Heat Pipe Electric Wire for High-Power EV Cooling
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Solution Overview
Problem
High-power conversion devices in electric vehicles, such as on-board chargers, inverters, and DC-DC converters, generate substantial heat due to high frequency and power, leading to performance deterioration and increased vulnerability to temperature, with existing cooling solutions being expensive and inefficient in managing heat generated by proximity and skin effects.
Innovation Solution
An electric wire with a heat pipe structure incorporating a wick part for phase-change refrigerant flow, a conductive part made of copper, and an insulating cover with via holes for efficient heat transfer and current conduction, minimizing current flow reduction and enhancing cooling functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooling system is added to manage heat in high-power conversion devices, then temperature control is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines the electrical conductor function and cooling function into a single integrated wire structure. The heat pipe structure is integrated within the wire, allowing heat dissipation without requiring separate cooling components. This merging approach improves temperature control while avoiding the complexity and cost of additional cooling systems.
Solution Approach 2:
The wire structure performs multiple functions simultaneously: it conducts electricity and dissipates heat through the integrated heat pipe mechanism. The conductive part serves both as an electrical conductor and as a thermal management component, eliminating the need for separate cooling devices and reducing overall system complexity.
2Temperature
If a heat pipe structure is integrated into the electric wire, then cooling functionality is improved, but current flow efficiency may be reduced
Solution Approach 1:
The heat pipe structure is positioned in the central non-conductive area of the wire, where it does not interfere with the electrical current flow path. The conductive part maintains its electrical conductivity while the central heat pipe structure provides cooling, allowing both functions to coexist without compromising current flow efficiency.
Solution Approach 2:
The non-conductive part acts as an intermediary that separates the electrical current flow path from the heat pipe structure. This intermediary layer allows the heat pipe to function effectively for cooling while preventing interference with the electrical current, maintaining both cooling functionality and current flow efficiency.
3Temperature
If the conductive part surface area is expanded for better heat dissipation, then cooling efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
Instead of expanding the surface area in two dimensions, the patent extends the heat dissipation function into the third dimension by incorporating a longitudinal heat pipe structure that runs along the wire. This dimensional approach allows heat dissipation along the length of the wire without requiring complex surface expansions, simplifying manufacturing while improving cooling efficiency.
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 electric wire effectively manages heat dissipation while maintaining current flow efficiency, reducing the impact of proximity and skin effects, and providing a cost-effective cooling solution for high-power conversion devices in electric vehicles.
Implementation Method 1
a wick part having a channel in an internal space to allow a refrigerant in a gas state with a phase changed by heat to flow, and passing the refrigerant in a liquid state with the phase changed by heat using a capillary phenomenon
Implementation Method 2
a heat pipe type of electric wire... using a heat exchange principle of a heat pipe
Implementation Method 3
using a heat exchange principle of a heat pipe
Data Source
AI summary
The electric wire is a heat pipe type of electric wire and includes a wick part having a channel in an internal space in which a refrigerant in a gas state with a phase changed by heat flows, and passing the refrigerant in a liquid state with the phase changed by heat using a capillary phenomenon. A conductive part surrounds and seals the wick part and is made of a conductive material and an insulating cover insulates the conductive part from the outside by surrounding the conductive part. The insulating cover has one or more via holes exposing the conductive part to the outside.