Bidirectional Isolated DC-DC Converter Assembly with Integrated Cooling
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Solution Overview
Problem
Conventional low voltage DC-DC converters in vehicles are unidirectional, failing to meet the increasing demand for bidirectional power transfer between high and low voltage stages, leading to space and efficiency issues when attempting to integrate both boosting and bucking functions in a single package.
Innovation Solution
A high power density bidirectional isolated DC-DC converter assembly is designed with a parallel configuration of buck and boost circuits, along with an optimized cooling structure, to efficiently package and cool the components, minimizing internal space and utilizing components in common across stages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a bidirectional LDC capable of both bucking and boosting functions is integrated into a single package, then power transfer capability is improved, but device complexity increases
Solution Approach 1:
The patent merges the buck circuit and boost circuit into a single integrated LDC package, allowing bidirectional power transfer between high voltage and low voltage stages. The circuits share common components including transformer, switching devices, and magnetic components, eliminating the need for separate mounting of boost type LDC and buck type LDC.
Solution Approach 2:
The LDC circuit is designed with universal components that serve multiple functions. The transformer and magnetic components are used in both bucking mode (high voltage to low voltage) and boosting mode (low voltage to high voltage), allowing a single device to perform both power conversion directions.
2Volume of moving object
If components are implemented as a single package, then space efficiency is improved, but internal dead space utilization becomes difficult
Solution Approach 1:
The patent employs a nested arrangement where the cooling passage is integrated within the housing structure, and magnetic components are positioned to utilize the dead space between other components. The cooling passage winds through the internal structure, effectively using the space between power electronic components.
Solution Approach 2:
The cooling passage is designed to utilize the third dimension (vertical space) by winding through the housing structure. The passage extends from the bottom surface through the internal components to the top surface, effectively using the height dimension to cool all components without increasing the footprint area.
3Temperature
If a cooling structure is added to the integrated LDC package, then cooling efficiency is improved, but device complexity increases
Solution Approach 1:
The cooling structure is designed to self-regulate by utilizing the natural flow of coolant through the passage. The housing structure itself serves as part of the cooling system, with the passage integrated directly into the mounting structure, eliminating the need for additional active cooling components.
Solution Approach 2:
The patent employs a liquid cooling system where coolant flows through a dedicated passage within the housing. The hydraulic flow of coolant absorbs heat from the power electronic components and magnetic components, efficiently removing thermal energy from the integrated package.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables efficient power transfer in both buck and boost modes while reducing component count, material costs, and space requirements, enhancing cooling efficiency and reducing the overall size and weight of the converter module.
Implementation Method 1
a cooling passage extending from a bottom surface of the housing to a top surface of the housing along an internal dead space of the housing so as to cool the power electronic components and the magnetic components
Data Source
AI summary
The present disclosure relates to a high electric power density bidirectional isolated low voltage DC-DC converter (LDC) assembly, in which a large-capacity bidirectional isolated LDC circuit is packaged in consideration of a flow of electric power so as to use components in common and minimize an internal dead space, and a cooling structure thereof. LDC assembly includes a power board subassembly (100) including the high voltage stage, a part of the buck circuit, and the boost circuit; a transformer subassembly (200) including a transformer of the buck circuit; an output power board subassembly (300) including a part of the buck circuit; and an EMC filter subassembly (400) including an EMC filter included in the low voltage stage.