Dual-Inverter Assembly Space Optimization
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Solution Overview
Problem
Conventional dual-inverter assemblies with single-sided cooling channels face challenges in optimizing space utilization due to the design limitations, particularly in stacked configurations where heat dissipation assemblies occupy more space and hinder efficient terminal connections and cooling flow management.
Innovation Solution
A dual-inverter assembly design featuring elongated power modules stacked on a base with a single-input and dual-output configuration, where a DC input copper busbar is integrated from the bottom to one sidewall and AC output copper busbars are connected from another sidewall, allowing for efficient space utilization by minimizing the distance between bulk capacitors and power modules, and incorporating a cooling flow channel with inlet and outlet for effective heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-sided cooling channel design is used in the heat dissipation assembly, then the cooling structure is simple, but the space utilization is poor and the assembly occupies more space
Solution Approach 1:
The patent transitions from a single-sided cooling channel to a dual-sided cooling channel design, utilizing both sides of the heat dissipation assembly for cooling. This dimensional change allows the cooling flow channel to serve two power modules simultaneously, improving space utilization without increasing overall assembly volume.
Solution Approach 2:
The heat dissipation assembly is designed to perform multiple functions: it provides cooling for both the first and second power modules through its dual-sided cooling channels, and serves as a structural base for mounting both power modules. This multi-functionality reduces the need for separate cooling components.
2Ease of manufacture
If the water outlet and water inlet are positioned on one side of the heat dissipation assembly, then the connection is simple, but it hinders efficient terminal connections and space optimization
Solution Approach 1:
The patent positions the water inlet on one side of the heat dissipation assembly and the water outlet on the opposite side, utilizing the dual-sided configuration. This spatial arrangement allows cooling flow channels to efficiently serve both power modules while optimizing the overall assembly layout and reducing volume.
3Reliability
If conventional heat dissipation assembly design is used in stacked dual-inverter configuration, then the cooling function is provided, but the space utilization is not optimized and terminal connections are hindered
Solution Approach 1:
The patent divides the cooling function into two independent cooling channels, one for each power module, with separate inlet and outlet connections. This segmentation allows each module to be cooled independently while optimizing the overall space utilization in the stacked configuration.
Solution Approach 2:
The heat dissipation assembly utilizes dual-sided cooling channels to serve both power modules from opposite sides, transitioning from a single-sided conventional design. This dimensional change optimizes space utilization in stacked configurations and facilitates efficient terminal connections.
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 optimizes space utilization by allowing for a more compact arrangement of power modules and capacitors, improving heat dissipation efficiency and enabling better integration of the control circuit board, thus enhancing overall space efficiency in limited spaces.
Implementation Method 1
The cooling flow channel disposed in the interior of the elongated base has the inlet and the outlet leading through the lower space, and serves as a cooling structure for two power modules and the bulk capacitors
Data Source
AI summary
A dual-inverter assembly is disclosed and includes an elongated base, a first power module, a second power module, an input copper busbar and two output copper busbars. The elongated base includes a first elongated sidewall and a second elongated sidewall opposite to each other and extended along a first direction. The first power module and the second power module are disposed on a first side and a second side of the elongated base along the first direction, respectively. The input copper busbar is spatially corresponding to the first elongated sidewall, and electrically connected to the first power module and the second power module. The two output copper busbars are spatially corresponding to the second elongated sidewall, and electrically connected to the first power module and the second power module, respectively, so as to achieve an optimized configuration.