Power Converter Thermal Management via Segmented Cooling Chassis
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Solution Overview
Problem
The existing power conversion apparatuses for electric and hybrid vehicles face challenges in downsizing due to differences in the number and area of electric circuits and electronic components between AC/DC converters and DC/DC converters, which affects cooling efficiency and overall size.
Innovation Solution
The apparatus integrates AC/DC and DC/DC converters with a cooling body, where the AC/DC converter's primary side circuits are mounted on the upper face and the secondary side and DC/DC converter's circuits are on the lower face, reducing the area difference and heat generation disparity, and using a cooling body with a high thermal conductivity material for efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the DC/DC converter is mounted on either the upper face or the lower face of the cooling body and the power module is mounted on the other face, then the cooling function is provided, but the size in the width direction must be designed according to the face having a larger number of electric circuits and electronic components, which interferes with downsizing of the apparatus
Solution Approach 1:
The patent segments the AC/DC converter into two separate sides: a first side with fewer electric circuits and electronic components, and a second side with more electric circuits and electronic components. This segmentation allows each face of the cooling body to be optimally utilized, with the first side mounted on one face and the second side mounted on the other face, thereby reducing the overall width direction size while maintaining effective cooling of all components.
2Temperature
If the AC/DC converter and DC/DC converter are integrated with a cooling body, then thermal management is improved, but the difference in the number and area of electric circuits and electronic components between the converters creates design complexity
Solution Approach 1:
The AC/DC converter is divided into a first side and a second side with different numbers and areas of electric circuits and electronic components. This segmentation simplifies the mounting configuration by allowing each side to be placed on appropriate faces of the cooling body, reducing design complexity while maintaining integrated thermal management.
Solution Approach 2:
The patent applies local quality by assigning different mounting positions to different sides of the AC/DC converter based on their specific characteristics (number and area of electric circuits and electronic components). The first side with fewer components is mounted on one face, while the second side with more components is mounted on the other face, optimizing both thermal management and design simplicity.
3Ease of manufacture
If all constituent circuits are mounted on a single face of the cooling body, then the mounting process is simplified, but the area occupied is maximized and cooling efficiency is reduced due to heat generation disparity
Solution Approach 1:
Instead of mounting all constituent circuits on a single face, the patent segments them across two faces of the cooling body. The first side of the AC/DC converter with fewer components is mounted on one face, while the second side with more components and the DC/DC converter are mounted on the other face. This segmentation reduces the occupied area on each face while maintaining mounting simplicity and improving cooling efficiency by distributing heat generation.
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 allows for efficient cooling and downsizing of the power conversion apparatus by reducing unnecessary space and heat generation differences between the converter sides, enhancing thermal management and compactness.
Implementation Method 1
a cooling body configured to cool both the AC/DC converter and the DC/DC converter
Data Source
AI summary
An AC/DC converter of a power conversion apparatus includes filters, a PFC circuit, a first full bridge circuit, a first transformer, and a first rectifier circuit and converts an AC voltage supplied from the outside to a DC voltage. A DC/DC converter includes filters, a second full bridge circuit, a second transformer, and a second rectifier circuit and lowers a DC voltage output from the AC/DC converter. Constituent circuits of the AC/DC converter located on the primary side of the first transformer are mounted on the upper face of a cooling chassis which cools both the converters. Constituent circuits of the AC/DC converter located on the secondary side of the first transformer and constituent circuits of the DC/DC converter are mounted on the lower face of the cooling chassis.