Integrated Heat Exchanger Channels to Prevent Seal Leakage
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Solution Overview
Problem
Conventional heat exchangers for power modules in inverter systems face challenges with fluid leakage due to the need for seals between separate portions of the heat exchanger, which can lead to corrosion and reduced robustness.
Innovation Solution
The heat exchanger features a body with integrally formed enclosed channels that are in fluid communication with the inlet and outlet, eliminating the need for separate seals and reducing the risk of fluid leakage. Additionally, the channels can define a meandering path to enhance heat extraction efficiency, and a constant width along the channel length ensures uniform heat extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate portions are used in the heat exchanger body, then manufacturing flexibility is improved, but seal leakage risk increases
Solution Approach 1:
The patent merges multiple separate portions into a single integrally formed heat exchanger body with enclosed channels. This eliminates the need for seals between portions, thereby removing the leakage risk while maintaining manufacturing flexibility through integral forming processes.
2Productivity
If channel width varies along the length, then flow distribution may be improved, but heat extraction uniformity deteriorates
Solution Approach 1:
The patent applies local quality by making the channel width constant along its length, ensuring uniform heat extraction characteristics throughout the channel. This consistent geometry provides stable and uniform thermal performance across the entire heat exchanger body.
3Ease of manufacture
If channel path is linear, then manufacturing simplicity is improved, but heat extraction efficiency deteriorates
Solution Approach 1:
The patent employs curved or meandering channel paths instead of linear channels. This curvature increases the effective heat transfer surface area and improves thermal contact between the fluid and heat exchanger body, thereby enhancing heat extraction efficiency while remaining manufacturable through integral forming.
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 design enhances the robustness of the heat exchanger by minimizing the risk of fluid leakage and corrosion, while also improving heat extraction efficiency through the meandering channel design and uniform width configuration.
Implementation Method 1
Heat is generated by the power modules in use, which can lead to overheating. Overheating is undesirable as it can impair the function of the power module, and ultimately lead to failure of the power module. Heat is typically extracted by a suitable heat exchanger to reduce the likelihood of overheating.
Implementation Method 2
Conventional heat exchangers operate by supplying a fluid to the heat exchanger so that the heat generated by the power module passes to the fluid.
Data Source
AI summary
A heat exchanger for a power module for an inverter system includes a body that defines an inlet and an outlet. At least one enclosed channel is integrally formed within the body. The at least one enclosed channel is in fluid communication with the inlet and the outlet. A power module for an inverter system includes a substrate, the heat exchanger, and a cover that at least partially covers the substrate and the heat exchanger.