Hybrid Module Heat Protection Hood Thermal Management

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Solution Overview

Problem

Existing cooling devices for hybrid vehicle modules fail to effectively cool actuators and control electronics in hot environments, such as near internal combustion engines or exhaust systems, leading to deactivation or damage from excessive heat.

Innovation Solution

A heat protection hood made of a heat-conducting material, such as aluminum or copper, is integrated with the actuator and housing part of the hybrid module, forming a closed heat sink system that efficiently dissipates heat away from critical components, while a smooth outer surface and heat insulation layer minimize heat absorption from the surroundings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the actuator is placed in the region of hot components (internal combustion engine or exhaust system), then the hybrid module can be compactly integrated, but the control electronics are exposed to excessive heat leading to damage or deactivation

Engineering Contradiction:

Improveintegration efficiencyVSAvoidheat exposure

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The housing is divided into a hot side housing part (exposed to engine heat) and a cold side housing part (containing control electronics), separated by a heat protection hood that acts as a thermal barrier, allowing compact integration while protecting sensitive components

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A heat protection hood made of heat-conducting material is introduced as an intermediary component between the hot environment and the control electronics, conducting heat away from the electronics while maintaining the compact hybrid module structure

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If a heat protection hood made of heat-conducting material is used to protect control electronics, then heat is effectively conducted away from critical components, but the hood itself absorbs heat from the surrounding hot environment

Engineering Contradiction:

Improveheat protectionVSAvoidhood temperature

Core Design Contradiction:

Object-affected harmful factorsVSTemperature

Solution Approach 1:

The heat protection hood has different surface properties on different sides: the inner surface facing control electronics is highly heat-conductive to protect them, while the outer surface exposed to hot environment is thermally insulated to reduce heat absorption from the surroundings

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The heat protection hood is constructed as a composite structure with an inner heat-conducting material (such as aluminum or copper) and an outer heat-insulating material, combining the benefits of both materials to achieve effective heat protection while minimizing heat absorption

Inventive Principle:

Principle #40Composite materials

3Temperature

If cooling ribs are added to the heat protection hood to increase heat dissipation, then heat removal efficiency improves, but the outer surface area increases leading to greater heat absorption from the surrounding hot environment

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidheat absorption

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

Cooling ribs are added only to the inner surface of the heat protection hood that faces the control electronics, where they enhance heat dissipation from the electronics without increasing the outer surface area that would be exposed to hot surrounding environment

Inventive Principle:

Principle #3Local quality

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 solution effectively protects the actuator and control electronics from excessive heat, preventing damage and ensuring reliable operation by maintaining a cooler temperature within the hybrid module, even in hot environments, thus enhancing the durability and performance of the hybrid vehicle's components.

Implementation Method 1

Heat generated by the hot external components or by the actuator and/or the control electronics can be introduced over a short path through the heat conducting material of the heat protection hood and into the housing part of the hybrid module

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

The heat protection hood has an outer surface with low heat transmission of the medium surrounding the heat protection hood on the outside into the heat protection hood

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS9636994B2Cooling device for a hybrid module of a hybrid vehicle

Publication Date: 2017.05.02 DR ING H C F PORSCHE AG

AI summary

A cooling device (2) is provided for a hybrid module (1) of a hybrid vehicle. The hybrid module (1) has an actuator arranged between an internal combustion engine and an electric drive unit of the hybrid vehicle for actuating a separating clutch for separating the internal combustion engine and the electric drive unit. The hybrid module (1) also has control electronics (7). The actuator and the control electronics (7) are arranged within a heat protection hood (9) and at least the control electronics (7) are connected to the heat protection hood (9). The heat protection hood (9) is composed of heat-conducting material and is connected to a housing part (5) of the hybrid module (1). The cooling device enables use of the hybrid module in the region of hot components, such as the internal combustion engine or an exhaust system.