Capacitor Housing Assembly With Segmented Cooling Channels
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Solution Overview
Problem
The existing cooling water passage structures in motor controllers suffer from tolerance issues during machining, leading to water leakage and unstable coolant pressure, which negatively impacts the heat dissipation efficiency of power modules.
Innovation Solution
A housing assembly for a capacitor and electric drive assembly is designed with double-sided cooling channels and partitioning features to prevent coolant leakage, ensuring stable coolant flow and efficient heat dissipation for both capacitors and power devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooling water passage structure is provided around power modules, then heat dissipation effect is improved, but water leakage occurs due to machining tolerance problems
Solution Approach 1:
The cooling water passage is divided into multiple independent segments using partitioning walls. Each segment is sealed independently, so that if one segment has machining tolerance issues, leakage is contained to that segment only and does not affect the entire cooling system. This segmentation approach maintains heat dissipation effectiveness while improving reliability by isolating potential leakage points.
2Temperature
If cooling water passages are provided for power modules, then heat dissipation is improved, but coolant pressure becomes unstable due to leakage
Solution Approach 1:
By segmenting the cooling passages into isolated sections with partitioning walls, the system maintains consistent coolant pressure within each sealed segment. The partitioning prevents pressure loss from leakage, ensuring stable coolant flow and consistent pressure throughout the cooling system, thereby maintaining reliable heat dissipation performance.
3Reliability
If partitioning protrusions and grooves are added to divide cooling channels, then coolant leakage is prevented, but device complexity increases
Solution Approach 1:
The partitioning walls are integrated directly into the housing structure, combining the sealing function with the structural framework. This merging approach prevents coolant leakage through effective partitioning while avoiding the need for separate, complex sealing components, thus improving reliability without excessively increasing device complexity.
4Temperature
If double-sided cooling channels are used for capacitors, then cooling efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The housing structure serves multiple functions simultaneously: it provides mechanical support, contains the capacitor, and forms the cooling channels on both sides. This multi-functionality allows double-sided cooling to be achieved without adding separate cooling components, thereby improving cooling efficiency while keeping manufacturing complexity manageable through structural integration.
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 housing assembly achieves higher cooling efficiency for capacitors and power devices through double-sided cooling, prevents coolant leakage, and reduces pressure loss, thereby enhancing the power density and performance of motor controllers.
Implementation Method 1
first cooling channels are formed respectively between the upper cover plate and an upper side surface of the intermediate housing and between the lower cover plate and a lower side surface of the intermediate housing
Implementation Method 2
first cooling channels are formed respectively between the upper cover plate and an upper side surface of the intermediate housing and between the lower cover plate and a lower side surface of the intermediate housing
Data Source
AI summary
A housing assembly of a capacitor and an electric drive assembly are provided. The housing assembly comprises an upper cover plate, an intermediate housing and a lower cover plate. The upper cover plate and/or the lower cover plate are provided with a first liquid inlet and a first liquid outlet. First cooling channels are formed respectively between the upper cover plate and an upper side surface of the intermediate housing and between the lower cover plate and a lower side surface of the intermediate housing, and second cooling channels are formed respectively between an outer side surface of the upper cover plate and power devices and between an outer side surface of the lower cover plate and power devices. The first cooling channel comprises a partitioning protrusion and a partitioning groove provided in the first cooling channel and extending in a length direction of the intermediate housing, and the partitioning protrusion extends into the partitioning groove and divides the first cooling channel into a first liquid inflow cooling channel and a first liquid outflow cooling channel. The housing assembly can realize the simultaneous cooling of the capacitor and the power devices, and can also prevent the occurrence of water leaking between the water passages, and the cooling and heat dissipation effect is better.