Integrated ECU Heatsink in Aluminum Body Casting

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Solution Overview

Problem

Existing heatsinks for ECUs in vehicles are separate components that require dedicated manufacturing and space, and increasing their surface area is difficult, leading to inefficient cooling and space utilization.

Innovation Solution

Integrally casting a heatsink with a vehicle body component, such as a single-piece aluminum diecast component, to enhance heat dissipation without significantly increasing size, using fins or pins for improved surface area and integrating a resin cover for design and thermal insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a separate heatsink is used for the ECU, then heat dissipation can be achieved, but dedicated manufacturing process and mounting space are required

Engineering Contradiction:

Improveheat dissipation capabilityVSAvoidcomponent structure

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The heatsink is integrated into the vehicle body component as a unified structure. The body component includes a heatsink on the back side of the portion to which the ECU is attached, eliminating the need for a separate heatsink component and dedicated mounting space while maintaining heat dissipation functionality

Inventive Principle:

Principle #5Merging (Combining)

2Temperature

If the heatsink surface area is increased to improve heat dissipation, then cooling performance improves, but the size of the heatsink becomes significantly larger

Engineering Contradiction:

Improveheat dissipation capabilityVSAvoidheatsink surface area

Core Design Contradiction:

TemperatureVSArea of stationary object

Solution Approach 1:

The heatsink utilizes the third dimension by extending toward the outside of the vehicle from the body component. This vertical extension allows increased heat dissipation surface area without significantly increasing the horizontal footprint, effectively solving the space constraint problem

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Temperature

If the heatsink extends toward the outside of the vehicle, then heat dissipation efficiency improves, but space for occupants may be reduced

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidoccupant space

Core Design Contradiction:

TemperatureVSVolume of moving object

Solution Approach 1:

The heatsink is positioned in the specific local region between the ECU and the occupant space, targeting the heat dissipation function in the direction away from the occupant. This localized placement ensures efficient heat dissipation while minimizing impact on occupant volume

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

Effectively cools the ECU while improving space efficiency and occupant comfort by enhancing heat dissipation and reducing thermal resistance, maintaining design quality and reducing costs.

Implementation Method 1

The body component includes a heatsink on the back side of a portion of the body component to which the ECU is attached. The body component is a single-piece aluminum diecast component including the heatsink.

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

The heatsink may include a plurality of heat dissipation fins arranged parallel to each other or a plurality of heat dissipation pins arranged in a two-dimensional array. This configuration increases the surface area of the heatsink and thus improves the heat dissipation effect of the heatsink.

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Implementation Method 3

causing the heatsink to protrude toward the outside of the vehicle allows efficient heat dissipation from the ECU

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20260054660A1Cooling structure for in-vehicle ecu

Publication Date: 2026.02.26 TOYOTA JIDOSHA KK

AI summary

A cooling structure for an in-vehicle ECU includes: a body component that is part of a vehicle body; and an ECU attached to the body component. The body component includes a heatsink on the back side of a portion of the body component to which the ECU is attached. The body component is a single-piece aluminum diecast component including the heatsink.