DC-DC Converter Switching Element Thermal Management
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Solution Overview
Problem
Existing power conversion apparatuses face challenges in effectively cooling switching elements with high heating values, particularly when these elements are arranged parallel, leading to increased thermal resistances and complex cooling routes, which complicates the cooling process.
Innovation Solution
The use of a metal case with heat conductive insulating materials and a metal radiator with improved heat conduction characteristics for mounting switching elements, allowing for efficient heat dissipation and minimizing thermal interference among neighboring elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooling plate is used to cool switching elements, then cooling capability is provided, but thermal resistance increases and cooling route becomes complicated when switching elements are arranged parallel
Solution Approach 1:
The invention divides the cooling function into two parts: the metal case provides base cooling through its inherent thermal conductivity, while the metal radiator attached to the metal case provides additional cooling capacity. This segmentation allows each component to have an optimized cooling route, reducing overall complexity while maintaining effective cooling of parallel switching elements
Solution Approach 2:
The invention adds a spatial dimension to the cooling system by attaching a metal radiator to the metal case. This creates a multi-layer cooling structure where heat can be dissipated through multiple thermal paths simultaneously, reducing thermal resistance without complicating the cooling route design
2Area of stationary object
If switching elements are arranged parallel to save space, then space utilization improves, but thermal interference among neighboring elements increases
Solution Approach 1:
The metal case serves as an intermediary thermal management component between parallel switching elements. Its high thermal conductivity provides efficient heat dissipation paths that prevent thermal accumulation and reduce thermal interference among closely spaced elements, enabling compact arrangement without excessive thermal buildup
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 enhances the cooling efficiency for switching elements outside the cooling range of the cooling channel, reducing adverse thermal influences and improving thermal diffusion characteristics, thereby effectively managing heat dissipation.
Implementation Method 1
the switching elements are fixed to the metal case via a heat conductive insulating material
Implementation Method 2
a metal radiator having a better heat conduction characteristic than the metal case
Data Source
AI summary
In a DC-DC converter, the cooling of switching elements has been performed only by means of a cooling plate; therefore, there is a problem in that, to effectively radiate heats generated by power MOSFETs that have large heating values and that are arranged parallel, it becomes necessary to reduce thermal resistances and complicate the cooling route of a water-cooling device. Plural switching elements for controlling currents flowing through inductor elements, which are used for voltage conversion of a DC-DC converter, are fixed to a metal case via a heat conductive insulating material and via a metal radiator having a better heat conduction characteristic than the metal case. Because there occur no large mixing phenomena of heat currents among neighboring switching elements, and there are only little heat interferences between the neighboring switching elements, the thermal diffusion characteristic is improved, and the cooling efficiency for the switching elements can be increased.