Deformable Cooling Element for Uneven Control Unit Surfaces
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Solution Overview
Problem
Existing cooling technologies for vehicle control units face inefficiencies due to thermal resistance, instability, and installation challenges, particularly with thermally conductive putty and rigid cooling plates, which lead to air pockets and increased costs.
Innovation Solution
A cooling device comprising a deformable cooling element, such as a bag or hose, combined with a heat dissipation element like a frame or Peltier element, that adapts to uneven surfaces and eliminates the need for thermally conductive putty, enhancing heat dissipation and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thermally conductive putty is used to improve contact surface between cooling plate and control unit, then contact surface quality is improved, but thermal resistance increases and installation complexity increases
Solution Approach 1:
The invention removes the thermally conductive putty from the cooling system. Instead of using putty to fill gaps, the cooling plate is designed with a deformable backing layer that directly adapts to the control unit surface, eliminating the need for additional thermal interface materials and reducing thermal resistance paths.
Solution Approach 2:
The cooling plate incorporates a deformable backing layer that changes its physical state from rigid to compliant, allowing it to conform to surface irregularities. This parameter change in material rigidity enables direct thermal contact without putty, improving both contact quality and thermal conductivity.
2Stability of the object's composition
If cooling plate is made rigid to maintain structural stability, then structural stability is improved, but adaptability to uneven surfaces deteriorates
Solution Approach 1:
The cooling plate is segmented into two functional layers: a rigid cooling function element that maintains structural stability and coolant channels, and a deformable backing layer that provides adaptability to uneven surfaces. This segmentation allows each layer to perform its specialized function independently.
Solution Approach 2:
The cooling plate uses a composite structure combining rigid materials (for the cooling function element) and deformable materials (for the backing layer). This composite approach integrates both structural stability and surface adaptability into a single component.
3Manufacturing precision
If cambering of cooling plate surface is applied to achieve flat contact pressure, then contact pressure distribution is improved, but production cost increases and tolerance problems arise
Solution Approach 1:
The deformable backing layer performs the function of cambering automatically through its own elasticity and deformability. When installed, it self-adjusts to the control unit surface geometry, eliminating the need for pre-cambering the cooling plate during manufacturing. This reduces production complexity and cost while maintaining good contact pressure distribution.
4Strength
If screws are used to secure cooling plate to control unit, then mechanical fixation is improved, but holding force decreases over time and construction stability deteriorates
Solution Approach 1:
The invention replaces the mechanical screw fixation system with a friction-based clamp connection. The clamp applies continuous radial pressure to the cooling plate, which is transmitted through the deformable backing layer to the control unit surface. This mechanical substitution eliminates screw loosening issues while maintaining strong fixation.
5Adaptability or versatility
If water bag material is made very thin to cling to uneven surface, then adaptability to surface is improved, but structural strength deteriorates
Solution Approach 1:
The cooling plate separates the adaptability function (deformable backing layer) from the structural function (rigid cooling function element with coolant channels). The thin deformable backing layer provides surface conformity without needing to bear structural loads, while the rigid cooling function element maintains structural integrity and coolant flow paths.
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 solution provides efficient heat dissipation, reduces installation space, and lowers production costs while ensuring stable contact with the control unit, even in the presence of surface irregularities.
Implementation Method 1
the water then flows through the profile and transports with it the heat absorbed from the metal sheets
Implementation Method 2
a cooling element (16), designed as a bag, for a coolant (20) and a heat dissipation element (18) arranged on the cooling element (16)
Data Source
AI summary
A cooling device including a cooling element designed as a bag for a coolant, and a heat dissipation element arranged on the cooling element and a motor vehicle with an embodiment of the cooling device. The heat dissipation element can be designed as a frame element for the cooling element, and the frame element can preferably have at least one groove on its longitudinal side. Additionally or alternatively, the heat dissipation element can be designed as a Peltier element, and the heat dissipation element can form an outer wall of the cooling element.