Power Converter Connector Structure for Flexible Pipe Interfaces
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Solution Overview
Problem
Existing power conversion devices for electric and hybrid vehicles face increased production costs due to the need for multiple connector shapes to accommodate various external pipe configurations, limiting versatility and efficiency.
Innovation Solution
A power conversion device with a connector system where the pipe portion and flange portion are made of metal and joined by a deformation process, allowing the pipe portion to be easily modified for different shapes while using a common flange portion, thereby reducing the need for multiple molds and enhancing versatility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple connector shapes are used to accommodate various external pipe configurations, then the adaptability to different pipe shapes is improved, but the production cost increases due to the need for multiple molds
Solution Approach 1:
The connector is divided into two separate parts: a flange portion that is secured to the case and a pipe portion that connects to external pipes. This segmentation allows the flange portion to remain standardized while the pipe portion can be modified in shape to accommodate different external pipe configurations, thereby maintaining versatility without requiring multiple molds for the entire connector.
Solution Approach 2:
The flange portion is designed as a universal component that can be used with various pipe portion shapes. By making the flange portion standardized and reusable across different configurations, the system achieves multi-functionality where a single flange design serves multiple connector variants, reducing the need for multiple molds while maintaining adaptability to different external pipe shapes.
2Adaptability or versatility
If multiple connector shapes are used to accommodate various external pipe configurations, then the versatility is improved, but the device complexity increases
Solution Approach 1:
By segmenting the connector into a standardized flange portion and variable pipe portion, the complexity is localized to only the pipe portion. The flange portion remains simple and consistent across all configurations, reducing the overall device complexity while still allowing the pipe portion to adapt to different external pipe shapes.
Solution Approach 2:
The universal flange portion serves as a common interface for all connector variants, simplifying the overall system architecture. Instead of having completely different connector designs for each external pipe configuration, the universal flange allows multiple pipe portion variations to interface with a single standardized component, thereby reducing device complexity while maintaining versatility.
3Strength
If the pipe portion and flange portion are made of metal and joined by deformation process, then the joining strength is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The deformation process modifies the physical parameters of the metal materials (such as local plastic deformation, work hardening, and residual stress distribution) to create a strong mechanical interlock between the pipe portion and flange portion. By carefully controlling the deformation parameters (force, temperature, deformation rate), the joining strength is enhanced while managing the precision requirements through process optimization.
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 minimizes production costs and improves the ability to connect with external pipes of various shapes, enhancing the device's versatility and efficiency while maintaining effective sealing and heat exchange performance.
Implementation Method 1
The cooling device includes a heat exchanger capable of exchanging heat with the semiconductor module
Implementation Method 2
heat exchanger capable of exchanging heat with the semiconductor module
Implementation Method 3
The pipe portion and the flange portion are made of a metal material and are joined to each other by a deformation process
Data Source
AI summary
A power conversion device includes a semiconductor module, a cooling device, a case, which accommodates the semiconductor module and the cooling device, a connector, which is connected to an inlet pipe, which is a refrigerant flow pipe of the cooling device, and a sealing member, which seals between the inlet pipe and the connector. The connector includes a pipe portion, which communicates with the inlet pipe, and a flange portion, which is secured to the case. The pipe portion and the flange portion are joined to each other with the pipe portion located in an insertion hole of the flange portion.