Control Unit PCM Housing for Coolant Failure Heat Buffering
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Solution Overview
Problem
Existing automotive control units for highly automated driving generate significant waste heat, requiring efficient cooling to prevent critical temperature exceedance, especially in the event of coolant pump failures, while existing solutions like redundant cooling paths and active air cooling introduce additional failure points and costs.
Innovation Solution
Incorporating phase change materials (PCMs) within the control unit housing to absorb and store heat during coolant failures, allowing the SoC to remain operational without additional actuators like pumps or fans.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If redundant cooling paths (separate pump or active air cooling) are installed, then cooling reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent applies beforehand cushioning by installing a phase change material (PCM) heat storage unit that can absorb excess heat before the cooling system fails. The PCM acts as a thermal buffer that cushions the thermal load on the SoC during coolant pump failures, maintaining safe operating temperatures without requiring redundant cooling paths. This resolves the contradiction by providing reliability through advance thermal buffering rather than through complex redundant cooling systems.
Solution Approach 2:
The patent uses an intermediary approach by introducing a PCM heat storage unit as a mediator between the heat-generating SoC and the cooling system. The PCM intermediate layer absorbs thermal energy during normal operation and releases it when cooling fails, acting as a buffer that decouples the SoC from cooling system failures. This eliminates the need for complex redundant cooling paths while maintaining reliability.
2Quantity of substance
If materials with high heat capacity (metals) are installed, then heat absorption capability is improved, but weight and volume increase
Solution Approach 1:
The patent applies phase transitions by using a phase change material (PCM) that undergoes phase change (e.g., solid-liquid transition) at a specific temperature to absorb and release large amounts of latent heat. This PCM heat storage unit provides high heat storage capacity in a compact form factor, significantly reducing the weight and volume compared to traditional metal heat sinks while maintaining effective thermal management during cooling failures.
3Power
If active air cooling systems are installed, then cooling capability is improved, but reliability decreases due to additional failure points
Solution Approach 1:
The patent applies self-service by using the PCM heat storage unit to automatically buffer thermal loads without requiring external control or additional actuators. The PCM passively absorbs excess heat during cooling failures through its phase change properties, providing self-regulating thermal management. This eliminates the need for complex active air cooling systems with multiple failure points while maintaining adequate cooling power during critical periods.
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
PCMs provide high heat storage capacity, enabling the control unit to maintain functionality during coolant failures, reducing the need for redundant systems and potential failure points, and allowing for cost-effective, reversible heat management.
Implementation Method 1
at least one space which is at least partially filled with a phase change material (PCM) is provided in the housing as well
Implementation Method 2
The phase change material (PCM) is a so-called latent heat storage material that can store a high proportion of heat and cold energy over a long period of time and release it again without loss
Implementation Method 3
This makes use of reversible thermodynamic changes in the state of a storage medium, e.g. during the phase transition from solid to liquid
Data Source
AI summary
Control unit including a housing in which a to-be-cooled electronic unit is provided, wherein at least one space which is at least partially filled with a phase change material is provided in the housing as well.