Electric Power Converter Thinner Partition Wall Cooling
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Solution Overview
Problem
The existing electric power converters face challenges in achieving high cooling performance for capacitors due to thermal resistance and difficulty in downsizing and lightening the device, primarily because of the gap between the capacitor case and the metal casing, which increases thermal resistance and requires thick partition walls to withstand pressing forces.
Innovation Solution
The electric power converter design includes a thinner interposing partition wall between the capacitor and the laminated body, with the sealing member filling the capacitor housing space to directly transmit heat to the metal case, eliminating gaps and allowing the partition walls to be thinner, thus enhancing cooling efficiency and enabling downsizing and lightening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a gap is formed between the capacitor case and the metal casing, then the capacitor can be housed in the capacitor housing space, but the thermal resistance from the capacitor elements to the metal casing becomes large, reducing cooling performance
Solution Approach 1:
The sealing member serves as a thermal intermediary between the capacitor elements and the metal casing. By filling the capacitor housing space and contacting both the capacitor elements and the metal casing, it provides a low-thermal-resistance heat transmission path, effectively mediating heat transfer from the capacitor to the cooling system.
Solution Approach 2:
The sealing member combines multiple functions: it seals the capacitor elements in the capacitor case, fills the gap between the capacitor case and metal casing, and creates a direct thermal conduction path to the metal casing. This merging of sealing and thermal conduction functions eliminates the need for separate thermal management components.
2Strength
If the partition wall is made thick to withstand the pressing force of the pressing member, then the partition wall can receive the pressing force without deforming, but the electric power converter becomes heavier and larger in size
Solution Approach 1:
The sealing member acts as a force intermediary between the pressing member and the partition wall. It receives the pressing force from the pressing member and transmits it to the partition wall, allowing the partition wall to be thinner while still withstanding the pressing force without deformation.
Solution Approach 2:
The sealing member changes the mechanical parameter distribution by providing a compliant interface that distributes pressing forces. This allows the partition wall thickness to be reduced while maintaining structural integrity under pressing loads.
3Strength
If the partition wall is made thick to withstand the pressing force, then the partition wall can maintain structural integrity, but the metal casing size increases, making it difficult to downsize the electric power converter
Solution Approach 1:
The sealing member serves as a mechanical intermediary that distributes pressing forces across a larger area. This force distribution mechanism allows the use of thinner partition walls, thereby reducing the overall volume of the metal casing while maintaining structural integrity.
4Force
If the sealing member fills the capacitor housing space and contacts the partition wall, then the pressing force can be transmitted through the sealing member, but the thermal resistance increases
Solution Approach 1:
The sealing member uses composite material properties that provide both mechanical compliance for force transmission and thermal conductivity for heat transfer. This composite functionality allows simultaneous achievement of pressing force transmission and low thermal resistance.
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 design significantly reduces thermal resistance, improves capacitor cooling efficiency, and allows for a more compact and lightweight electric power converter by eliminating gaps and utilizing the sealing member to receive pressing forces, making the device more efficient and compact.
Implementation Method 1
the heat generated from the capacitor elements is transmitted to the metal casing via the sealing member, the capacitor case, and the gap. Therefore, a thermal resistance from the capacitor elements to the metal casing is large
Implementation Method 2
a plurality of cooling pipes for cooling the semiconductor modules
Implementation Method 3
a plurality of cooling pipes for cooling the semiconductor modules
Data Source
AI summary
An electric power converter includes a laminated body, a capacitor, a case, and a pressing member. The laminated body is formed by laminating semiconductor modules and cooling pipes. The pressing member presses the laminated body in a laminating direction of the laminated body. The case has outer wall portions that form an outer shell, and partition wall portions formed in the case and are connected to the outer wall portions. The capacitor has capacitor elements and a sealing member. The sealing member is filled in a capacitor housing space in a state where the capacitor elements are sealed. Pressing force of the pressing member is applied to an interposing partition wall portion interposing between the laminated body and the capacitor among the partition wall portions. A thickness of the interposing partition wall portion is made thinner than any other parts of the outer wall portions.