Electric Power Converter Base Plate Thermal Path
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Solution Overview
Problem
The miniaturization of electric power converters for hybrid cars and electric vehicles leads to increased heat generation and loss due to higher current densities, necessitating improved cooling solutions for bus bars and smoothing capacitors.
Innovation Solution
Incorporating a base plate that forms a heat path for heat radiation from the bus bar to a flow channel forming body, while also serving as a positioning jig and noise filter grounding component, to enhance cooling performance and reduce thermal effects on the smoothing capacitor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the electric power converter is miniaturized, then the mountability on the vehicle is improved, but the heat generation increases due to higher current density
Solution Approach 1:
A base plate is introduced as an intermediary component between the bus bar and the smoothing capacitor. This base plate serves as a heat dissipation intermediary, conducting heat away from the bus bar and capacitor to prevent excessive temperature rise while maintaining the miniaturized configuration.
2Volume of moving object
If the electric power converter is miniaturized, then the mountability on the vehicle is improved, but the loss due to large current increases
Solution Approach 1:
The base plate acts as a thermal intermediary that facilitates heat dissipation pathways, reducing the thermal effects of large current flow in the miniaturized bus bar and capacitor assembly, thereby reducing energy loss.
3Temperature
If the base plate is added between the bus bar and capacitor cell, then the cooling performance is improved, but the device complexity increases
Solution Approach 1:
The base plate performs multiple functions simultaneously: it provides mechanical support and positioning for the capacitor cell, serves as a heat dissipation pathway, and acts as an electrical ground reference. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity while achieving improved cooling performance.
4Reliability
If the base plate is used for grounding the capacitor, then the electromagnetic compatibility is improved, but the device complexity increases
Solution Approach 1:
The base plate serves as both a structural support element and an electrical ground reference for the capacitor. By integrating the grounding function into the existing base plate structure, the electromagnetic compatibility is improved without requiring additional grounding components, thus limiting the increase in device complexity.
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
This configuration reduces heat reception in the smoothing capacitor, allows for operation within maximum temperature limits, and improves electromagnetic compatibility by shortening grounding distances and reducing impedance.
Implementation Method 1
a heat path, on which heat generated in a bus bar is radiated toward a flow channel forming body through a base plate
Implementation Method 2
heat generated in a bus bar is radiated toward a flow channel forming body
Data Source
AI summary
An object of the invention is to improve the cooling performance for a bus bar and a smoothing capacitor in an electric power converter. The electric power converter of the present invention includes a power semiconductor module including a power semiconductor element that converts a DC current to an AC current, a capacitor cell that smooths a DC voltage, a bus bar that electrically connects the power semiconductor module and the capacitor cell, a base plate that is disposed between the bus bar and the capacitor cell, and a sealing material that seals the capacitor cell, the bus bar, and the base plate. The base plate forms an opening through which a capacitor terminal extending from the capacitor cell passes.