Electric Vehicle Power Module Cooling and Positioning
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Solution Overview
Problem
Existing electric vehicle power modules face challenges with inefficient cooling, particularly when stationary, and pose safety risks in accidents due to potential fire or electric shock from high amperage power signals.
Innovation Solution
A motor vehicle design with a power module positioned to minimize impact damage, featuring a longitudinal and/or transverse placement within the engine compartment, combined with a forced ventilation system using an air duct to enhance cooling, and a redundant cooling system with heat pipes oriented to maintain efficiency during vehicle motion and stationary periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air duct cooling is used for the power module, then cooling efficiency during vehicle movement is improved, but cooling effectiveness deteriorates when the vehicle is stationary
Solution Approach 1:
The cooling system dynamically adapts its operation mode based on vehicle state. During vehicle movement, the air duct provides passive convective cooling. When the vehicle is stationary, the system automatically activates the active cooling device (fan) to maintain cooling effectiveness. This dynamic switching resolves the contradiction between movement-based and stationary-based cooling requirements.
Solution Approach 2:
The control unit acts as an intermediary that monitors vehicle state and switches between cooling modes. It receives signals about vehicle movement status and activates the appropriate cooling mechanism (air duct natural convection or active fan cooling), ensuring continuous effective cooling regardless of vehicle state.
2Reliability
If the power module is positioned to minimize impact damage, then safety in accidents is improved, but accessibility for maintenance and repair deteriorates
Solution Approach 1:
The power module is positioned in a segmented location within the engine compartment, specifically in the rear section away from impact-prone areas. This spatial segmentation allows the module to be protected from front and side impacts while still being accessible through the rear or side panels for maintenance purposes.
Solution Approach 2:
The power module is positioned in a three-dimensional space that optimizes both protection and accessibility. By placing it in the rear portion of the engine compartment, it gains protection from common impact directions (front and sides) while maintaining accessibility through rear panel removal or side panel access, effectively utilizing spatial dimensionality to resolve the contradiction.
3Reliability
If redundant cooling system with heat pipes is implemented, then cooling reliability is improved, but device complexity increases
Solution Approach 1:
The heat pipe cooling system is merged with the existing air duct structure. The heat pipes are integrated into the power module housing and connect to the air duct, allowing the same airflow path to serve both passive convection cooling and active heat pipe cooling functions. This merging reduces overall system complexity compared to having completely separate cooling systems.
Solution Approach 2:
The heat pipe system provides passive, self-regulating cooling that requires no external control or power input. The heat pipes automatically transfer heat from the power module to the air duct based on temperature gradients, providing redundant cooling capability without adding complex control systems or increasing operational 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
The design effectively reduces the risk of power module damage and fire in accidents, ensures efficient cooling in all vehicle use scenarios, and maintains cooling system reliability and robustness.
Implementation Method 1
an air duct (120) arranged to guide the air along a guiding profile, between an inlet mouth (1206) located on a front portion of the vehicle, and an outlet mouth (1208) located at the power module (110)
Implementation Method 2
a cooling system arranged to cool the power module (110)
Data Source
AI summary
The invention relates to a motorised vehicle (10) comprising (i) an electric motor (130) situated in an engine compartment (11), the said electric motor (130) being designed to propel the vehicle (10), (ii) a cabin (12) of the vehicle (10), separated from the engine compartment (11) by a dividing wall (70), (iii) an energy storage device (23) configured to supply electrical power to the electric motor (130), (iv) a power module (110) designed to shape at least one electric power signal configured to power the electric motor (130), the said power module (110) being situated between the electric motor (130) and the cabin (12).