Fin-Compartment Cooling Plate for Uniform EV Power Electronics Heat Removal
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Solution Overview
Problem
Existing cooling systems for high-power electronics in electric vehicles face inefficiencies due to high pressure drop and non-uniform temperature distribution, particularly in configurations with meander-shaped coolant paths that reduce turbulence and mixing.
Innovation Solution
A cooling device with an inner coolant chamber featuring arrays of fins that create turbulence and mixing by allowing coolant to flow laterally through compartments, using recesses to overlap fins and guide coolant in opposite directions, enhancing thermal uptake and temperature uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If meander-shaped coolant paths are used to cool electronics, then the coolant flow path is extended and cooling coverage is improved, but pressure drop increases substantially
Solution Approach 1:
The cooling device divides the coolant chamber into multiple compartments using arrays of fins as compartment walls. This segmentation allows the coolant to flow through multiple compartments in series, extending the cooling path and improving cooling coverage while managing pressure drop through controlled compartment transitions.
Solution Approach 2:
The fins extend into the coolant chamber from the coolant chamber walls, creating a three-dimensional flow structure. The coolant flows laterally through compartments formed by these fins, adding a lateral flow dimension that extends the cooling path without substantially increasing pressure drop compared to simple meander paths.
2Productivity
If smooth canal-forming fins are used to reduce turbulence, then pressure drop is reduced and flow speed is increased, but mixing of coolant is reduced and thermal uptake capacity is not fully exploited
Solution Approach 1:
The fins are configured with specific geometric properties (spacing, length, arrangement) that create controlled turbulence in specific regions of the coolant chamber. This local turbulence enhancement improves mixing and thermal uptake in the coolant without substantially reducing overall flow speed or increasing pressure drop.
3Temperature
If arrays of fins are used to create turbulence and mixing, then thermal uptake is enhanced and temperature uniformity is improved, but device complexity increases
Solution Approach 1:
The arrays of fins serve multiple functions simultaneously: they act as compartment walls to divide the coolant chamber, create turbulence and mixing through their geometric configuration, and provide thermal conduction paths from the coolant chamber walls to the coolant. This multi-functionality achieves temperature uniformity without proportionally increasing device 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 solution achieves improved cooling efficiency by increasing turbulence and mixing, resulting in uniform temperature distribution and enhanced thermal energy transfer, suitable for low-cost mass production.
Implementation Method 1
For flow through the compartment, the coolant crosses the fins, which creates turbulence in the compartments for better mixing of the coolant and increased thermal uptake
Implementation Method 2
the electronic components are provided on an outer side of a first coolant chamber wall of a cooling device... a thermally conductive support plate
Data Source
Figure 1~2
Figure 3
Figure 4A~4B
AI summary
For efficient cooling of electronic components (3), in particular power electronics in an electric vehicle, the electronic components (3) are provided on an outer side of a first coolant chamber wall (2A) of a cooling device (1). The cooling device (1) has an inner coolant chamber (10) with an array of compartments (14) formed by first and second fins (13A, 13B) lateral to the flow direction (5). For flow through the compartments (14), the coolant flows between a pair of two fins (13A, 13B) that form compartment walls (20).