Configurable Power Inverter With Soft Switching and Liquid Cooling
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Solution Overview
Problem
In electrified vehicles, existing power conversion equipment faces challenges in synchronizing switching devices for AC power generation, leading to potential equipment damage and inefficiencies due to excess thermal energy, which also increases the weight and size of the equipment, hindering space efficiency and flexibility.
Innovation Solution
A configurable power inverter module with switching circuitry that can generate single-phase, two-phase, or three-phase AC power, incorporating switch controllers for soft turn on and zero-current switching, and a heatsink with liquid cooling provisions to manage thermal energy, using semiconductor materials like silicon carbide or gallium nitride for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional switching devices are used for AC power generation, then power conversion can be achieved, but excess thermal energy is generated causing equipment damage and inefficiency
Solution Approach 1:
The patent changes the material parameter of the switching devices from conventional silicon-based semiconductors to wide bandgap semiconductor materials (such as silicon carbide or gallium nitride). This material parameter change enables the devices to operate at higher temperatures with lower on-resistance and higher breakdown voltage, thereby reducing thermal energy loss during switching operations while improving overall equipment reliability under thermal stress
Solution Approach 2:
The patent converts the harmful thermal energy that would normally be wasted into a manageable parameter by implementing liquid cooling provisions directly integrated with the switching devices. The cooling system captures and removes the thermal energy, transforming it from a harmful byproduct into a controlled thermal management process, thereby preventing equipment damage while maintaining high efficiency operation
2Reliability
If traditional power conversion equipment is used, then power conversion function is provided, but weight and size increase reducing space efficiency
Solution Approach 1:
The patent merges multiple functions into a single integrated module: the wide bandgap switching devices, the liquid cooling system, and the power conversion circuitry are combined into one compact unit. This integration eliminates the need for separate cooling systems and discrete components, significantly reducing overall equipment weight and volume while maintaining reliable power conversion functionality
Solution Approach 2:
The use of wide bandgap semiconductor materials changes the operational parameters of the power conversion equipment, allowing it to operate at higher frequencies and voltages. This enables the use of smaller magnetic components and capacitors, thereby reducing the overall size and weight of the equipment while maintaining or improving conversion reliability
3Productivity
If conventional switching devices are used, then power conversion is achieved, but equipment size and weight increase
Solution Approach 1:
The patent changes the material composition parameter to wide bandgap semiconductors, which enable higher switching frequencies and更高效 power conversion. This parameter change allows for the reduction of passive component sizes (inductors, capacitors) and enables more compact equipment design while improving power conversion efficiency
Solution Approach 2:
The patent introduces liquid cooling provisions that add a thermal management dimension to the power conversion system. By implementing direct liquid cooling channels integrated with the switching devices, the system achieves high efficiency power conversion in a compact volume by efficiently managing thermal energy in a dedicated cooling dimension rather than requiring large heat dissipation surfaces
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 and flexible power conversion with reduced thermal issues, enhancing the reliability and longevity of power conversion equipment while minimizing weight and size, thus improving space efficiency and reducing logistical support needs.
Implementation Method 1
a heatsink, coupled to the switching circuitry, to receive thermal energy generated by the switching circuitry
Implementation Method 2
the heatsink of the electronics module includes provisions for liquid cooling of the heatsink
Implementation Method 3
switching circuitry arranged to convert DC input power into single-phase, two-phase, or three-phase alternating current output power
Implementation Method 4
transistor elements that utilize a semiconductor material having a band gap of at least 2.5 electron volts. In particular embodiments, the semiconductor material includes silicon carbide or gallium nitride
Implementation Method 5
the substrate to accommodate one or more capacitive devices to provide DC-link capacitance between a DC input power portion, which is a portion of the DC input power, and an AC output power portion
Data Source
AI summary
Subject matter disclosed herein may relate to electronic systems, devices, and/or modules such as a power inverter that is configurable and may have input power ports to receive the direct current voltage, a plurality of output power ports to provide single-phase, two-phase, or phase alternating current power, and signal ports to receive commands to select single-phase, two-phase, or three-phase alternating current power.