Cooled Electric Assembly Heat Pipe Cooling Tube
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Solution Overview
Problem
Existing cooling systems for high-voltage electrical components in electric vehicles face challenges in efficiently removing heat without causing damage through corrosion or short-circuiting when using liquid coolants, as they need to prevent liquid coolant contact with electrical components.
Innovation Solution
A cooled electric assembly with a molded distribution box containing a seamless cooling tube and a heat pipe that circulates a liquid coolant, minimizing direct contact risks while effectively transferring heat from high-voltage conductors to the coolant.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a liquid coolant is used to remove heat from electrical components, then heat removal efficiency is improved, but the risk of corrosion and short-circuiting increases
Solution Approach 1:
The system divides the cooling function into separate components: a cooling tube for coolant circulation and a heat pipe for heat transfer. This segmentation allows the coolant to remain isolated from electrical components while still achieving effective heat removal through the heat pipe interface.
Solution Approach 2:
The heat pipe serves as an intermediary between the electrical conductor and the cooling tube. It transfers heat from the electrical component to the coolant without allowing direct contact between the coolant and the electrical component, thus eliminating the risk of corrosion and short-circuiting while maintaining cooling efficiency.
2Temperature
If a cooling system is added to remove heat from electrical components, then heat removal capability is improved, but device complexity increases
Solution Approach 1:
The cooling tube is integrated into the distribution box structure, and the heat pipe directly contacts both the electrical conductor and the cooling tube. This merging of components reduces the number of separate parts and simplifies the overall system architecture while maintaining effective heat removal capability.
Solution Approach 2:
The heat pipe performs multiple functions: it conducts heat from the electrical conductor, transfers it to the cooling tube, and provides a physical barrier that prevents coolant contact with electrical components. This multi-functionality reduces the need for additional protective components, thereby simplifying the system.
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
The system efficiently removes heat from high-voltage electrical components, reducing the risk of damage from corrosion or short-circuiting while maintaining effective heat transfer, thus protecting components and ensuring safe operation.
Implementation Method 1
The thermal conductor is in thermal contact with the electrical conductor. The thermal conductor is in thermal contact with the cooling tube.
Implementation Method 2
A liquid coolant is passed through the cooling tube. The cooling tube extends between a pipe inlet that is located outside the interior space and a pipe outlet that is located outside the interior space.
Data Source
AI summary
A cooled electric assembly includes a box that defines an interior space. An electrical conductor is located within the interior space. A cooling tube is attached to the box. A thermal conductor is located at least partially within the interior space and is in thermal contact with the electrical conductor and in thermal contact with the cooling tube.