IGBT Load Controller Double-Sided Cooling and Compact Layout
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Solution Overview
Problem
Existing load controllers in electric vehicles have low cooling efficiency due to single-sided contact between coolers and power modules, and an inefficient layout that occupies large space with a small size.
Innovation Solution
A load controller with an IGBT power module that employs double-sided cooling using heat-dissipating fins and a compact layout of the busbar, capacitor, and power module within the casing to achieve high cooling efficiency and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If single-sided contact cooling is used between cooler and power module, then the structure is simple, but the cooling efficiency is low
Solution Approach 1:
The patent transitions from single-sided contact cooling to double-sided cooling by adding heat-dissipating fins on both sides of the IGBT power module. This dimensional change in heat dissipation approach significantly improves cooling efficiency while maintaining reasonable structural complexity through the integration of fins into the module design.
2Ease of manufacture
If unreasonable layout of busbar, power module and cooler is used, then the components are easy to install, but the space occupation is large
Solution Approach 1:
The patent integrates the busbar, IGBT power module, and cooler into a compact unified structure where components are closely arranged and interconnected. The heat-dissipating fins are integrated with the module housing, and the busbar is positioned to optimize space utilization, achieving high power density while maintaining ease of assembly through modular design.
Solution Approach 2:
The patent employs a nested arrangement where the IGBT power module is positioned within the cooler structure, and the busbar is integrated into the same housing space. This nested layout allows multiple components to occupy overlapping or adjacent spaces efficiently, minimizing the overall volume of the load controller while keeping the structure modular for easy installation.
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 results in a load controller that is small in size, light in weight, and high in cooling efficiency, with a simple and reliable connection structure, enhancing the safety and efficiency of electric vehicle operations.
Implementation Method 1
both sides of each IGBT are provided with heat-dissipating fins, thereby realizing double-sided cooling and high cooling efficiency
Implementation Method 2
heat-dissipating fins, thereby realizing double-sided cooling
Data Source
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AI summary
A load controller and an electric vehicle having the load controller are disclosed. The load controller includes a casing; a busbar module, the busbar module including a DC busbar and an AC busbar connected to a load; a capacitor connected to an external DC power supply, the capacitor being connected to the DC busbar; an IGBT power module, an input end of each IGBT being connected to the DC busbar, and an output end of each IGBT being connected to the AC busbar; a heat-dissipating module, the heat-dissipating module including multiple heat-dissipating fins, each IGBT in a same column of IGBTs being sandwiched between adjacent two heat-dissipating fins; a driving circuit board, the driving circuit board being electrically connected to each IGBT; and a control circuit board, the control circuit board being connected to the driving circuit board, where all of the busbar module, the IGBT power module, the heat-dissipating module, the driving circuit board and the control circuit board are mounted on the casing. The load controller according to an embodiment of the present invention is high in cooling efficiency, good in cooling effect and small in size.