Cold-Spray Liquid Cooler Bonding for EV Power Module Heat Dissipation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional liquid-cooling coolers for electric vehicles fail to meet the high heat dissipation demands of power modules, leading to temperature exceedance and potential damage.
Innovation Solution
A large-size liquid-cooling cooler with a liquid-cooling cooler body and cold spray coating bonding interface layers, featuring a projection area greater than 150 cm², thickness between 0.03 mm and 0.25 mm, and 30 μm to 90 μm roughness, designed for efficient heat transfer and bonding with power modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional liquid-cooling coolers are used for heat dissipation, then the structure is simple and easy to manufacture, but the heat dissipation capacity is insufficient for high-power power modules
Solution Approach 1:
The cooler body is divided into multiple cooling flow channels instead of a single channel, allowing cooling fluid to flow through multiple paths simultaneously. This segmentation increases the total heat exchange area and improves heat dissipation capacity while maintaining a relatively simple overall structure
Solution Approach 2:
The patent transitions from conventional two-dimensional cooling surfaces to three-dimensional cooling flow channels embedded within the cooler body. The channels extend through the thickness of the cooler, creating a volumetric heat exchange structure that significantly increases heat dissipation capacity without proportionally increasing external dimensions
2Temperature
If bonding interface layer is made thinner to reduce thermal resistance, then heat transfer efficiency improves, but bonding strength and structural stability deteriorate
Solution Approach 1:
The patent optimizes the bonding interface layer thickness to a specific range (0.03-0.25 mm) that balances thermal resistance and mechanical strength. Additionally, the surface roughness is controlled within 30-90 μm to enhance both thermal contact and bonding adhesion, demonstrating parameter optimization to resolve the contradiction
Solution Approach 2:
The bonding interface layer uses cold spray coating technology to create a composite structure with enhanced properties. The coating combines good thermal conductivity with adequate mechanical strength, allowing the layer to be thin for heat transfer while maintaining sufficient bonding strength through the specialized coating material and process
3Power
If cooling flow channel height is increased to improve cooling efficiency, then heat dissipation performance improves, but the cooler body thickness and overall size increase
Solution Approach 1:
Instead of using a single tall cooling channel, the patent divides the cooling function into multiple smaller flow channels arranged in parallel. This segmentation allows heat to be dissipated across multiple channels with reduced height, improving cooling efficiency without increasing the cooler body thickness
Solution Approach 2:
The patent compensates for reduced channel height by increasing the number of channels and optimizing their lateral arrangement. The cooling efficiency is maintained through increased channel count and optimized flow distribution across the cooling surface, rather than relying on increased channel height
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
Enhances heat dissipation, improves bonding strength, and extends product stability and service life by effectively removing heat from power modules.
Implementation Method 1
The at least one bonding interface layer is a cold spray coating layer formed on the liquid-cooling cooler body by cold spraying and corresponds in position to the cooling flow channel
Implementation Method 2
a cooling flow channel is formed inside the liquid-cooling cooler body for allowing cooling fluid to flow through the cooling flow channel
Data Source
AI summary
A large-size liquid-cooling cooler for an electric vehicle includes a liquid-cooling cooler body and at least one bonding interface layer. The liquid-cooling cooler body has a projection area greater than 150 cm2, and a cooling flow channel is formed inside the liquid-cooling cooler body for allowing cooling fluid to flow through the cooling flow channel. The at least one bonding interface layer is a cold spray coating layer formed on the liquid-cooling cooler body by cold spraying and corresponds in position to the cooling flow channel. A projection area of the at least one bonding interface layer is greater than 30 cm2, a thickness of the at least one bonding interface layer is between 0.03 mm and 0.25 mm, and a ten-point average roughness (Rz) of a surface of the at least one bonding interface layer is from 30 μm to 90 μm.