Integrated Cooling Boss Cold Plate for Power Module Uniformity
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Solution Overview
Problem
Current cooling solutions for high-heat flux components in aircraft electrical power conversion and distribution systems, such as power modules and circuit breakers, are inadequate, leading to temperature non-uniformity and reduced reliability, especially at increased power levels required for electrified propulsion and future high-power applications.
Innovation Solution
An additively manufactured cold plate with integrated cooling bosses and fins, featuring variable fin density and z-axis cooling, is designed to achieve temperature uniformity and enhanced heat transfer, utilizing additive manufacturing processes like 3D printing to form a unitary body with optimized internal channels and flow direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If power levels are increased for electrified propulsion and future high-power applications, then power capability is improved, but heat dissipation increases leading to temperature non-uniformity and reduced reliability
Solution Approach 1:
The cold plate is divided into multiple regions with dedicated cooling channels for each power module, allowing independent thermal management. Each power module has its own cooling boss with internal channels, enabling localized heat dissipation and preventing temperature non-uniformity across the entire plate.
Solution Approach 2:
Different regions of the cold plate are designed with varying cooling intensities based on local heat generation. Power modules with higher heat dissipation have dedicated cooling bosses with optimized channel configurations, while lower-heat regions have reduced cooling infrastructure, achieving uniform temperature distribution across non-uniform heat sources.
2Power
If power modules are made larger to handle increased power levels, then power capability is improved, but susceptibility to temperature non-uniformity increases
Solution Approach 1:
Large power modules are segmented into multiple cooling zones with dedicated channels. Instead of relying on a single cooling system for the entire module, each zone has its own cooling boss with internal channels, ensuring uniform heat removal across large surfaces and maintaining temperature uniformity even in high-power applications.
Solution Approach 2:
Cooling channels are extended into the third dimension through vertical cooling bosses that penetrate the cold plate. This three-dimensional channel configuration increases the effective heat transfer surface area and improves thermal contact with power modules, effectively managing heat in large-scale high-power applications.
3Ease of manufacture
If conventional cooling solutions are used for high-heat flux components, then manufacturing simplicity is maintained, but cooling effectiveness is inadequate at increased power levels
Solution Approach 1:
The cold plate and cooling channels are merged into a single integrated component manufactured by additive manufacturing. The cooling bosses with internal channels are built directly into the plate structure, eliminating the need for separate cooling components and assembly operations while achieving superior cooling effectiveness for high-power applications.
Solution Approach 2:
The manufacturing process parameters of additive manufacturing are optimized to create complex internal channel geometries that are impossible to achieve with conventional methods. This allows for optimized flow paths, variable channel cross-sections, and precise thermal management features that dramatically improve cooling effectiveness without increasing manufacturing complexity.
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 provides improved temperature uniformity and thermal management, enhancing the reliability of power modules and bus bars by maintaining consistent temperatures across large surface areas and critical mounting locations.
Implementation Method 1
cold plate with temperature uniformity and integrated cooling bosses for an electrical power conversion and distribution system
Implementation Method 2
defining a first interior channel extending across the region in a first plane... the frame defines a second interior channel communicative with the first interior channel
Implementation Method 3
The cold plate body includes fins extending through the first interior channel
Data Source
AI summary
A cold plate is provided and includes an additively manufactured integral components layered together to form a unitary body. The additively manufactured integral components include a cold plate body having a region on which a power module is disposable and defining a first interior channel extending across the region in a first plane, a frame to support the cold plate body and a cooling boss. The frame defines a second interior channel communicative with the first interior channel and extends along a periphery of the cold plate body in the first plane. The cooling boss is attached to the frame. The cooling boss defines a third interior channel communicative with the second channel and extends in a second plane transverse to the first plane.