Cooling Fin Geometry Zoning for Uniform EV Module Temperatures
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Solution Overview
Problem
Existing cooling modules in electric vehicle systems have limited thermal performance optimization capabilities and high pressure drop, leading to uneven temperature distribution among power modules and increased energy consumption.
Innovation Solution
A cooling module design featuring varying sinusoidal wave geometries in cooling fins along the coolant flow direction, with changing wavelengths to optimize thermal performance and reduce pressure drop, ensuring uniform temperature distribution across power modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling modules use uniform cooling fin geometry, then manufacturing is simple, but thermal performance optimization is limited and temperature distribution is uneven
Solution Approach 1:
The cooling module employs cooling fins with varying geometries distributed across different zones of the cooling plate. Each zone has cooling fins optimized for local thermal conditions, creating non-uniform local properties that collectively achieve uniform temperature distribution across the entire power module surface.
Solution Approach 2:
The cooling plate is divided into multiple zones, each containing cooling fins with specific geometries tailored to local heat generation patterns. This segmentation allows independent optimization of each zone's cooling characteristics while maintaining overall system performance.
2Temperature
If cooling modules increase cooling fin surface area, then thermal performance improves, but pressure drop increases
Solution Approach 1:
The cooling fin geometry parameters (height, thickness, spacing, wavelength) are varied across different zones to optimize the balance between heat dissipation surface area and fluid flow resistance. This parameter optimization reduces pressure drop while maintaining effective thermal performance.
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 design enhances thermal management by reducing parasitic losses, improving power module performance, and extending the driving range of electric vehicles through balanced temperature regulation and reduced energy consumption.
Implementation Method 1
a cooling module in a flow of coolant from the inlet port to the outlet port
Implementation Method 2
first cooling fins with a first cooling fin geometry, second cooling fins with a second cooling fin geometry
Data Source
AI summary
A cooling module includes: first cooling fins with a first cooling fin geometry, second cooling fins with a second cooling fin geometry, the second cooling fins downstream of the first cooling fins along a flow of coolant from an inlet port to an outlet port, and third cooling fins with a third cooling fin geometry, the third cooling fins downstream of the second cooling fins along the flow of coolant from the inlet port to the outlet port, wherein the first cooling fin geometry is a first sinusoidal wave having a first uniform wavelength, the second cooling fin geometry is a second sinusoidal wave having a second uniform wavelength that is shorter than the first uniform wavelength, and the third cooling fin geometry is a third sinusoidal wave having a third uniform wavelength that is longer than the second uniform wavelength.