Electrical Pack Thermal Management via Segmented Modules
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Solution Overview
Problem
The reliability of electrical packs in vehicles is compromised due to overheating of control components caused by proximity to electromagnetic and power components, especially in high-altitude aircraft environments or when ventilation fails.
Innovation Solution
The electrical pack design separates power and control modules with thermally conductive support plates and insulating component-carrying plates, creating a spaced configuration that minimizes heating through convection and radiation, and uses intermediate metal frames for air flow and heat dissipation, while also providing mechanical and thermal connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If power components and control components are grouped together in the same module, then the device complexity is reduced and manufacturing is simplified, but the control components are subjected to overheating from power components
Solution Approach 1:
The electrical pack is segmented into separate power modules and control modules. Each module has its own support plate and component carrier plate, allowing thermal isolation while maintaining modular architecture. The control components are housed in a control module that is physically separated from power components in power modules, preventing heat transfer while preserving manufacturing efficiency.
Solution Approach 2:
An insulating component carrier plate is introduced as an intermediary between the thermally conductive support plate and the control components. This intermediary structure provides mechanical support and electrical connectivity while thermally isolating the control components from the heat-generating power components, resolving the contradiction between thermal management and structural integration.
2Reliability
If power components and control components are separated into different modules, then overheating of control components is reduced, but the device complexity increases
Solution Approach 1:
The support plate structure serves multiple functions: it provides mechanical support, thermal conduction for power components, and thermal isolation for control components through the insulating component carrier plate. The modular design with standardized interfaces allows the same basic structure to be used for both power modules and control modules, reducing overall system complexity despite functional separation.
Solution Approach 2:
The thermal conductivity parameter is selectively applied: high thermal conductivity support plates for power modules to dissipate heat, and insulating component carrier plates for control modules to protect against heat. This parameter differentiation enables reliable thermal management while maintaining a unified modular architecture that doesn't significantly increase device complexity.
3Temperature
If ventilation is provided for cooling, then control component overheating is prevented, but the device complexity increases and reliability decreases in high-altitude environments
Solution Approach 1:
The support plate structure itself provides passive thermal management through its inherent thermal conductivity properties. Power module support plates are made of thermally conductive material to automatically dissipate heat from power components, while control module support plates use insulating component carrier plates to automatically protect control components from heat, without requiring active ventilation systems that may fail in high-altitude environments.
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 design effectively reduces overheating of control components, enhances reliability, and ensures correct module installation by preventing tool access until disassembly, while allowing flexible configuration of power and control modules.
Implementation Method 1
each power module comprises a support plate made of thermally good conductive metal with which is associated an insulating component carrier plate carrying power components
Implementation Method 2
an air flow is established between the component-carrying plate and the support plate so that the support plate is thermally associated with the component-carrying plate and therefore serves as a cooling radiator for the power components
Implementation Method 3
the control module being protected by the support plate against heating from an adjacent power module
Data Source
Figure 1~3
Figure 2
Figure 4
AI summary
The electrical package (1) comprises power components grouped together according to power modules (4) and control components grouped together according to a control module (3) which is separate from the power modules (4).