Dummy Module Interleaved Power-Module Assembly
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Solution Overview
Problem
Current power-module assemblies for electric drivetrains in vehicles face challenges in efficient coolant flow and thermal management, leading to suboptimal performance and reliability due to limitations in coolant circulation patterns and pressure drops within the power inverter systems.
Innovation Solution
The implementation of a power-module assembly with interleaved coolant chambers and a dummy module that reroutes coolant flow, allowing for distinct coolant flow directions in different portions of the assembly, thereby enhancing cooling efficiency and reducing pressure drops through a series-parallel cooling strategy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If coolant chambers are formed by interleaved power modules, then cooling efficiency is improved, but pressure drops increase due to complex flow paths
Solution Approach 1:
The power module assembly is segmented into multiple modules arranged in an interleaved pattern, with coolant chambers formed between adjacent modules. This segmentation allows coolant to flow through multiple discrete chambers rather than a single complex path, improving cooling efficiency while managing pressure drops through distributed flow paths.
Solution Approach 2:
A dummy module is introduced as an intermediary element within the array to redirect coolant flow. The dummy module defines a coolant pocket that cooperates with adjacent power modules to form additional coolant chambers, effectively rerouting coolant to reduce pressure drops while maintaining cooling efficiency.
2Temperature
If power modules are stacked in an interleaved array, then cooling coverage is improved, but device complexity increases
Solution Approach 1:
The dummy module serves multiple functions: it acts as a structural filler to complete the interleaved array pattern, defines a coolant pocket that forms additional coolant chambers, and redirects coolant flow to optimize pressure distribution. This multi-functionality improves cooling coverage without proportionally increasing device complexity.
3Stress or pressure
If coolant flow is redirected through dummy modules, then pressure drops are reduced, but manufacturing complexity increases
Solution Approach 1:
The dummy module is designed with the same footprint as the power modules, allowing it to be integrated into the existing interleaved array pattern without requiring unique mounting procedures or specialized tooling. This homogeneity in dimensions and interface design simplifies manufacturing despite the added functionality for coolant redirection.
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 improves cooling efficiency by allowing uniform coolant distribution and flow rates, reducing thermal resistance, and minimizing pressure drops, leading to enhanced performance and reliability of the power inverter systems.
Implementation Method 1
coolant flows through the coolant chambers of the first portion in a first direction and coolant flows through the coolant chambers of the second portion in a second direction
Implementation Method 2
coolant circulation patterns and pressure drops within the power inverter systems
Data Source
AI summary
A power-electronics system includes a plurality of power modules each having a power stage and defining a side pocket. The power stages are stacked in an array such that the side pockets are interleaved with the power stages. A dummy module defines a first coolant pocket and is disposed within the array such that the first coolant pocket cooperates with one of the side pockets to define a coolant chamber.