Closed Cooler Module Sinter Joining Without Flow Structure Damage
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Solution Overview
Problem
Existing methods for connecting power electronics modules to high-performance coolers using sintered connections are complex and can damage delicate flow structures, especially in closed coolers, requiring additional support structures and increased operational complexity.
Innovation Solution
A method involving the use of a glycol-filled coolant flow structure within a closed cooler module, combined with a sinter paste application and pressure/heat, allows for a stable sintered connection without needing additional support structures, using ethylene, propylene, or butylene glycol to maintain uniformity and stability during the sintering process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If sintered connections are used to connect power module to cooler, then thermal conductivity is improved, but flow structures inside the cooler are damaged due to high pressure
Solution Approach 1:
The patent applies preliminary action by filling the cooler with glycol before the sintering process. This pre-filled glycol provides internal support to the flow structures during the high-pressure sintering process, preventing damage while enabling the formation of strong sintered connections between the power module and cooler.
Solution Approach 2:
The glycol acts as an intermediary substance that serves dual purposes: it is the coolant for the system and simultaneously provides structural support during sintering. This intermediary role allows the process to achieve both high thermal conductivity through sintering and protection of flow structures.
2Reliability
If support structure is added to protect flow structure during sintering, then flow structure integrity is improved, but device complexity increases
Solution Approach 1:
The cooler serves itself by using its own coolant (glycol) to provide the necessary support during the sintering process. This self-service approach eliminates the need for external support structures, reducing device complexity while maintaining flow structure integrity.
Solution Approach 2:
The glycol performs multiple functions: it is both the operational coolant for heat removal and the support medium during manufacturing. This multi-functionality eliminates the need for separate support structures, simplifying the overall device design.
3Temperature
If closed cooler is used, then cooling efficiency is improved, but sintering process becomes complex requiring additional support structures
Solution Approach 1:
The closed cooler is prepared in advance by filling it with glycol before the sintering process. This preliminary action ensures that the glycol is present to provide support during sintering, enabling the use of closed coolers without requiring additional support structures or complex modifications to the sintering process.
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
Enables efficient and simplified connection of closed coolers to metal plates with improved thermal conductivity, reducing operational complexity and ensuring uniform sintered connections without deformation or damage to the cooler's flow structure.
Implementation Method 1
at least one glycol is introduced between the coolant flow structure... The glycol remains inside the housing... provides uniform support during the sintering process
Implementation Method 2
a sinter paste is applied... sintering is carried out to connect the metal plate and the first side of the housing. This is done using pressure and heat
Data Source
AI summary
The present invention relates to a method of connecting a cooler module (4) to a metal plate by a sintering process, wherein the cooler module (4) comprises a metallic housing (5) having a coolant inlet (7), a coolant outlet (8) and a first housing side (9), and within the housing (5) a coolant flow structure (6), and wherein the method comprises the steps of: introducing at least one glycol between the coolant flow structure (6), applying a sinter paste and sintering to join the metal plate and the first housing side (9) under pressure and temperature.