Dual-Side Cold Plate Cooling for Power Modules
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Solution Overview
Problem
Power modules generating significant heat during operation pose a challenge for effective cooling, which is crucial for maintaining performance, especially in high current and voltage applications like electric motor driving systems.
Innovation Solution
A power module cooling system comprising a cold plate with fluid passageways and cooling fins, where the power modules are positioned in an opposing relationship within the cold plate to maximize coolant interference and flow, with seals and fasteners to secure and prevent fluid leakage, and manifolds for efficient fluid exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If power modules are cooled using conventional single-sided cooling configurations, then the cooling effectiveness is limited, but the packaging size increases to accommodate larger cooling surfaces
Solution Approach 1:
The patent transitions from single-sided cooling to dual-sided cooling by utilizing both sides of the cold plate, effectively adding a dimensional aspect to the cooling configuration. This allows heat dissipation from both power modules simultaneously without increasing the overall packaging footprint, as the cooling surface is doubled within the same volume envelope
Solution Approach 2:
The patent combines two power modules and their cooling systems into a single integrated cold plate structure. The cold plate serves dual functions by cooling both power modules concurrently, merging what would traditionally be separate cooling systems into one unified thermal management solution, thereby reducing total packaging requirements
2Temperature
If cooling fins are positioned close together to maximize cooling efficiency, then heat dissipation improves, but fluid flow through the passageway is restricted
Solution Approach 1:
The patent applies different fin configurations to different regions of the cold plate, optimizing local heat transfer characteristics. By varying fin density, spacing, or geometry in specific areas, the design achieves enhanced heat dissipation where needed while maintaining adequate fluid flow channels, balancing thermal performance with flow requirements in a localized manner
Solution Approach 2:
The cooling system is divided into multiple discrete fin sections or zones within the fluid passageway. This segmentation allows different regions to serve different functions - some areas with tighter fin spacing for maximum heat extraction, while other areas provide larger flow channels to maintain coolant velocity and prevent flow starvation, achieving overall system optimization
3Reliability
If seals are added around the entire perimeter of the fluid passageway to prevent fluid leakage, then cooling reliability improves, but device complexity increases
Solution Approach 1:
The sealing function is merged with the cold plate structure itself, where the cold plate incorporates integrated sealing features or interfaces that prevent fluid leakage without requiring separate, complex sealing systems. The sealing is built into the fundamental structure, eliminating the need for additional sealing components and reducing overall system complexity
Solution Approach 2:
The cold plate design includes self-sealing characteristics or features that automatically prevent fluid leakage without requiring external sealing mechanisms. The structure itself provides the sealing function through its geometry, material properties, or assembly configuration, making the system self-sufficient and reducing complexity
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 effectively cools both power modules with minimal packaging size, ensuring efficient heat dissipation and maintaining performance without significant size increases, suitable for high-power applications like DC/AC inverters in electric vehicles.
Implementation Method 1
a cold plate having a top side shaped to receive the first power module and a bottom side shaped to receive the second power module, the top side and the bottom side being spaced apart to define a fluid passageway into which the first and second plurality of cooling fins extend
Implementation Method 2
the fluid passage extending between first and second apertures included within respective first and second lateral sides of the cold plate, the first aperture directing received fluid through the fluid passageway to the second aperture to facilitate cooling of the first and second plurality of cooling fins
Data Source
AI summary
A direct current (DC) link capacitor operable within an electrically drivable vehicle having a high-voltage battery is provided configured to facilitate output of a DC voltage to an inverter configured to process the DC voltage to facilitate powering an electric motor used to drive the vehicle. The DC link capacitor includes a housing enclosing capacitive elements configured to facilitate capacitive processing between an input and an output, at least a first pair of terminals configured to deliver the DC voltage to the input, the capacitive elements processing the DC voltage received at the input into a capacitive DC voltage, and at least a second pair of terminals configured to output the capacitive DC voltage to the inverter, the inverter relying on the capacitive DC voltage to facilitate powering the electric motor.