating elements 32 is obtained. In addition, one end of the heat dissipation member 33 is configured to be in the shape of a comb so that a maximum heat dissipation area is obtained. The heat dissipation member 33 may be disposed in the housing 10 of the charger 100. The heat dissipation member 33 may be exposed from the housing 10 and implement a heat dissipation function as a part of the housing 10. It is to be noted that the function of the heat dissipation member 33 in this example is to transfer, with the good thermal conductivity of the heat dissipation member 33, the heat generated by the multiple heating elements 32 to air, the preceding material and shape of the heat dissipation member 33 cannot limit the present application, and those skilled in the art should specifically configure the material and shape of the heat dissipation member 33 according to actual conditions.
In some examples, the charger 100 further includes a deflector 17 detachably disposed in the housing 10 and used for guiding a flow direction of the cooling airflow flowing into the housing 10 so that the heat dissipation efficiency of the charger 100 is improved. Specifically, the deflector 17 is disposed in the accommodation space 10a formed by the housing 10 and detachably connected to the upper housing 11. After the deflector 17 is fixedly mounted to the upper housing 11, the deflector 17, the lower housing 12, and part of the upper housing 11 constitute a heat dissipation channel 40 for the cooling airflow to flow through. It is to be noted that the deflector 17 in this example can be detachably connected to the upper housing 11 through assembly, and such design has the advantage of facilitating later maintenance such as reducing maintenance costs. On the other hand, the heat dissipation channel can be flexibly adjusted according to heat dissipation requirements so that different heat dissipation requirements are met. The deflector 17 may be configured to be integrally formed with the housing 10, which is not limited herein. The deflector 17 is configured to be made of the same material as the housing 10, such as plastics. The deflector 17 may be configured to be made of another material with good thermal conductivity, and the material of the deflector 17 is not limited in the present application.
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In some examples, the fan 20 may be disposed near the air outlet 16. When the charger 100 starts working, the fan 20 is started and under the action of the fan 20, the air outside the housing 10 enters the housing 10 from the air inlet 15, sequentially passes through the first channel 41, the second channel 42, and the third channel 43, flows through the fan 20, and finally flows out from the air outlet 16. After entering the housing 10 from the air inlet 15, the cooling airflow directly enters the heat dissipation channel 40. Since the cross-sectional area of the first port 411 of the first channel 41 is larger than the cross-sectional area of the second port 412, the cooling airflow gradually accelerates in the first channel 41 to rapidly flow through the second channel 42 and carry away the heat on the circuit board assembly 30.
In some examples, the circuit board assembly 30 is at least partially disposed in the second channel 42. Specifically, the heating elements 32 and the heat dissipation member 33 connected to the heating elements 32 in the thermally conductive manner are at least partially disposed in the second channel 32. In this manner, the cooling airflow enters the housing 10 from the air inlet 15, passes through the fan 20, flows through the first channel 41, enters the second channel 42, takes away the heat on the circuit board assembly 30 at least partially disposed in the second channel 42, flows through the third channel 43, and finally flows out of the housing 10 from the air outlet 16. Specifically, the third channel 43 has a third port 431 away from the air outlet 16 and the fourth port 432 close to the air outlet 16, where a cross-sectional area of the third port 431 is substantially the same as the cross-sectional area of the second channel 42, a cross-sectional area of the fourth port 432 is larger than the cross-sectional area of the third port 431, and further, the cross-sectional area of the fourth port 432 is smaller than or equal to the cross-sectional area of the first port 411. In this example, a ratio of the cross-sectional area of the fan air outlet 22 to the cross-sectional area of the second channel 42 is greater than or equal to 1 and less than or equal to 2. Specifically, the ratio of the cross-sectional area of the fan air outlet 22 to the cross-sectional area of the second channel 42 is 1.4. The cross-sectional area of the fan air outlet 22 is defined as an area of a circle having a blade of the fan 20 as a radius.
The charger 100 in this example is particularly suitable for charging battery packs of the large power tools or battery packs with large capacities. Output power of the charger in this example ranges from 1200 W to 1600 W. It is to be understood that the charger 100 has relatively high output power, the circuit board assembly 30 inevitably generates a relatively large amount of heat when energized, and therefore, the fan 20 for generating the cooling airflow must have a relatively high rotational speed to generate a large amount of air, causing noise with a relatively great influence. Specifically, when the output power of the charger 100 in this example can be as high as 1600 W, in order that the heat can be better dissipated so as to ensure that the charger can charge the battery pack normally and safely, preferably, the blade of the fan 20 has a diameter of 120 mm, and the rotational speed of the fan 20 is higher than or equal to 2000 rpm and lower than or equal to 3000 rpm. When the fan 20 rotates at a high speed, after the air enters the housing 10 from the air inlet 15, relatively loud noise is generated on the blade and a nearby inner wall of the housing due to the high-speed flow of the air, affecting user experience.
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In this example, a distance between the fan air inlet 21 and an inner wall 15a of the housing in the left and right direction is L1, where the inner wall 15a of the housing is disposed opposite to the air inlet 15. L1 can also be considered as a distance between the fan air inlet 21 and the air inlet 15. A blade 24 of the fan 20 has a diameter D1, and when a ratio of the diameter D1 of the blade to the distance L1 is greater than or equal to 6, the charger 100 generates lowest noise in operation. It is to be noted that it is relatively proper that the preceding ratio relationship is applicable to the case where only one fan is provided. In some other examples, multiple fans 20 are provided. In this case, those skilled in the art need to set a proper distance L1 according to actual conditions. The preceding distance L1 may be obtained through simulation or a relatively proper distance L1 may be obtained through data of multiple tests so that the charger 100 has less noise interference in operation. Further, in this example, a distance L1 between the fan air inlet 21 and the air inlet 15 in the left and right direction is set to be greater than or equal to 15 mm, the diameter D1 of the blade 24 is set to be 80 mm, and a distance L2 between the fan air outlet 22 and the circuit board 31 in the left and right direction is set to be greater than or equal to 10 mm. The charger 100 designed in this manner, in particular, the charger with the function of high-power output, can ensure a compact structure and low noise and has a relatively good heat dissipation effect and relatively good user experience so that on the basis of the own noise of the fan, the charger 100 can control, in the working process, the overall noise to be in a range of 10 dB or lower.
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Number | Date | Country | Kind |
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202111664490.1 | Dec 2021 | CN | national |