Integrated Heat Exchanger Assembly for Multi-Source ECU Cooling
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Solution Overview
Problem
High-performance electronic control units in vehicles generate significant heat that needs to be effectively managed to ensure safe and efficient operation, particularly under high loads, and existing cooling solutions are inadequate.
Innovation Solution
A heat exchanger assembly comprising a heat exchanger with primary and terminal tubes, interconnected by fluid channels, and multiple heat source modules, including PCB boards with integrated circuits, sandwiched between the tubes, and a chassis for mounting and protection, facilitating efficient heat exchange and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If air cooling is used for heat sources, then the cooling system is simple, but the heat dissipation effectiveness is insufficient for high-performance units
Solution Approach 1:
The patent introduces a heat exchanger assembly as an intermediary component between the heat sources and the cooling system. This assembly includes a primary tube with heat exchange fluid channels and multiple attachments with contact portions that directly touch the heat sources, effectively transferring heat from the heat sources to the cooling fluid.
Solution Approach 2:
The patent transitions from single-point or single-surface air cooling to multi-point thermal contact by providing multiple attachments with contact portions that touch different locations on the heat sources. This dimensional expansion of thermal contact areas significantly improves heat dissipation effectiveness.
2Reliability
If multiple heat sources are cooled separately, then each heat source receives dedicated cooling, but the overall system complexity increases
Solution Approach 1:
The patent merges multiple cooling functions into a single integrated heat exchanger assembly. Multiple attachments are connected to a common primary tube that contains heat exchange fluid channels, allowing simultaneous cooling of multiple heat sources through one unified structure rather than separate cooling systems for each heat source.
Solution Approach 2:
The primary tube serves multiple functions: it contains the heat exchange fluid, provides structural support for multiple attachments, and acts as a common thermal pathway for heat from multiple different heat sources. This multi-functional design reduces overall system complexity while maintaining effective thermal management.
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 assembly provides effective thermal management for high-performance electronic control units by efficiently dissipating heat from multiple heat sources, ensuring reliable operation and compact integration within vehicle environments.
Implementation Method 1
an attachment with a plurality of contact portions exposed to the plurality of first heat sources, mounted on the primary tube adjacent to the first fluid channel
Implementation Method 2
a primary tube including a first fluid channel for a heat exchange fluid
Data Source
AI summary
A heat exchanger assembly, including a heat exchanger with a primary tube including a first fluid channel for a heat exchange fluid; a first heat source module with a plurality of first heat sources; an attachment with a plurality of contact portions exposed to the plurality of first heat sources, mounted on the primary tube adjacent to the first fluid channel.