Double-Sided Liquid Cooler Structure for Low Pressure Loss
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Solution Overview
Problem
Current liquid-cooling type double-sided coolers face limitations in cooling efficiency due to temperature deviations, pressure losses, and increased risk of blockages in the bending process, which affect the performance and reliability of power modules in eco-friendly vehicles.
Innovation Solution
The design incorporates a separate coupling structure with communication holes and edge portions that connect the upper and lower cooling portions, reducing pressure loss and preventing blockages, while maintaining efficient cooling through strategically positioned cooling pins and thermal grease for improved heat exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the number of cooling pins is increased to enhance cooling efficiency, then cooling performance is improved, but the flow path size is reduced and the risk of blockages is increased
Solution Approach 1:
The cooling device is divided into multiple independent cooling portions (first cooling portion, second cooling portion, etc.), each with its own cooling pins and flow paths. This segmentation allows for optimized cooling pin distribution without excessive concentration in one area, maintaining cooling effectiveness while reducing blockage risk through distributed flow paths.
Solution Approach 2:
The invention transitions from a single-plane cooling structure to a multi-dimensional arrangement with cooling portions positioned at different heights and locations. The first cooling portion contacts the upper surface while the second cooling portion contacts the lower surface, creating a three-dimensional cooling architecture that improves heat dissipation without requiring excessive cooling pins in a single plane.
2Temperature
If a bending process is used to form cooling tubes, then the cooling portions can contact upper and lower surfaces, but pressure loss increases and the flow path may be narrowed or blocked
Solution Approach 1:
The invention extracts the problematic bending process from the manufacturing method. Instead of bending cooling tubes to achieve the desired configuration, the design uses separately formed cooling portions with integrated flow paths that naturally accommodate the upper and lower surface contacts without requiring bending operations, thereby eliminating associated pressure losses and blockage risks.
Solution Approach 2:
The cooling portions are pre-formed with their final configurations before assembly. The first cooling portion is prepared with its cooling pins and flow paths already in position, and the second cooling portion is similarly prepared. This preliminary formation eliminates the need for bending during assembly, preventing flow path narrowing and blockages that would occur with post-formation bending.
3Ease of manufacture
If cooling portions are formed through extrusion and bending processes, then the structure can be manufactured, but manufacturing complexity and potential defects increase
Solution Approach 1:
The manufacturing process is segmented into separate formation steps for different cooling portions. Each cooling portion (first cooling portion, second cooling portion) is independently formed with its specific configuration, allowing for specialized manufacturing techniques optimized for each component's requirements. This segmentation reduces the complexity of forming entire cooling systems in single operations and minimizes defect propagation.
Solution Approach 2:
Cooling portions are pre-formed with their final geometries and flow paths before assembly into the complete cooling device. The first cooling portion is pre-formed with its cooling pins and channels, and the second cooling portion is pre-formed separately. This preliminary formation ensures high manufacturing precision for critical flow path features without the complications of post-assembly bending or joining operations.
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 cooling efficiency, reduces pressure loss, and minimizes the risk of blockages, leading to improved performance and reliability of power modules by maintaining consistent cooling liquid flow and preventing over-temperature issues.
Implementation Method 1
a liquid-cooling type double-sided cooler which contacts cooling portions within which cooling liquid flows with upper and lower surfaces of the power module
Implementation Method 2
a first cooling liquid path within which the cooling liquid flows and to flow and discharge the cooling liquid into one end of the first cooling portion
Data Source
AI summary
The present disclosure provides a liquid-cooling type double-sided cooler, including a first cooling portion and a second cooling portion. In the liquid-cooling type double-sided cooler, another end of the first cooling portion is formed with a first communication hole that is configured to penetrate the first cooling liquid path and an outside of the first cooling portion, another end of the second cooling portion is formed with a second communication hole that is configured to penetrate the second cooling liquid path and an outside of the second cooling portion; and the first cooling portion and the second cooling portion are positioned such that the first communication hole and the second communication hole face each other, and the first cooling liquid path and the second cooling liquid path are connected with each other.