Integrated Power Control Assembly with Built-in Cooling

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Solution Overview

Problem

Conventional motor drive systems in electric and hybrid electric vehicles face inefficiencies due to separate motor and power control unit enclosures, leading to increased power loss, weight, and complexity, with inadequate heat management from conventional heat sinks.

Innovation Solution

Integrated power control assemblies with built-in cooling systems, featuring power plates, cooling plates, and circuit boards mounted directly on the motor, eliminating the need for separate cooling systems and reducing thermal resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional heat sinks are used for cooling power control assemblies, then cooling capability is provided, but thermal resistance increases and packaging size increases

Engineering Contradiction:

Improveoperating temperatureVSAvoidthermal management complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The cooling mechanism is merged directly into the power control assembly structure. The heat sink is integrated with the PCB and power components, eliminating the need for separate cooling systems and reducing thermal resistance through direct thermal coupling without additional bonding layers.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent removes conventional heat sinks and cooling structures from the system, replacing them with an integrated cooling mechanism built directly into the power control assembly, thereby eliminating packaging size increases and thermal management complexity.

Inventive Principle:

Principle #2Taking out (Extraction)

2Adaptability or versatility

If separate enclosures are used for motor and power control unit, then design flexibility is maintained, but power density decreases and system efficiency reduces

Engineering Contradiction:

Improvedesign flexibilityVSAvoidpower density

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The power control assembly is merged directly onto the motor structure, with the PCB mounted on the motor housing and power components positioned in close proximity to the motor windings. This integration eliminates separate enclosures while maintaining design flexibility through modular component placement.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If interconnecting cables are used between motor and power control unit, then electrical connections are established, but power loss increases and weight increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidpower loss

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent removes interconnecting cables from the system by directly mounting the power control assembly onto the motor. Electrical connections are made through direct bonding of power components to motor terminals, eliminating cable-related power losses and weight.

Inventive Principle:

Principle #2Taking out (Extraction)

4Temperature

If conventional heat sinks are used, then cooling is provided, but additional bonding layers and thermal matching materials are required

Engineering Contradiction:

Improveheat dissipationVSAvoidpackaging materials

Core Design Contradiction:

TemperatureVSQuantity of substance

Solution Approach 1:

The patent eliminates conventional heat sinks and the associated bonding layers, thermal interface materials, and matching substrates by integrating the cooling mechanism directly into the power control assembly structure, thereby reducing packaging materials.

Inventive Principle:

Principle #2Taking out (Extraction)

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

Enhances thermal management, reduces weight and volume, and improves efficiency by integrating cooling mechanisms directly into the power control assemblies, effectively managing heat generated during operation.

Implementation Method 1

one or more cooling plates coaxially disposed on and thermally connected to the one or more power plates

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11476737B2Integrated power control assemblies with built-in cooling systems

Publication Date: 2022.10.18 TOYOTA JIDOSHA KK

AI summary

An integrated power control assembly configured as an inverter for a motor is mounted directly on an axial end of the motor. The integrated power control assembly includes one or more power plates, one or more cooling plates coaxially disposed on and thermally connected to the one or more power plates, and one or more circuit boards circumferentially disposed around the one or more power plates. An individual power plate has a power card having one or more switching semiconductor devices corresponding to individual phases of the motor. The individual power card is electrically coupled to the motor through one or more busbars. An individual circuit board is electrically coupled to an individual power card corresponding to an individual phase of the motor. The individual circuit board has a first surface electrically coupled to the one or more power plates and a second surface opposite to the first surface.