High power density DC-AC power inverter

• US 10,143,117 B2
• Filed: 04/06/2017
• Issued: 11/27/2018
• Est. Priority Date: 04/06/2017
• Status: Active Grant

• Current Assignee: Chyng Hong Electronic Co., Ltd.
• Original Assignee: Chyng Hong Electronic Co., Ltd.
• Inventors: Lin, Mu-Chun
• Primary Examiner(s): Pape, Zachary
• Application Number:
  US15/480,706
• Publication Number:
  US 20180295755A1
• Time in Patent Office: 600 Days
• Field of Search: 361695, 165 801- 802, 257721-722
• CPC Class Codes: H01L 23/467 by flowing gases, e.g. air H01L23/473 takes precedence
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H02M 7/44 by static converters
• CPC Class Codes: H05K 7/1492 having electrical distribution arrangements, e.g. power supply or data communications
• CPC Class Codes: H05K 7/20909 Forced ventilation, e.g. on heat dissipaters coupled to components
• CPC Class Codes: H05K 7/20918 the components being isolated from air flow, e.g. hollow heat sinks, wind tunnels or funnels

Abstract

A high power density DC-AC power inverter includes a casing corresponding to a rack. The casing has air inlets and air outlets arranged in a honeycomb shape and a fan unit. The casing is provided with two choke coils and a heat sink therein. The heat sink includes fins facing downward. A plurality of power elements are laterally provided on top of the heat sink. The heat generated from the power elements can be conducted to the fins of the heat sink quickly. The fan unit guides the outside air to the heat sink and the choke coils through the air inlets, and the heat is smoothly expelled out of the casing through the air outlets of the casing. The power inverter in a high density configuration still has a good heat dissipation effect.

Claims

1. A high power density DC-AC power inverter, mounted to a rack, the high power density DC-AC power inverter comprising:

a casing, corresponding in size to the rack and having a rectangular shape, a front side of the casing being formed with a plurality of air inlets, a rear side of the casing being formed with a plurality of air outlets, a bottom of the casing being provided with a bottom plate;

a fan unit, disposed at one side of the casing, for guiding outside cold air to enter the casing via the air inlets and discharge to the outside via the air outlets in a guide direction;

a heat sink, disposed in the casing, the heat sink including a plurality of spaced fins, the fins each having a long side parallel to the guide direction;

a plurality of power elements, each having a heat dissipation surface, the heat dissipation surfaces of the power elements being laterally attached to the heat sink;

a circuit board module, laterally disposed above the heat sink and electrically connected with the power elements;

when the power inverter is actuated, the power elements generate heat and the heat is conducted to the fins of the heat sink via a shortest route, the fan unit guides the outside cold air into the casing via the air inlets of the casing to pass through the fins of the heat sink for heat dissipation, and the heat is expelled out of the casing via the air outlets of the casing;

a wind scooper disposed in the casing, the wind scooper being located between the fan unit and the heat sink, the wind scooper having a guide entrance adjacent to the fan unit and a guide exit adjacent to the heat sink for guiding the outside air from the air inlets to the fins of the heat sink, the wind scooper further having a plurality of guide holes adjacent to the power elements, the guide holes being located above the heat sink, the guide entrance of the wind scooper being greater than the guide exit and the guide holes, the guide exit being greater than the guide holes; and

a choke coil module disposed in the casing, the choke coil module including a retainer, the retainer including an upper plate and a lower plate which are laterally disposed, the lower plate being fixed to a bottom of the casing.

2. The high power density DC-AC power inverter as claimed in claim 1, wherein the upper plate being located above the lower plate and fixedly connected to the lower plate through a plurality of longitudinal locking rods so that the retainer is formed with an accommodation space between the upper plate and the lower plate, the upper plate and the lower plate each having two slots, the choke coil module including two choke coils in the accommodation space of the retainer, the choke coils being disposed in the accommodation space of the retainer in a staggered manner and slanting from bottom to top toward the rear side of the casing, top portions and bottom portions of the choke coils protruding out of and leaning against the slots of the upper plate and the lower plate, respectively.

3. The high power density DC-AC power inverter as claimed in claim 1, wherein the circuit board module includes a power element circuit board, a drive board, and a control board, wherein the power element circuit board, the drive board and the control board are superposed from bottom to top and spaced from each other to form a gap and are electrically connected.

4. The high power density DC-AC power inverter as claimed in claim 1, wherein the rear side of the casing is provided with a rear panel, the rear panel is formed with the air outlets, wherein a lower edge of the rear panel is bent inwardly to form a connecting portion, and the connecting portion is overlapped with the bottom plate of the casing so that a portion of the air outlets is located at the junction of the rear panel and the bottom plate.

5. The high power density DC-AC power inverter as claimed in claim 1, wherein the air inlets and the air outlets are arranged in a honeycomb shape.

6. The high power density DC-AC power inverter as claimed in claim 1, wherein the fan unit is disposed in the casing close to the air inlets.

7. The high power density DC-AC power inverter as claimed in claim 1, wherein the power elements are metal oxide semiconductor field effect transistors.