Vehicle power electronics cooler with integrated heating element

Abstract

A cooler for power electronics, comprising: a housing having a cooling surface configured for contact with the power electronics; an inlet and an outlet coupled to the housing; a manifold inside the housing providing a flow of coolant within the cooler, the manifold being coupled to the inlet and the outlet; and a heating element mounted on the housing and configured to heat the coolant, the heating element being controlled independently of the power electronics.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application claims priority to U.S. Patent Application No. 18 / 338,865, filed on June 21, 2023, titled "VEHICLE POWER ELECTRONICS COOLER WITH INTEGRATED HEATING ELEMENT", the disclosure of which is hereby incorporated by reference in its entirety.

[0002] This document relates to a vehicle power electronics cooler with an integrated heating element.

Background Art

[0003] Power electronics are used in a variety of situations. In an electric vehicle (EV), power electronics can be used in the vehicle's on - board charger, current converter, junction box, and / or heater control components. Power electronics generate heat, which may need to be managed. Current power electronics coolers may not be flexible enough for today's EV requirements.

Summary of the Invention

[0004] In one aspect, a cooler for power electronics includes a housing having a cooling surface configured for contact with the power electronics; an inlet and an outlet coupled to the housing; a manifold inside the housing that provides a flow of coolant within the cooler, the manifold being coupled to the inlet and the outlet; and a heating element attached to the housing and configured to heat the coolant, the heating element being independently controlled from the power electronics.

[0005] The implementation may include any or all of the following features: The heating element is located downstream in the flow of the coolant from the inside of the cooling surface. The heating element is located inside the manifold. The heating element is U-shaped with two arms parallel to each other. The heating element is located on the outer surface of the housing. The manifold has (i) an inlet manifold coupled to the inlet, (ii) an outlet manifold coupled to the outlet, and (iii) a coolant passage coupled to the inlet manifold and the outlet manifold, the coolant passage being partially formed by the inside of the cooling surface. The cooler further comprises a structure inside the coolant passage for influencing the flow. The manifold is configured such that a first flow direction of the flow inside the coolant passage is substantially perpendicular to a second flow direction of the flow in the inlet manifold and a third flow direction of the flow in the outlet manifold. The second and third flow directions are opposite to each other. The second and third flow directions are a common flow direction. The manifold further comprises a channel structure housing the heating element, wherein the fourth flow direction of the flow within the channel structure is opposite to the second and third flow directions. The heating element comprises a plurality of arms parallel to each other, and the channel structure has a channel for each of the plurality of arms. The channel structure includes a first channel and a second channel, which are formed on both sides of a raised portion on the inside of the manifold, and the housing further comprises a member covering the channel structure to form the first and second channels. The coolant passage is located between the heating element and the inside of the cooling surface. After passing through the outlet manifold in the third flow direction, the coolant makes a substantially 180-degree turn and flows along the heating element in the fourth flow direction. The housing has a substantially rectangular shape, including first and second parallel long sides and first and second parallel short sides. The inlet is located on the first short side, and the outlet is located on the second short side.The heating element is located on the second short side. The heating element has a coil comprising a plurality of turns. The inlet is located on the first short side, and the outlet is located on the first short side. The housing further has a plurality of openings in the coolant passage, the openings of which lead to channels housing the heating element. The cooler further comprises mounts on the cooling surface, the mounts configured to attach the power electronics and the cooler to each other. [Brief explanation of the drawing]

[0006] [Figure 1] An example of a cooler for power electronics is shown.

[0007] [Figure 2] Figure 1 shows the first example of an exploded view of the cooler.

[0008] [Figure 3] Figure 2 shows an exemplary cross-section of the cooler.

[0009] [Figure 4] Figure 2 shows an example of coolant flow in a cooler. [Figure 5] Figure 2 shows an example of coolant flow in a cooler.

[0010] [Figure 6] Figure 2 shows an exemplary cross-section of the cooler.

[0011] [Figure 7] Figure 2 shows an example of the base of a cooler equipped with an inlet, outlet, heating element, and turbulator.

[0012] [Figure 8] The first example of the flow within the cooler is shown.

[0013] [Figure 9] Figure 8 shows a second example of the flow inside the cooler.

[0014] [Figure 10] An example of a heating element is shown.

[0015] [Figure 11] An example of a cooler equipped with the heating element of FIG. 10 is shown.

[0016] [Figure 12] An example of a cooler is shown.

[0017] [Figure 13] An exemplary cross-section of the cooler of FIG. 12 is shown.

[0018] [Figure 14] An example of a cooler is shown.

[0019] [Figure 15] An exemplary cross-section of the cooler of FIG. 14 is shown.

[0020] [Figure 16] A second example of an exploded view of the cooler of FIG. 1 is shown.

[0021] Like reference numerals in the various drawings indicate like elements.

Best Mode for Carrying Out the Invention

[0022] This document describes examples of systems and techniques for providing power electronics coolers with integrated heating elements. In some implementations, the cooler may provide a structural chassis (cooler plate) on which the power electronics are mounted. The cooler plate may allow coolant flow to maintain the temperature of critical power electronics components in a system such as an EV, while the integrated heating element may, if necessary, heat the outflowing coolant to provide supplemental heat to other systems in the vehicle. The heating element may be implemented in a manner that maximizes heating / cooling efficiency based on packaging requirements. In some implementations, the heating element is located entirely downstream of the cooling plate. In some implementations, the coolant may extend beyond the heating element along its longitudinal spread. For example, this may maximize the coolant velocity over its entire length. The heating element may be positioned within the cooler based on the dimensions of the cooling surface of the power electronics and / or the location of the cooler's inlet or outlet. The heating element may have any of a variety of shapes, including but not limited to the examples shown herein. The heating element may be positioned alongside the cooling surface to maintain the planar shape of the cooler. Examples shown herein are illustrated by multiple drawings. Some of the figures in this drawing are shown partially transparent for clarity.

[0023] In some implementations, the heater may be integrated within a cooling plate used to cool the power electronics unit. Cooling of the component may occur via heat transfer into the coolant flowing through the joint surface of the cooling plate and through internal passages on the opposite side of where the component is placed in the cooling plate. A heating element integrated within the cooling plate, directly in the coolant, and / or on the external surface of the cooling plate may be operated (e.g., via control of an integrated heater) to heat the coolant flowing within the cooling plate to provide heat to other vehicle systems. Such other vehicle systems may include, but are not limited to, a passenger cabin heater core or a high-voltage battery. This subject may provide a solution for integrating coil heaters into cooling plates that maximizes cooling / heating and minimizes packaging space.

[0024] The examples described herein refer to power electronics. As used herein, power electronics includes any circuit that converts power using solid-state electronics (e.g., one or more semiconductor devices). In some implementations, power electronics may include an on-board charger for a vehicle. Power electronics may relate to direct current (DC). For example, power electronics may include a DC-DC converter (or simply DC-DC converter). Power electronics may relate to alternating current (AC). For example, power electronics may include an AC junction box. Power electronics may include one or more circuit boards with components (e.g., functioning as controllers).

[0025] The examples described herein refer to coolants. When used herein, a coolant includes any fluid used to regulate temperature. To name just one example, a coolant may include water (with one or more additives of optional choice). Coolants passing through coolers described herein may circulate in a thermal system. For example, such a system may also include one or more features for releasing heat, such as conduction, convection, and / or radiation.

[0026] Examples as used herein refer to vehicles. A vehicle is a machine that transports occupants, cargo, or both. A vehicle may have one or more motors that use at least one type of fuel or other energy source (e.g., electricity). Examples of vehicles include, but are not limited to, cars, trucks, and buses. The number of wheels may vary between types of vehicles, and one or more (e.g., all) of the wheels may be used for propulsion. A vehicle may include an occupant compartment that accommodates one or more people.

[0027] The examples described herein refer to the top, bottom, front, side, or rear. These and similar expressions relatively identify things or aspects based on an explicit or arbitrary concept of viewpoint. That is, these terms are merely illustrative and used for explanatory purposes and do not necessarily indicate the only possible position, direction, etc.

[0028] In the examples described herein, the term “joined” or variations thereof is used when describing how the first and second features are joined together. As used herein, being joined means that the features are in fluid communication with each other. In the above examples, the coolant may flow from the first feature to the second feature and / or from the second feature to the first feature.

[0029] The examples described herein describe two or more feature parts that are in contact with or in contact with each other. As used herein, "in contact" means that the feature parts are physically touching each other.

[0030] Figure 1 shows an example of a cooler 100 for power electronics. Figure 2 shows a first example of an exploded view of the cooler 100 of Figure 1. A second example of an exploded view of the cooler 100 is described later in this specification. The cooler 100 may be used in conjunction with one or more other examples described elsewhere in this specification.

[0031] The cooler 100 is configured for use in cooling at least one power electronics unit 102. The power electronics unit 102 is schematically shown herein and may include, but is not limited to, an on-board charger for an electric vehicle, a DC-DC converter, an AC junction box, a heater control unit, or an inverter. For example, the power electronics unit 102 may include, but is not limited to, one or more circuit boards, including printed circuit boards. The cooler 100 has a surface 104 configured for coupling to the power electronics unit 102 for cooling. The power electronics unit 102 is in contact with the surface 104. In some implementations, the surface 104 includes a mount 116 extending substantially perpendicular to the surface 104. The power electronics unit 102 may be configured for contact with the surface 104. For example, the power electronics unit 102 is in contact with the surface 104 by being mounted on part or all of the mount 116.

[0032] The cooler 100 may include at least one inlet pipe 106 and at least one outlet pipe 108, both coupled to the housing of the cooler 100. The inlet pipe 106 and outlet pipe 108 are configured to facilitate the flow of coolant through the cooler 100. Although only a single inlet and a single outlet are shown here, more than one inlet and / or more than one outlet may be used in certain non-limiting implementations described herein. The cooler 100 includes a cooling plate 110, which may provide a surface 104 such that the surface 104 faces the power electronics unit 102. For example, the inlet pipe 106 may be coupled to an inlet 112 in the cooling plate 110. In another example, the outlet pipe 108 may be coupled to an outlet 114 in the cooling plate 110. The terms inlet and outlet are used here merely as examples, and in some implementations, the coolant may instead enter the cooler 100 through the outlet 114 and exit the cooler 100 through the inlet 112.

[0033] In some implementations, the cooler 100 may include at least one of the mounts 116 configured for mounting the power electronics unit 102 and the cooler 100 to each other. For example, the mount 116 may include a metal or composite material member configured for mounting to the power electronics unit 102 and to the cooler 100 in order to position the power electronics unit 102 relative to the surface 104.

[0034] The cooler 100 includes a structure 118 configured to be positioned within the coolant passage of the cooler 100 so as to affect the flow of coolant through the cooler 100. The structure 118 may include holes or other structural features (e.g., placed at regular or irregular intervals) that can affect the flow of coolant. For example, the structure 118 may include turbulators, pin fin arrays, and / or punched plates (e.g., dimpled plates). That is, a cooler using a structure in the cooling passage may use any of several methods, including but not limited to punched dimples and / or forged pin fins.

[0035] The cooler 100 includes a member 120 configured for covering one or more channels inside the housing of the cooler 100. For example, the member 120 may include a plate of metal or composite material having a planar or non-planar shape (e.g., by punching).

[0036] The cooler 100 includes a heating element 122, which is mounted in a housing and configured to heat the coolant. The heating element 122 may be controlled independently of the power electronics unit 102. That is, the control of the heating element 122 may be linked to the operation of the power electronics unit 102 in its intended function, but the heating element 122 may be off when the power electronics unit 102 is on, or vice versa, or both the power electronics unit 102 and the heating element 122 may be on (or off) simultaneously. For example, the heating element 122 may generate heat and heat the coolant regardless of whether the power electronics unit 102 is operating or not. Any type of heating element may be used. In some implementations, the heating element 122 includes a resistance heater. For example, the heating element 122 is U-shaped with two arms parallel to each other. The heating element 122 is presented for illustrative purposes only. A number of other shapes and / or heating techniques may be used, including but not limited to planar heating elements, ceramic heating elements, coil heating elements, L-shaped heating elements, or tubular heating elements.

[0037] The coolant flowing through the cooler 100 may be used to remove heat generated by the power electronics unit 102, which would cause the temperature of the cooler to rise. Furthermore, a heating element 122 may be operated to further raise the temperature of the coolant. For example, this heating may be performed so that the coolant provides heat to other vehicle systems after it has passed through the cooler 100.

[0038] The cooler 100 includes a base 124. In some implementations, at least the cooling plate 110 and the base 124 may form the housing of the cooler 100. The cooling plate 110 and the base 124 may be configured to form a manifold inside the cooler 100, coupled to an inlet 112 and an outlet 114. The manifold is a closed volume except for the openings of the inlet 112 and the outlet 114. In some implementations, the base 124 includes a raised portion 126. For example, the raised portion 126 may be formed in a punching process. Channels 128A and 128B may be formed on either side of the raised portion 126. Channels 128A-128B may form a channel structure that houses a heating element 122. That is, if the heating element 122 includes, for example, multiple arms (as part of a U-shaped configuration), the channel structure may include (for example, consist of) a channel for each of the multiple arms. Member 120 may be configured for covering channel structures (e.g., channels 128A-128B). For example, this may ensure that each arm of the heating element 122 is housed in its respective channel, which provides a higher flow velocity on the surface of the heating element 122, and thus improves flow and / or heat transfer efficiency.

[0039] Figure 3 shows an exemplary cross-section of the cooler 100 of Figure 2. The cross-section is taken along line AA in Figure 1. The inlet 112 and outlet 114 are shown. Arrow 300 schematically indicates that the coolant enters the inlet 112 and flows into the inlet manifold 302 coupled to the inlet 112. The cooler 100 has a coolant passage 304 from which the coolant can flow out of the inlet manifold 302, as schematically indicated by arrow 306. The coolant passage 304 may be partially formed by the inside of the cooling surface of the cooler 100 (for example, the cooling surface may be surface 104 in Figure 1).

[0040] Cooler 100 has an outlet manifold 308 coupled to an outlet 114. Coolant passages 304 are coupled to an inlet manifold 302 and the outlet manifold 308. The coolant passages 304, the inlet manifold 302, and the outlet manifold 308 may collectively form the manifold of cooler 100, and the heating element 122 may be located inside the manifold. Coolant may flow into the outlet manifold 308 as schematically indicated by arrow 310. Cooler 100 includes a channel structure 312 that houses the heating element 122. The channel structure 312 may provide separate channels for multiple arms of the heating element 122. After the coolant passes through the outlet manifold 308 as indicated by arrow 310, the coolant makes a substantially 180-degree turn as schematically indicated by arrow 314 and flows along the heating element 122 as schematically indicated by arrow 316. Therefore, the heating element 122 is positioned downstream in the flow of coolant from the inside of the cooling surface of the cooler 100. A 180-degree turn is shown here, but this implementation is presented for illustrative purposes only. Any of a number of other configurations may be used. In some implementations, the flow path inside the cooling plate may have a different configuration, including but not limited to U-shaped, meandering, and / or cross-flow configurations.

[0041] Figures 4 and 5 show an example of coolant flow in the cooler 100 of Figure 2. For illustrative purposes, some elements are referenced from the description in Figure 3. Arrows 300 and 400 indicate that the coolant flows through the inlet and through the inlet manifold 302. Arrow 402 indicates that the coolant flows through the coolant passage 304. Arrow 404 indicates that the coolant flows through the outlet manifold 308. Arrows 500 and 502 indicate that the coolant flows through the channel structure 312 and exits through the outlet. Thus, the first flow direction of the flow inside the coolant passage in this example (e.g., arrow 402) is substantially perpendicular to the second flow direction of the flow in the inlet manifold (e.g., arrow 400) and the third flow direction of the flow in the outlet manifold (e.g., arrow 404). The second and third flow directions (e.g., arrows 400 and 404) may be common (i.e., the same) flow direction. After passing through the outlet manifold in the third flow direction, the coolant may make a substantially 180-degree turn and flow along the heating element in the fourth flow direction (e.g., arrow 500). The fourth flow direction of the coolant within the channel structure may be opposite to the second and third flow directions. In this example, the flow profiles represented by arrows 400, 402, 404, 500, and 502 may be characterized as triport shapes. Triport shapes (e.g., as shown) can offer a favorable balance between pressure loss and performance. Some implementations may use more or fewer branches than those shown here.

[0042] In this example, the housing of the cooler 100 has a substantially rectangular shape, with first and second parallel long sides and first and second parallel short sides. The inlet 112 is located on the first short side (here, on the right side in the illustration), and the outlet 114 is also located on the first short side. In other implementations, the housing of the cooler 100 may have a different shape.

[0043] Figure 6 shows an exemplary cross-section of the cooler 100 in Figure 2. The cross-section is taken along line BB in Figure 1. The channel structure 312 here includes channel 600 for arm 602 of heating element 122 and channel 604 for arm 606 of heating element 122. The coolant may flow through inlet manifold 302, through coolant passage 304, through outlet manifold 308, and finally through channels 600-604.

[0044] Figure 7 shows an example of the base of the cooler 100 of Figure 2, which includes an inlet 112, an outlet 114, a heating element 122, and a turbulator 700. The turbulator 700 is shown schematically here and is an example of a structure that may be positioned inside the coolant passage to influence flow and / or heat transfer.

[0045] Figure 8 shows a first example of flow within the cooler 800. The cooler 800 may be used in conjunction with one or more other examples described elsewhere in this specification. Arrows 802 and 804 indicate that the coolant flows through the inlet of the cooler 800 and through the inlet manifold of the cooler 800. Arrow 806 indicates that the coolant flows through the coolant passage. The coolant passage may be partially formed by the inside of the cooling surface of the cooler 800. Arrows 808 and 810 indicate that the coolant flows through the outlet manifold of the cooler 800 and exits through the outlet of the cooler 800. The coolant comes into contact with the heating element of the cooler 800 before exiting. For example, the heating element is located within the outlet manifold. In this first example, the flow direction at the inlet (e.g., arrows 802 and 804) is opposite to the flow direction at the outlet (e.g., arrows 808 and 810). Therefore, the heating element is positioned downstream in the flow of coolant from the inside of the cooling surface of the cooler 800.

[0046] Figure 9 shows a second example of the flow within the cooler 800 of Figure 8. Arrows 802 and 804 indicate that the coolant flows through the inlet of the cooler 800 and through the inlet manifold of the cooler 800. Arrow 806 indicates that the coolant flows through the coolant passage. Arrows 900 and 902 indicate that the coolant flows through the outlet manifold of the cooler 800 and exits through the outlet of the cooler 800. The coolant comes into contact with the heating element of the cooler 800 before exiting. For example, the heating element is located in the outlet manifold. In this second example, the flow direction at the inlet (e.g., arrows 802 and 804) is the same as the flow direction at the outlet (e.g., arrows 900 and 902). The housing of the cooler 800 has a substantially rectangular shape with first and second parallel long sides and first and second parallel short sides. The entrance is located on the first short side (the left side in this diagram), and the exit is located on the second short side (the right side in this diagram).

[0047] Figure 10 shows an example of a heating element 1000. Figure 11 shows an example of a cooler 1100 with the heating element 1000 of Figure 10. The heating element 1000 and / or the cooler 1100 may be used in conjunction with one or more other examples described elsewhere in this specification. The heating element 1000 includes a coil with multiple turns and may be a resistance heating element. The heating element 1000 is located on the outer surface of the housing of the cooler 1100. Arrows 1102 and 1104 indicate that the coolant flows through the inlet of the cooler 1100 and through the inlet manifold of the cooler 1100. Arrow 1106 indicates that the coolant flows through the coolant passage. Arrow 1108 indicates that the coolant flows through the outlet manifold of the cooler 800 and comes into contact with the heating element 1000. Arrow 1110 indicates that the coolant exits through the outlet of the cooler 1100. Therefore, the heating element 1000 is positioned downstream in the flow of coolant from the inside of the cooling surface of the cooler 1100. In this example, the flow direction at the inlet (e.g., arrows 1102 and 1104) is opposite to the flow direction at the outlet (e.g., arrow 1108). The housing of the cooler 1100 has a substantially rectangular shape, with first and second parallel long sides and first and second parallel short sides. The inlet is located on the first short side (here on the left side in the illustration), and the heating element 1000 and the outlet are also located on the first short side.

[0048] Figure 12 shows an example of a cooler 1200. Figure 13 shows an exemplary cross-section of the cooler 1200 in Figure 12. The cross-section in Figure 13 is taken along the CC line in Figure 12. The cooler 1200 may be used in conjunction with one or more other examples described elsewhere in this specification. An inlet 1202 is shown, and the cooler 1200 here has an outlet pipe 1204 to an outlet 1206. Coolant enters the inlet 1202 and flows into an inlet manifold 1208 coupled to the inlet 1202, as indicated by arrow 1209. The cooler 1200 has a coolant passage 1210 from which coolant can flow out of the inlet manifold 1208, as indicated by arrow 1211. The coolant passage 1210 may be partially formed by the inside of the cooling surface of the cooler 1200 (for example, the cooling surface may be surface 104 in Figure 1). In this example, the flow direction at the inlet (e.g., arrow 1209) is opposite to the flow direction at the outlet (e.g., arrow 1216).

[0049] The cooler 1200 has an outlet manifold 1212 coupled to an outlet 1206. The coolant passage 1210 is coupled to an inlet manifold 1208 and to the outlet manifold 1212. The coolant can flow through the coolant passage 1210, over the heating element 1214, and into the outlet manifold 1212. The coolant passage 1210, the inlet manifold 1208, and the outlet manifold 1212 may collectively form the manifold of the cooler 1200, and the heating element 1214 may be located inside the manifold. After the coolant has passed through the outlet manifold 1212, the coolant can exit the cooler 1200 through the outlet 1206, as indicated by the arrow 1216. In some implementations, the outlet 1206 is instead located at the end of the cooler 1200 opposite the inlet 1202. Thus, the heating element 1214 is located downstream in the flow of coolant from the inside of the cooling surface of the cooler 1200. The housing of the cooler 1200 has a substantially rectangular shape, with first and second parallel long sides and first and second parallel short sides. The inlet 1202 is located on the first short side (here on the right side in the illustration), and the outlet 1206 is also located on the first short side.

[0050] Figure 14 shows an example of a cooler 1400. Figure 15 shows an exemplary cross-section of the cooler 1400 in Figure 14. The cross-section is taken along the line DD in Figure 14. The cooler 1400 may be used in conjunction with one or more other examples described elsewhere in this specification. An inlet 1402 is shown, and the cooler 1400 has an outlet pipe 1404 to an outlet 1406 here. Coolant enters the inlet 1402 and flows into an inlet manifold 1408 coupled to the inlet 1402, as indicated by arrow 1409. The cooler 1400 has a coolant passage 1410 from which coolant can flow out of the inlet manifold 1408, as indicated by arrow 1411. The coolant passage 1410 may be partially formed by the inside of the cooling surface of the cooler 1400 (for example, the cooling surface may be surface 104 in Figure 1). In this example, the flow direction at the inlet (e.g., arrow 1409) is opposite to the flow direction at the outlet (e.g., arrow 1416).

[0051] Cooler 1400 has an outlet manifold 1412 coupled to an outlet 1406. Coolant passage 1410 is coupled to an inlet manifold 1408 and the outlet manifold 1412. Coolant can flow through coolant passage 1410, through a number of openings 1413 within coolant passage 1410, over the heating element 1414, and into the outlet manifold 1412. That is, cooler 1400 has openings 1413 that lead to channels housing the heating element 1414. Coolant passage 1410, inlet manifold 1408, and outlet manifold 1412 may collectively form a manifold of cooler 1400, and the heating element 1414 may be located inside the manifold. After the coolant has passed through the outlet manifold 1412, it may exit cooler 1400 through outlet 1406, as indicated by arrow 1416. In some implementations, the outlet 1406 is instead located at the end of the cooler 1400 opposite the inlet 1402. Thus, the heating element 1414 is located downstream in the flow of coolant from the inside of the cooling surface of the cooler 1400. The housing of the cooler 1400 has a substantially rectangular shape with first and second parallel long sides and first and second parallel short sides. The inlet 1402 is located on the first short side (here on the left in the illustration), and the outlet 1406 is also located on the first short side.

[0052] Figure 16 shows a second example of an exploded view of the cooler 100 of Figure 1. Some components of the cooler are the same as or identical to those illustrated above in the description of Figure 2 and are not described in detail here. The cooler 100 is configured for use in cooling at least one power electronics unit. The cooler 100 has a surface 104, an inlet tube 106, an outlet tube 108, a cooling plate 110, an inlet 112, an outlet 114, a mount 116, a structure 118, and a base 124. The cooler 100 includes a heating element 1600 positioned on the outer surface of the housing and configured to heat the coolant. The heating element 1600 may be controlled independently of the power electronics unit. Any type of heating element may be used. In some implementations, the heating element 1600 includes a resistance heater. For example, the heating element 1600 may be substantially planar and positioned flat with respect to the outer surface of the heating element 1600.

[0053] The terms “substantially” and “about” as used throughout this specification are used to describe and account for small variations, such as those resulting from processing variability. For example, they may mean less than or equal to ±5%, less than or equal to ±2%, less than or equal to ±1%, less than or equal to ±0.5%, less than or equal to ±0.2%, less than or equal to ±0.1%, or less than or equal to ±0.05%. Also, as used herein, indefinite articles such as “a” or “an” mean “at least one.”

[0054] It should be understood that all combinations of the aforementioned concepts and any additional concepts discussed in more detail below (provided that such concepts are not mutually contradictory) are intended to be part of the subject matter of the invention disclosed herein. In particular, all combinations of the claimed subject matter appearing at the end of this disclosure are intended to be part of the subject matter of the invention disclosed herein.

[0055] Several implementations have been described. Nevertheless, it should be understood that various modifications may be made without deviating from the intent and scope of this specification.

[0056] Furthermore, the logical flow shown in the diagram does not require a specific or sequential order to achieve the desired result. In addition, other processes may be provided, or processes may be excluded from the described flow; other components may be added to or removed from the described system. Therefore, other implementations fall within the scope of the following claims.

[0057] While specific features of the described implementations have been shown as described herein, many modifications, substitutions, alterations, and equivalents will now come to mind for those skilled in the art. It should be understood that the appended claims are intended to encompass all such modifications and alterations that fall within the scope of the implementations. They are presented merely as examples and not as limitations, and it should be understood that various modifications may be made in form and detail. Any parts of the apparatus and / or methods described herein may be combined in any combination, except for mutually exclusive combinations. The implementations described herein may include various combinations and / or partial combinations of the functions, components, and / or features of the different implementations described.

Claims

1. A cooler for power electronics, A housing having a cooling surface configured for contact with the power electronics; Inlet and outlet connected to the housing; A manifold inside the housing provides the flow of coolant within the cooler, the manifold is coupled to the inlet and the outlet; and A heating element is attached to the housing and configured to heat the coolant, the heating element being controlled independently of the power electronics. A cooler equipped with a cooling system.

2. The cooler according to claim 1, wherein the heating element is positioned downstream in the flow of the coolant from the inside of the cooling surface.

3. The cooler according to claim 2, wherein the heating element is located inside the manifold.

4. The cooler according to claim 3, wherein the heating element is U-shaped and has two arms parallel to each other.

5. The cooler according to claim 2, wherein the heating element is arranged on the outer surface of the housing.

6. The cooler according to claim 1, wherein the manifold has (i) an inlet manifold coupled to the inlet, (ii) an outlet manifold coupled to the outlet, and (iii) a coolant passage coupled to the inlet manifold and the outlet manifold, the coolant passage being partially formed by the inside of the cooling surface.

7. The cooler according to claim 6, further comprising a structure inside the coolant passage for influencing the flow.

8. The cooler according to claim 6, wherein the manifold is configured such that the first flow direction of the flow inside the coolant passage is substantially perpendicular to the second flow direction of the flow in the inlet manifold and the third flow direction of the flow in the outlet manifold.

9. The cooler according to claim 8, wherein the second flow direction and the third flow direction are opposite to each other.

10. The cooler according to claim 8, wherein the second flow direction and the third flow direction are a common flow direction.

11. The cooler according to claim 10, wherein the manifold further comprises a channel structure for housing the heating element, and the fourth flow direction of the flow within the channel structure is opposite to the second and third flow directions.

12. The cooler according to claim 11, wherein the heating element comprises a plurality of arms parallel to each other, and the channel structure has a channel for each of the plurality of arms.

13. The cooler according to claim 12, wherein the channel structure includes a first channel and a second channel, the first channel and the second channel being formed on both sides of a raised portion on the inside of the manifold, and the housing further comprises a member covering the channel structure to form the first channel and the second channel.

14. The coolant passage is located between the heating element and the inside of the cooling surface, according to claim 10.

15. The coolant according to claim 14, wherein, after passing through the outlet manifold in the third flow direction, the coolant makes a substantially 180-degree turn and flows along the heating element in the fourth flow direction.

16. The cooler according to claim 6, wherein the housing has a substantially rectangular shape, including first and second parallel long sides and first and second parallel short sides.

17. The cooler according to claim 16, wherein the inlet is located on the first short side and the outlet is located on the second short side.

18. The cooler according to claim 17, wherein the heating element is located on the second short side.

19. The cooler according to claim 18, wherein the heating element has a coil including a plurality of turns.

20. The cooler according to claim 16, wherein the inlet is located on the first short side and the outlet is located on the first short side.

21. The cooler according to claim 6, wherein the housing further has a plurality of openings in the coolant passage, the plurality of openings being connected to channels for housing the heating element.

22. The cooler according to any one of claims 1 to 21, further comprising a mount on the cooling surface, wherein the mount is configured to attach the power electronics and the cooler to each other.

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