Double-Sided Cooling Layout for Thin Sealed Power Converters
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Solution Overview
Problem
Existing power conversion devices are not adequately thin and efficient in cooling performance while maintaining sealing performance to prevent refrigerant leakage.
Innovation Solution
A power conversion device design incorporating a first and second substrate with flow path forming bodies that form refrigerant paths on both surfaces, cooling power modules from both sides and preventing refrigerant leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a three-phase bridge rectifier circuit is used, then the power conversion device can be compact and lightweight, but the number of switching elements increases leading to higher loss and reduced reliability
Solution Approach 1:
The patent divides the three-phase bridge rectifier circuit into two separate single-phase bridge rectifier circuits. Each single-phase circuit processes one phase independently, reducing the number of switching elements required in each circuit while maintaining the overall power conversion functionality. This segmentation allows for fewer switching elements per phase, thereby reducing total loss and improving reliability.
2Volume of moving object
If a three-phase bridge rectifier circuit is used, then the power conversion device can be compact and lightweight, but the complexity of the control circuit increases
Solution Approach 1:
The control circuit is segmented into two independent control circuits, each managing one single-phase bridge rectifier circuit. This segmentation simplifies the control logic for each individual circuit compared to controlling a three-phase bridge rectifier, as each control circuit only needs to manage two switching elements rather than six. The independent control of single-phase circuits reduces overall control complexity.
3Power
If six switching elements are used in a three-phase bridge rectifier, then power conversion is achieved, but the device exhibits poor resistance to transient overvoltage
Solution Approach 1:
By segmenting the three-phase bridge rectifier into two single-phase bridge rectifiers, the patent reduces the number of switching elements from six to four total. This reduction decreases the potential failure points and improves transient overvoltage resistance. Each single-phase circuit with fewer switching elements demonstrates better resistance to transient overvoltage compared to a conventional three-phase bridge rectifier with six switching elements.
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
Achieves a thinner power conversion device with enhanced cooling and sealing performance, efficiently cooling power modules and control circuit substrates while preventing refrigerant leakage.
Implementation Method 1
a first diode bridge circuit 11 that performs rectification of the AC power
Implementation Method 2
a capacitor 12 for smoothing the rectified power
Implementation Method 3
a DC-DC converter 20 that transforms the DC power into power having a predetermined voltage
Data Source
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AI summary
A power conversion device according to the present invention comprises: a capacitor which is for smoothing DC power; a plurality of power modules which are for converting the DC power to AC power; a first substrate on which the plurality of power modules are installed; a second substrate which is disposed facing the first substrate; a first flow path forming body which, together with a surface of the first substrate and a surface of the second substrate, forms a flow path for circulating a refrigerant; and a second flow path forming body which forms the flow path together with the surface of the first substrate, wherein both surfaces of each of the power modules are cooled by the refrigerant.