Integrated Power Module Thermal Management via Intermediate Cold Plate
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Solution Overview
Problem
Conventional DC-link capacitor designs face challenges in thermal management due to low thermal conductivity of materials, leading to high thermal resistance and overheating, especially when integrated with power modules in electric vehicles, where the operating temperature differences between components pose additional heating issues.
Innovation Solution
An integrated capacitor and power module design featuring an intermediate cold plate with a fluid circulation system and busbars that connect oppositely oriented capacitor cell arrays, providing enhanced thermal paths and electrical isolation, while using metalized film capacitors supported by a copper base plate with thermal interface material for improved heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional DC-link capacitor designs are used with low thermal conductivity materials, then manufacturing is simpler, but thermal resistance increases leading to overheating
Solution Approach 1:
The patent employs composite material construction for the capacitor module housing, combining materials with different thermal properties. The housing includes thermally conductive portions (such as metal busbars and housing sections) that provide thermal pathways, while other portions may use insulating materials. This composite approach allows the module to achieve low thermal resistance where needed while maintaining manufacturing feasibility through modular assembly of different material components.
2Volume of moving object
If power module and capacitor module are integrated closer to downsize the system, then system weight and volume are reduced, but thermal management becomes more difficult due to operating temperature differences
Solution Approach 1:
The patent introduces an intermediate cold plate as a mediator between the power module and capacitor module. This cold plate serves as a thermal interface component that facilitates heat transfer from both modules to a shared cooling system. The intermediate cold plate includes coolant flow channels that allow thermal coupling between the two modules, enabling them to be positioned closer together while maintaining effective thermal management through the mediating thermal pathway.
Solution Approach 2:
The intermediate cold plate performs multiple functions: it serves as a thermal pathway for both the power module and capacitor module, provides structural support for mounting both modules, and acts as a coolant distribution manifold. This multi-functional component enables compact integration by consolidating thermal management, mechanical support, and fluid distribution functions into a single element.
3Reliability
If busbars are designed to connect oppositely oriented cell arrays, then electrical connectivity is improved, but structural complexity increases
Solution Approach 1:
The patent merges the electrical connection function and thermal management function into the busbar structure. The busbars are designed to electrically connect oppositely oriented capacitor cell arrays while simultaneously serving as thermal pathways to the intermediate cold plate. This merging of functions reduces the need for separate connection components and simplifies the overall structure despite the complex electrical connectivity requirements.
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 effectively reduces thermal resistance and enhances cooling efficiency, allowing for downsized traction drive systems by efficiently managing heat transfer between the power and capacitor modules, thus addressing the overheating challenges and enabling closer integration without exceeding temperature limits.
Implementation Method 1
A fluid circulation system is operatively connected to the intermediate cold plate to circulate a fluid through the cold plate
Implementation Method 2
a base cold plate with a layer of thermal interface material between the metal plate and the base cold plate
Implementation Method 3
An integrated capacitor and power module design featuring an intermediate cold plate with a fluid circulation system... providing enhanced thermal paths... for improved heat dissipation
Data Source
AI summary
An integrated capacitor and power module include a power module, an intermediate cold plate, and a capacitor module. The intermediate cold plate has a first side attached to the power module and a second side opposite the first side. The capacitor module is attached to a second side of the intermediate cold plate. The capacitor module includes a plurality of metalized film capacitor cells supported by a metal plate and a base cold plate with a layer of thermal interface material between the metal plate and the base cold plate. A fluid circulation system is operatively connected to the intermediate cold plate to circulate a fluid through the cold plate. The capacitor module includes a housing, a plurality of capacitor cells and first and second busbars. Alternating cell arrays have a P-end and an N-end that are inverted relative to each other.