Power module cooling system

Abstract

The embodiment of the invention relates to a power module cooling system. In particular, some embodiments of the present disclosure relate to a power module cooling system having a structure for creating three-dimensional vortices and rollovers in a liquid coolant flowing within a chamber of the cooling system. Other embodiments may be disclosed or claimed.

Description

Technical Field

[0001] The present disclosure relates to a power module cooling system. In particular, embodiments of the present disclosure relate to a power module cooling system having a structure for generating three-dimensional vortices and tumbles in a liquid coolant flowing in a chamber of the cooling system. Background Art

[0002] Power modules are used in a variety of different systems and applications. For example, in electric or hybrid vehicles, power modules are often used in conjunction with a multi-level inverter system coupled between the vehicle's battery and electric motor.

[0003] In many applications, power modules (particularly power modules with relatively high power dissipation) require a liquid cooling system to function. Embodiments of the present disclosure provide a power module cooling system with enhanced capabilities to increase thermal conductivity, facilitate efficient manufacturing, and allow multiple power modules to be cooled with a single cooling system to reduce the overall power module footprint in space-constrained applications (e.g., in vehicles). Summary of the invention

[0004] In an exemplary embodiment, a power module cooling system is provided. The power module cooling system includes a housing having a chamber defined by a top, a bottom opposite to the top, and a plurality of sides. The power module cooling system also includes an inlet for allowing liquid coolant to enter the chamber, an outlet for allowing the liquid coolant to leave the chamber, a first set of fins extending from the top into the chamber, and a second set of fins extending from the bottom into the chamber, wherein the first set of fins does not contact the bottom, the second set of fins does not contact the top, and the first set of fins overlaps the second set of fins in both a first plane and a second plane orthogonal to the first plane.

[0005] In addition to one or more features described herein, the housing has an external portion, the top external portion is adapted to be coupled to a first power module, and the bottom external portion is adapted to be coupled to a second power module, wherein the power module cooling system cools the first power module and the second power module simultaneously as liquid coolant passes through the first set of fins and the second set of fins between an inlet and an outlet within the chamber.

[0006] In addition to one or more features described herein, the liquid coolant swirls and tumbles as the liquid coolant passes through the first set of fins and the second set of fins between the inlet and the outlet within the chamber.

[0007] In addition to one or more features described herein, the housing has a length between a first side and a second side opposite the first side, a width between a third side and a fourth side opposite the third side, and a height between the top and the bottom.

[0008] In addition to one or more features described herein, the inlet is in the first side and the outlet is in the second side, or the inlet is in the top and the outlet is in the bottom.

[0009] In addition to one or more features described herein, the length is greater than the width, and wherein the inlet is in the third side, and the outlet is in the fourth side.

[0010] In addition to one or more features described herein, at least one of: a connection between at least one fin in the first set of fins and the top portion is rounded; and a connection between at least one fin in the second set of fins and the bottom portion is rounded.

[0011] In addition to one or more features described herein, the housing includes a plurality of inlets and a plurality of outlets.

[0012] In another exemplary embodiment, a power module cooling system includes a housing having an outer portion and a chamber defined by a top, a bottom opposite to the top, and a plurality of sides. The power module cooling system includes an inlet for allowing liquid coolant to enter the chamber, an outlet for allowing liquid coolant to leave the chamber, a first set of fins extending from the top into the chamber, and a second set of fins extending from the bottom into the chamber. The first set of fins does not contact the bottom, the second set of fins does not contact the top, and the first set of fins overlaps the second set of fins in both a first plane and a second plane orthogonal to the first plane. The outer portion of the top is suitable for coupling to a first power module, the outer portion of the bottom is suitable for coupling to a second power module, and when the liquid coolant passes through the first set of fins and the second set of fins between the inlet and the outlet in the chamber, the power module cooling system cools the first power module and the second power module simultaneously.

[0013] In addition to one or more features described herein, the liquid coolant swirls and tumbles as the liquid coolant passes through the first set of fins and the second set of fins between the inlet and the outlet within the chamber.

[0014] In addition to one or more features described herein, the housing has a length between a first side and a second side opposite the first side, a width between a third side and a fourth side opposite the third side, and a height between the top and the bottom.

[0015] In addition to one or more features described herein, the inlet is in the first side and the outlet is in the second side, or the inlet is in the top and the outlet is in the bottom.

[0016] In addition to one or more features described herein, the length is greater than the width, and wherein the inlet is in the third side, and the outlet is in the fourth side.

[0017] In addition to one or more features described herein, at least one of: a connection between at least one fin in the first set of fins and the top portion is rounded, and a connection between at least one fin in the second set of fins and the bottom portion is rounded.

[0018] In addition to one or more features described herein, the housing includes a plurality of inlets and a plurality of outlets.

[0019] In another exemplary embodiment, a vehicle includes a first power module, a second power module, and a power module cooling system. The power module cooling system includes a housing having an outer portion and a chamber defined by a top, a bottom opposite to the top, and a plurality of sides. The power module cooling system includes an inlet for allowing liquid coolant to enter the chamber, an outlet for allowing liquid coolant to leave the chamber, a first set of fins extending from the top into the chamber, and a second set of fins extending from the bottom into the chamber. The first set of fins does not contact the bottom, the second set of fins does not contact the top, and the first set of fins overlaps the second set of fins in both a first plane and a second plane orthogonal to the first plane. The outer portion of the top is adapted to be coupled to the first power module, the outer portion of the bottom is adapted to be coupled to the second power module, and when the liquid coolant passes through the first set of fins and the second set of fins between the inlet and the outlet in the chamber, the power module cooling system simultaneously cools the first power module and the second power module.

[0020] In addition to one or more features described herein, the liquid coolant swirls and tumbles as the liquid coolant passes through the first set of fins and the second set of fins between the inlet and the outlet within the chamber.

[0021] In addition to one or more features described herein, the housing has a length between a first side and a second side opposite the first side, a width between a third side and a fourth side opposite the third side, and a height between the top and the bottom.

[0022] In addition to one or more features described herein, the inlet is in the first side and the outlet is in the second side, or the inlet is in the top and the outlet is in the bottom.

[0023] In addition to one or more features described herein, the length is greater than the width, and wherein the inlet is in the third side, and the outlet is in the fourth side.

[0024] The above features and advantages and other features and advantages of the present disclosure are apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Other features, advantages and details appear, by way of example only, from the following detailed description, which refers to the accompanying drawings, in which:

[0026] Figure 1 is a schematic diagram of a vehicle for use in conjunction with embodiments of the present disclosure;

[0027] Figure 2 is a schematic diagram of an inverter system according to an embodiment of the present disclosure;

[0028] Figure 3A is a side view of a system according to an embodiment of the present disclosure;

[0029] Figure 3B The embodiment according to the present disclosure is shown Figure 3A A top view of the power module cooling system in FIG.

[0030] Figure 4A is an example of a perspective view of a power module cooling system according to an embodiment of the present disclosure;

[0031] Figure 4B According to the embodiment of the present disclosure Figure 4A A partial cross-sectional perspective view of a power module cooling system;

[0032] Figure 4C According to the embodiment of the present disclosure Figure 4A Another partial cross-sectional perspective view of the power module cooling system in FIG.

[0033] Figure 5A is a side view of another power module cooling system according to an embodiment of the present disclosure; and

[0034] Figure 5B According to the embodiment of the present disclosure Figure 5A Top view of the power module cooling system in Figure 1. DETAILED DESCRIPTION

[0035] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate the same or corresponding parts and features.

[0036] Embodiments of power module cooling systems are described herein. Among other things, embodiments of the present disclosure help achieve three-dimensional swirls and tumbles of liquid coolant through the cooling system to increase thermal conductivity relative to other cooling systems. Embodiments of the present disclosure also provide overlapping patterns of fins that can be efficiently manufactured and can be used to cool multiple power modules simultaneously. Although embodiments of the present disclosure are described herein with reference to the cooling of power modules, alternative embodiments of the cooling system can be used to cool other components and systems. In addition, the cooling system of the present disclosure can be used to cool one or more different components (e.g., single-sided or double-sided cooling of power modules or other components).

[0037] The novel power module cooling system of the present disclosure allows for enhanced liquid cooling of power modules by providing three-dimensional cooling channels to generate complex swirl and tumble flows in orthogonal planes, thereby increasing thermal conductivity and reducing pumping pressure drops and losses. Some embodiments of the present disclosure may also provide a symmetrical structure to help promote efficient manufacturability and cost reduction. Embodiments also allow power modules to be mounted on both sides of the cooling system to reduce system size and increase power density, which is beneficial to systems such as multi-level inverters (for electric vehicles and hybrid vehicles) with relatively high switch counts.

[0038] Reference now Figure 1 , shows a schematic diagram of a vehicle 100 for use in conjunction with one or more embodiments of the present disclosure. In this example, a power module cooling system 150 is located near a battery pack used to power an electric motor to propel the vehicle.

[0039] Figure 2 is a schematic diagram of an inverter system 200 according to an embodiment of the present disclosure. In this example, the inverter system 200 (shown from the side) includes a power module cooling system 150 having a first power module 210 coupled to the top of the power module cooling system 150 and a second power module 220 coupled to the bottom of the power module cooling system 150. In this example, the power modules 210, 220 of the inverter system 200 are coupled to a capacitor 230, which in turn is coupled to a high voltage energy storage system (not shown), such as a battery pack of the vehicle 100. At box 240, the power modules 210, 220 are also coupled to an electric motor of the vehicle 100.

[0040] Figure 3A 3 is a side view of a system according to an embodiment of the present disclosure. In this example, the system 300 (viewed from the side) includes a power module cooling system 150, which includes a housing having a chamber 152, the chamber 152 being defined by a top 155, a bottom 165 opposite the top 155, and a plurality of sides (not shown in this cutaway side view). Figure 3AA flow 310 of liquid coolant is shown entering the chamber 152 through an inlet (not shown) in the left side wall of the cooling system 150 and about to flow through an outlet (not shown) in the right side wall of the cooling system. The cooling system 150 includes a first set of fins 160 extending from the top 155 into the chamber 152, and a second set of fins 170 extending from the bottom 165 into the chamber 152. As shown, the first set of fins 160 does not contact the bottom 165, and the second set of fins 170 does not contact the top 155. The first set of fins 160 are arranged in a first plane (e.g., Figure 3A ) and a second plane orthogonal to the first plane (e.g., Figure 3B The fins 170 overlap with the second set of fins 170 in both the XY plane shown in the top view of the cooling system in FIG. In alternative embodiments, the fins of the cooling system need not be parallel or orthogonal to each other, but may be formed at any suitable angle relative to each other.

[0041] Figure 3B The embodiment according to the present disclosure is shown Figure 3A 1. In this example, the left figure shows a top view of the first set of fins 160 in the chamber 152 (e.g., at the same Figure 3A The middle figure shows a top view of the second set of fins 170 within the chamber 152. The right figure shows the assembly of the first set of fins 160 and the second set of fins 170 within the chamber 152 to form overlapping alternating sets of fins. Figure 3B Also shown is the flow 360 of the liquid coolant in the XY plane, as shown in FIG. Figure 3A 310 of the liquid coolant in the XZ plane. In addition, the cooling system 150 causes the flows 310, 360 in the liquid coolant to generate eddies and tumbles in the liquid coolant as it passes through the chamber 152 between the inlet and the outlet, thereby increasing the thermal conductivity of the cooling system 150 relative to a system that causes the liquid coolant to flow in only two dimensions.

[0042] Figure 4A4 is an example of a perspective view of a power module cooling system 400 according to an embodiment of the present disclosure. In this example, the cooling system 400 includes a housing having an elongated structure having a chamber 152 formed by a top 155, a bottom 165, a first side 410, a second side 420 opposite the first side 410, a third side 430, and a fourth side 440 opposite the third side 430. The housing of the cooling system 400 has a length between the first side 410 and the second side 420, a width between the third side 430 and the fourth side 440 (where the length is greater than the width), and a height between the top 155 and the bottom 165. In alternative embodiments, the lengths of 410 and 420 may be longer than the lengths of 430 and 440.

[0043] As shown in this example, multiple power modules may be simultaneously cooled by cooling system 400 , such as power modules 210 and 212 coupled to top portion 155 and power modules 220 and 222 coupled to bottom portion 165 . Figure 4B yes Figure 4A FIG. 4 is a partial cross-sectional perspective view of a power module cooling system 400 , and FIG. Figure 4C Provided Figure 4A Another partial cross-sectional perspective view of the power module cooling system 400 in FIG.

[0044] The power module cooling system disclosed herein, for example Figure 4A The cooling system 400 in FIG. 4 may include any suitable number of inlets and outlets to allow liquid coolant to enter and exit the cooling system, respectively. Various embodiments may have different numbers of inlets and outlets, different sizes of inlets, different sizes of outlets, and different sizes of inlets relative to the outlets. The inlets and outlets may be formed in the housing of the cooling system horizontally, vertically, or at any suitable angle. For example, in some embodiments, the direction and angle of the inlets and outlets may be optimized to minimize pumping losses and maximize flow.

[0045] For example, in some embodiments, the power module cooling system 400 may include one or more inlets in the first side 410 and one or more outlets 420 in the second side to flow the liquid coolant along the length of the cooling system 400. Alternatively, the cooling system 400 may include one or more inlets in the third side and one or more outlets in the fourth side to flow the liquid coolant across the width of the cooling system 400. In alternative embodiments, the inlets and outlets may be formed in the top 155 and the bottom 165.

[0046] Figure 5A is a side view of another power module cooling system 500 according to an embodiment of the present disclosure. Figure 5B yes Figure 5A1. A top view of a power module cooling system 500 in FIG. 1. The fins 160, 170 may have any suitable dimensions (e.g., length, width, height) and may be formed from any suitable material to help optimize thermal conductivity. In some embodiments, as Figure 5A and Figure 5B As shown in the illustrated example, the power module cooling system 500 may include one or more fins that are rounded at their respective connections to the top or bottom. Figure 5A A fin 160 is shown extending from a top 155 having a rounded connection on one side of the fin 160 (and an angled connection on the other side) and a fin 170 is shown extending from a bottom 165 having rounded connections on both sides of the fin 170 .

[0047] in addition, Figure 5A and Figure 5B The cooling system 500 in can generate vertical turbulence, in part for flow and turbulence optimization. For example, the cooling system 500 provides an open vertical flow, in which the cooling modules 210, 220 are not positioned until the respective front edges 210a, 220a of the power modules 210, 220. Among other things, this helps to provide a lower pressure drop within the chamber of the cooling system 500 and increase vertical turbulence. The cooling system 500 can also close the vertical flow and only allow flow in the XY plane at a position below the power modules 210, 220 to help partially increase the flow and turbulence in the XY plane. In the example shown in FIG. 5, the "o" symbol represents the flow of liquid coolant in the X direction, and the "+" symbol represents the flow of liquid coolant in the opposite X direction.

[0048] In some embodiments, the flow rate of the liquid coolant in the cooling system of the present disclosure can be optimized by adjusting the total cross-sectional area of ​​the flow path of the coolant. In some embodiments, this can be achieved by adjusting the spacing between the fins 160, 170.

[0049] The term "one" does not indicate a limitation of quantity, but rather indicates the presence of at least one of the referenced items. Unless the context clearly indicates otherwise, the term "or" means "and / or". References to "aspects" throughout the specification mean that a particular element (e.g., a feature, structure, step, or characteristic) described in conjunction with that aspect is included in at least one aspect described herein, and may or may not be present in other aspects. In addition, it should be understood that the described elements may be combined in any suitable manner in the various aspects.

[0050] When an element such as a layer, film, region, or substrate is referred to as being "on" another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being "directly on" another element, there are no intervening elements present.

[0051] Unless otherwise indicated herein, all test standards are the most current standards in effect as of the filing date of this application or, if priority is claimed, the filing date of the earliest priority application in which the test standards appear.

[0052] Unless defined otherwise, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.

[0053] Although the above disclosure has been described with reference to exemplary embodiments, it will be appreciated by those skilled in the art that various changes may be made and equivalents may be substituted for its elements without departing from its scope. In addition, many modifications may be made to adapt specific circumstances or materials to the teachings of the disclosure without departing from the basic scope of the disclosure. Therefore, it is intended that the disclosure is not limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A power module cooling system, comprising: a housing having a chamber defined by a top, a bottom opposite the top, and a plurality of sides; an inlet that allows liquid coolant to enter the chamber; an outlet allowing the liquid coolant to exit the chamber; a first set of fins extending from the top into the chamber; as well as A second set of fins extends from the bottom into the chamber, wherein the first set of fins does not contact the bottom, the second set of fins does not contact the top, and the first set of fins overlaps the second set of fins in both a first plane and a second plane orthogonal to the first plane.

2. The power module cooling system according to claim 1, wherein: The housing has an outer portion, the outer portion of the top portion is adapted to be coupled to a first power module, and the outer portion of the bottom portion is adapted to be coupled to a second power module, wherein the power module cooling system cools the first power module and the second power module simultaneously as the liquid coolant passes through the first set of fins and the second set of fins between the inlet and the outlet within the chamber.

3. The power module cooling system according to claim 1, wherein: As the liquid coolant passes through the first and second groups of fins between the inlet and the outlet in the chamber, the liquid coolant swirls and tumbles.

4. The power module cooling system according to claim 1, wherein: The housing has a length between a first side and a second side opposite to the first side, a width between a third side and a fourth side opposite to the third side, and a height between the top and the bottom.

5. The power module cooling system according to claim 4, wherein: The inlet is in the first side and the outlet is in the second side, or the inlet is in the top and the outlet is in the bottom.

6. The power module cooling system according to claim 4, wherein: The length is greater than the width, and wherein the inlet is in the third side and the outlet is in the fourth side.

7. The power module cooling system according to claim 1, wherein: At least one of the following: A connection between at least one fin of the first set of fins and the top portion is rounded; and The connection between at least one fin of the second set of fins and the bottom is rounded.

8. The power module cooling system according to claim 1, wherein: The housing includes a plurality of inlets and a plurality of outlets.

9. A power module cooling system, comprising: a housing having an exterior portion and a chamber defined by a top, a bottom opposite the top, and a plurality of sides; an inlet that allows liquid coolant to enter the chamber; an outlet allowing the liquid coolant to exit the chamber; a first set of fins extending from the top into the chamber; as well as a second set of fins extending from the bottom into the chamber, wherein the first set of fins does not contact the bottom, the second set of fins does not contact the top, and the first set of fins overlaps the second set of fins in both a first plane and a second plane orthogonal to the first plane, wherein an outer portion of the top is adapted to be coupled to a first power module, an outer portion of the bottom is adapted to be coupled to a second power module, and wherein the power module cooling system cools the first power module and the second power module simultaneously as the liquid coolant passes through the first set of fins and the second set of fins between the inlet and the outlet within the chamber.

10. A vehicle comprising: A first power module; A second power supply module; as well as Power module cooling system, including: a housing having an exterior portion and a chamber defined by a top, a bottom opposite the top, and a plurality of sides; an inlet that allows liquid coolant to enter the chamber; an outlet allowing the liquid coolant to exit the chamber; a first set of fins extending from the top into the chamber; and a second set of fins extending from the bottom into the chamber, wherein the first set of fins does not contact the bottom, the second set of fins does not contact the top, and the first set of fins overlaps the second set of fins in both a first plane and a second plane orthogonal to the first plane, wherein an outer portion of the top is adapted to be coupled to a first power module, an outer portion of the bottom is adapted to be coupled to a second power module, and wherein the power module cooling system cools the first power module and the second power module simultaneously as the liquid coolant passes through the first set of fins and the second set of fins between the inlet and the outlet within the chamber.

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