Flow-Guided Cooling Element for Low-Pressure-Loss ECU Cooling
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Solution Overview
Problem
Conventional cooling systems for automotive electronic devices suffer from increased pressure loss and reduced cooling effectiveness due to flow disturbances and vortex formation, which are exacerbated by space constraints in tight automotive assemblies.
Innovation Solution
A cooling system featuring a flow reverse element and a flow guiding element that guides coolant from an inflow channel to an outflow channel, reducing pressure loss and enhancing heat exchange by minimizing flow separation and vortex formation, while maintaining a compact size to accommodate space restrictions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional closing caps are used to turn the flow in cold plates, then the flow can be redirected from the first flow channel to the second flow channel, but flow disturbances and vortex formation occur causing increased pressure loss
Solution Approach 1:
The flow guiding element employs curved surfaces and rounded edges to guide the coolant flow smoothly from the first flow channel to the second flow channel. The curved geometry eliminates sharp corners that would cause flow separation and vortex formation, thereby reducing pressure loss while maintaining effective flow redirection.
2Loss of energy
If the size of corners is increased to turn flow smoothly, then pressure loss is reduced, but more space is required for the closing caps
Solution Approach 1:
The flow guiding element introduces localized curved surface features only at the critical flow transition zones where smooth turning is needed, rather than increasing the overall size of the closing cap. This allows smooth flow redirection with minimal space requirement, as the curvature is applied locally at the flow guidance surfaces rather than throughout the entire component.
3Ease of manufacture
If simple longitudinal profiles are used for cold plates, then manufacturing is simplified and cost-effective, but closing caps are needed to close flow conduits which cause flow disturbances
Solution Approach 1:
The flow guiding element is integrated as part of the closing cap structure, combining the flow redirection function with the sealing function in a single component. This maintains the simplicity of the overall cold plate manufacturing while eliminating the need for separate flow guidance features that would compromise cooling effectiveness.
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 with reduced pressure loss and increased heat exchange, allowing for a larger effective cooling surface within a smaller footprint, making it more economical and suitable for automotive applications.
Implementation Method 1
flow disturbances and vortex formation, which are exacerbated by space constraints in tight automotive assemblies
Implementation Method 2
flow disturbances and vortex formation
Implementation Method 3
enhancing heat exchange by minimizing flow separation and vortex formation
Data Source
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AI summary
The present invention relates to a cooling system for an electrical control unit of a vehicle, the cooling system (1) comprising: a cooling element (10) comprising a first (11) and second (12) flow channel for a coolant; a flow reverse element (20; 20'; 20") adapted to guide coolant from the first flow channel (11) to the second flow channel (12); a flow guiding element (30; 30') for guiding at least part of the coolant from the first flow channel (11) to the second flow channel.