DC-Link Capacitor Housing Cooling With Integrated Coolant Channels

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing cooling systems for DC-link capacitors in power inverters face challenges in efficiently managing thermal conductivity and require complex machining and casting designs, which complicate the routing of coolant and increase energy consumption.

Innovation Solution

A cooling system comprising a plastic capacitor housing with integrated coolant channels and a metal casting housing that directs coolant through specific openings, avoiding direct contact with the metal casting surfaces, forms an efficient coolant circuit that cools the capacitor and power module without a separate heat sink or thermal pad, utilizing the structural support of the capacitor housing for the power module.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If coolant channels are integrated into the capacitor housing and casting, then coolant routing is simplified and energy consumption is reduced, but the manufacturing complexity of the housing and casting increases

Engineering Contradiction:

Improveenergy consumption for coolingVSAvoidcoolant circuit configuration

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The patent integrates coolant channels directly into the capacitor housing and casting structure, merging the cooling function with the structural components. This eliminates the need for separate cooling systems and reduces energy consumption while simplifying the overall coolant routing path through the inverter assembly.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing and casting serve dual functions: providing structural support and enclosing components while simultaneously acting as heat dissipation pathways through integrated coolant channels. This multi-functionality reduces the need for additional dedicated cooling components and lowers energy consumption.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If the capacitor housing is formed of plastic and the casting is formed of metal, then the structural support is enhanced and thermal conductivity is improved, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvestructural supportVSAvoidhousing and casting fabrication

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent employs a composite construction where a plastic capacitor housing is integrated with a metal casting. The plastic provides electrical insulation and cost-effective manufacturing, while the metal casting provides enhanced structural support and superior thermal conductivity for heat dissipation, balancing strength requirements with manufacturing considerations.

Inventive Principle:

Principle #40Composite materials

3Temperature

If the coolant circuit is configured to avoid direct contact with metal casting surfaces, then thermal management efficiency is improved, but the complexity of the cooling system increases

Engineering Contradiction:

Improvethermal management efficiencyVSAvoidcoolant circuit design

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent configures the coolant circuit to make selective contact with specific surfaces - the plastic capacitor housing and specific metal surfaces - while avoiding direct contact with certain metal casting surfaces. This localized approach optimizes thermal management by directing coolant flow to areas where it provides maximum cooling efficiency while preventing unwanted thermal pathways.

Inventive Principle:

Principle #3Local quality

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

This configuration simplifies coolant routing, reduces energy consumption for cooling, and enhances the structural support for the power module, potentially increasing vehicle mileage and extending the lifespan of electrical components.

Implementation Method 1

For operational and lifetime purposes the DC-link capacitor has to be cooled down. Thermal conductivity can be used to cool the DC-Link capacitor.

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

The method further including directing coolant from a heat exchanger, through an inlet opening of the metal casting, and then through the capacitor housing.

Methodology Applied

Scientific EffectHeat exchanger: Heat Exchanger

Data Source

PatentUS11785737B2Systems and methods for cooling electronic components of a vehicle

Publication Date: 2023.10.10 DELPHI INT OPERATIONS LUXEMBOURG SARL

AI summary

A cooling system for a capacitor may include a housing for the capacitor, the housing comprising of a bottom surface, a top surface, and at least one side surface connecting the bottom surface and the top surface, the housing further including: a bottom inlet manifold and a bottom outlet manifold extending along the bottom surface; an inlet side channel extending along the side surface, the inlet side channel being in fluid communication with the bottom inlet manifold; an outlet side channel extending along the side surface, the outlet side channel being in fluid communication with the bottom outlet manifold; a top inlet manifold extending along the top surface, the top inlet manifold being in fluid communication with the inlet side channel; and a top outlet manifold extending along the top surface, the top outlet manifold being in fluid communication with the outlet side channel.