Integrated Power Converter with Shared Cooling Paths
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Solution Overview
Problem
In electric vehicles, the high temperature environment in the engine room accelerates the degradation of inverter and DC/DC converter components, and existing cooling mechanisms complicate cooling paths and increase in-vehicle space.
Innovation Solution
A power converter design where an inverter and a DC/DC converter are detachably integrated, with a shared cooling system using coolant paths within the inverter case, allowing efficient cooling of both components while minimizing space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If separate cooling mechanisms are used for the inverter and DC/DC converter, then each component can be cooled effectively, but the cooling paths become complicated and the in-vehicle space increases
Solution Approach 1:
The patent combines the cooling mechanisms of the inverter and DC/DC converter into a single integrated cooling system. The inverter case includes coolant paths that thermally contact both the inverter power semiconductor modules and the DC/DC converter components, allowing one cooling system to serve multiple heat-generating components simultaneously, thereby simplifying the overall cooling path structure while maintaining effective cooling for each component
2Temperature
If separate cooling mechanisms are used for the inverter and DC/DC converter, then each component can be cooled effectively, but the in-vehicle space increases
Solution Approach 1:
The patent merges the cooling systems into a single integrated structure where the inverter case houses both the inverter components and the DC/DC converter, with shared coolant paths. This integration allows both components to be cooled effectively while occupying a single consolidated space in the vehicle engine room, thereby reducing the total volume required compared to separate cooling systems
Solution Approach 2:
The inverter case serves multiple functions: it houses the inverter power semiconductor modules, provides cooling paths for the inverter, thermally contacts the DC/DC converter for cooling, and acts as a structural housing. This multi-functionality reduces the need for separate dedicated cooling structures for each component, minimizing the overall in-vehicle space required
3Volume of stationary object
If the inverter and DC/DC converter are integrated in a high temperature environment, then space is saved, but component degradation and functional deterioration accelerate
Solution Approach 1:
The patent integrates the inverter and DC/DC converter into a single housing structure to reduce device size, while simultaneously implementing a shared cooling system with coolant paths that thermally contact both components. This integrated cooling approach ensures that both components operate at lower temperatures despite the high ambient temperature environment, thereby preventing accelerated degradation and maintaining component reliability
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 prevents component degradation and functional deterioration due to high temperatures while reducing the overall device size and complexity of cooling paths.
Implementation Method 1
a first coolant path 19a is formed in the cooling block 12a... a third coolant path section 19c is formed in the cooling block 12c... the heating components are arranged in an area surrounded by the cooling blocks 12a to 12c in which the coolant paths 19a to 19c are formed
Implementation Method 2
coolant paths 19a to 19c are formed... coolant flows through the coolant paths... cooling the heating components
Data Source
AI summary
A power converter includes an inverter in an inverter case, and a DC/DC converter in a converter case detachably fixed to the inverter case. The inverter includes power semiconductor modules, and the DC/DC converter includes a down-converter circuit and/or a boost converter circuit. The inverter case includes first and second path-forming members thermally contacting the converter case. In the first path-forming member, the power semiconductor module is inserted into a first coolant path. In the second path-forming member, the power semiconductor module inserted into the second coolant path, which is parallel to the first coolant path. The DC/DC converter includes an inductance device, and a switching device board on which a switching device con rolling electric current in the inductance device is mounted. The inductance and switching devices are in an area of the converter case thermally contacting first and second path forming members.