Integrated Heat Exchanger for Rack Power Components
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Solution Overview
Problem
Traditional heat exchangers for rack assemblies are inadequate for both power electronic and electromagnetic components, requiring complex and expensive ventilation arrangements, which complicates thermal management and component installation in low voltage applications like battery charger installations.
Innovation Solution
A heat exchanger structure with a shaped body of thermally conductive material, featuring a first portion for power electronic components and a second portion with a recess for power electromagnetic components, providing mechanical support, heat absorption, and dissipation, while facilitating cooling fluid passage and segregation of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional separate heat exchangers are used for power electronic components and power electromagnetic components, then each component type can be cooled individually, but the ventilation arrangements become complex and expensive
Solution Approach 1:
The patent combines the heat exchangers for power electronic components and power electromagnetic components into a single integrated heat exchanger structure. This unified structure includes a first heat exchanging portion for electronic components and a second heat exchanging portion for electromagnetic components, both forming part of the same heat exchanger assembly. This merging eliminates the need for separate ventilation arrangements for each component type, thereby reducing system complexity and cost while maintaining effective cooling for both component types.
Solution Approach 2:
The integrated heat exchanger structure serves multiple functions simultaneously: it provides heat exchange for both power electronic components and power electromagnetic components, acts as a structural support element, and facilitates thermal management for the entire power converter assembly. This multi-functionality reduces the overall number of components needed and simplifies the ventilation arrangement design.
2Reliability
If traditional heat exchangers are used that only support power electronic components, then cooling for electronic components is effective, but power electromagnetic components require additional complex ventilation arrangements
Solution Approach 1:
The heat exchanger structure merges the cooling functions for both power electronic components and power electromagnetic components into a single integrated system. The first heat exchanging portion accommodates electronic components while the second heat exchanging portion accommodates electromagnetic components, both within the same heat exchanger assembly. This integration maintains effective cooling for power electronic components while simultaneously providing cooling for power electromagnetic components, thereby simplifying thermal management operations.
3Reliability
If separate ventilation arrangements are implemented for electronic and electromagnetic components, then each component type is properly cooled, but the overall system cost increases
Solution Approach 1:
The patent merges separate heat exchanger systems into a single integrated heat exchanger structure that serves both power electronic components and power electromagnetic components. This consolidation reduces the total number of components, simplifies manufacturing processes, and lowers production costs while maintaining proper cooling performance for all components.
Solution Approach 2:
The integrated heat exchanger structure provides universal cooling functionality for multiple component types (both electronic and electromagnetic components) through a single system. This multi-functionality reduces the overall system cost by eliminating redundant components and simplifying the manufacturing process, while ensuring reliable cooling for all power converter components.
4Ease of operation
If traditional heat exchanger designs are used, then power electronic components are supported and cooled, but power electromagnetic components require separate complex ventilation arrangements
Solution Approach 1:
The integrated heat exchanger structure combines support and cooling functions for both power electronic components and power electromagnetic components into a single assembly. This merger simplifies component installation as both types of components can be mounted on the same heat exchanger structure, and reduces ventilation arrangement complexity by using a unified cooling system instead of separate arrangements.
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 enables efficient cooling and structural integration of both electronic and electromagnetic components, simplifying thermal management and installation, while reducing costs and complexity, and ensuring compliance with international standards.
Implementation Method 1
a shaped body of thermally conductive material... adapted to absorb and dissipate heat generated by said power electronic components
Implementation Method 2
adapted to absorb and dissipate heat generated by said power electromagnetic components
Data Source
Figure 1
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AI summary
Heat exchanger structure for a rack assembly formed by a shaped body of thermally conductive material. The heat exchanger structure comprises a first heat exchanging portion adapted to provide a mechanical support for one or more power electronic components of said rack assembly and adapted to absorb and dissipate heat generated by said power electronic components. The heat exchanger structure comprises a second heat exchanging portion adapted to provide a mechanical support for one or more power electromagnetic components of said rack assembly and adapted to absorb and dissipate heat generated by said power electromagnetic components.