Fuel Cell Step-Up Converter Thermal Management

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Solution Overview

Problem

Existing power source systems for vehicles with multiphase converters face inefficiencies that lead to excessively high temperatures in reactor and semiconductor elements, compromising their longevity.

Innovation Solution

A power source system incorporating a fuel cell with a step-up converter that dynamically adjusts the number of drive phases based on output conditions and temperature readings of the reactor and semiconductor elements, ensuring efficient operation while protecting these components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If the multiphase converter operates at maximum efficiency by increasing current passing volume, then energy conversion efficiency is improved, but the reactor and semiconductor elements become excessively hot

Engineering Contradiction:

Improveenergy conversion efficiencyVSAvoidtemperature of reactor and semiconductor elements

Core Design Contradiction:

Loss of energyVSTemperature

Solution Approach 1:

The patent applies dynamics by making the number of drive phases adjustable rather than fixed. The control unit dynamically changes the number of drive phases based on real-time temperature conditions and output requirements, allowing the system to adapt between high-efficiency operation and thermal protection modes

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent changes the operational parameter of the converter by adjusting the number of drive phases (1-phase to 4-phases). This parameter change allows the system to modify its current distribution and thermal characteristics while maintaining voltage conversion functionality

Inventive Principle:

Principle #35Parameter changes

2Power

If the number of drive phases is increased to meet large current output, then power output capability is improved, but the temperature of configuration parts increases excessively

Engineering Contradiction:

Improvecurrent output capabilityVSAvoidtemperature of reactor and semiconductor elements

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The system dynamically adjusts the number of drive phases based on real-time temperature feedback and power output requirements. When temperature exceeds thresholds, the control unit reduces the number of drive phases even if high power is needed, prioritizing component protection

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent implements feedback control by continuously monitoring temperature conditions of the reactor and semiconductor elements, then using this information to adjust the number of drive phases. This closed-loop control ensures power output is maintained within safe thermal limits

Inventive Principle:

Principle #23Feedback

3Productivity

If the multiphase converter operates continuously at high efficiency, then productivity is improved, but the reliability of configuration parts decreases due to excessive heat

Engineering Contradiction:

Improveoperational efficiencyVSAvoidreliability of reactor and semiconductor elements

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies beforehand cushioning by setting temperature thresholds and preparing phase-reduction strategies in advance. When temperatures approach critical levels, the control unit proactively reduces the number of drive phases before damage occurs, preventing reliability degradation

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The system transitions from static high-efficiency operation to dynamic operation that adjusts the number of drive phases based on thermal conditions, maintaining productivity within safe operational boundaries

Inventive Principle:

Principle #15Dynamics

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 allows for high-efficiency power delivery while maintaining the thermal integrity of the reactor and semiconductor elements, preventing overheating and extending their lifespan.

Implementation Method 1

a power source for generating power by an electrochemical reaction between a fuel gas and an oxidation gas

Methodology Applied

Scientific EffectElectrochemical reaction: Fuel Cell

Implementation Method 2

a step-up converter that boosts power from the power source

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS9473026B2Step-up converter for boosting voltage from a power source system

Publication Date: 2016.10.18 TOYOTA JIDOSHA KK

AI summary

The step-up converter includes the plurality of converting units, each having the reactor and the semiconductor element part having electronic parts such as the transistor and the diodes. The ECU performs changeover control of increase or decrease of the number of drive phases of the converting units, based on the output condition from the fuel cell, the temperature condition of the reactor, and the temperature condition of the semiconductor element part.