Vehicle Control Module Housing With Integrated Heat Sink and EMI Shielding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing control modules for hybrid and electric vehicles face challenges in efficiently managing heat dissipation, leading to the need for expensive, low-loss components and potential issues with electromagnetic interference (EMI) between transmission and power electronics.
Innovation Solution
A compact control module design featuring a housing with a heat sink integrated into the plastic sheathing, thermally and mechanically connected to the transmission control electronics, which includes a printed circuit board and electronic components, and a shield to reduce EMI and thermal interaction, utilizing thermal materials for efficient heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a separate cooling device is used for transmission control electronics, then heat dissipation is effective, but device complexity and cost increase
Solution Approach 1:
The patent combines the cooling function directly into the housing structure by integrating a heat sink with the housing upper part. This merging of the cooling device with the housing eliminates the need for separate cooling components, thereby reducing device complexity while maintaining effective heat dissipation for the transmission control electronics.
2Loss of energy
If expensive low-loss components are used, then energy loss is reduced, but cost increases
Solution Approach 1:
The patent converts the harmful heat generated by the transmission control electronics into a manageable thermal flow by directing it through an integrated heat sink to a coolant. This approach eliminates the need for expensive low-loss components by efficiently managing the heat at its source, thereby reducing energy loss without increasing cost.
3Volume of moving object
If transmission control electronics and converter electronics are placed close together, then device compactness is improved, but electromagnetic interference increases
Solution Approach 1:
The patent introduces a housing structure with an integrated heat sink as an intermediary between the transmission control electronics and the converter electronics. This housing acts as a physical barrier that maintains compact spacing while preventing electromagnetic interference, thus achieving both compactness and EMI protection.
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 heat dissipation without the need for expensive components, reduces EMI, and provides a compact, effective cooling system for both attached and standalone applications in vehicles.
Implementation Method 1
The converter electronics are, in turn, thermally conductively connected to the heat sink. The housing upper part made up of the transmission control electronics and plastic sheathing is thermally conductively connected to the heat sink in such a way that a heat transfer occurs from the transmission control electronics to the edge of the heat sink and, therefore, to the heat sink itself.
Implementation Method 2
a heat sink arranged between the housing upper part and the housing lower part such that the heat sink forms a part of the housing
Implementation Method 3
a coolant which is arranged on a side of the heat sink opposite the housing upper part and which is in engagement with a corresponding receptacle in the heat sink
Data Source
AI summary
A control module for a vehicle with at least one electric motor and a transmission is provided. The control module has a housing for receiving transmission control electronics and converter electronics for controlling an electric motor. The control module also has a heat sink. The housing includes a housing upper part and a housing lower part. The heat sink is arranged between the housing upper part and the housing lower part such that the heat sink forms a part of the housing. The transmission control electronics are surrounded by a plastic sheathing. The transmission control electronics and the plastic sheathing form the housing upper part. The converter electronics are thermally conductively connected to the heat sink, and the housing upper part is thermally conductively connected to the heat sink in such a way that a heat transfer occurs from the transmission control electronics to the edge of the heat sink.