Integrated Power Unit with Nested Cooling Channels
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Solution Overview
Problem
Existing power conversion systems in hybrid, electric, and fuel cell vehicles face challenges in cooling efficiency, size reduction, and versatility in handling various capacities due to the complex integration of power modules, capacitor modules, and coolant flow paths.
Innovation Solution
A power unit with a power module, cooling modules, and capacitor modules integrated in a compact structure, where cooling channels absorb heat and capacitors are mounted on the power module, with a stackable design and non-conductive capacitor housing, and elastic support for efficient cooling and capacity adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If power module, capacitor module, and coolant flow paths are separately configured, then ease of manufacture is improved, but device complexity and size increase
Solution Approach 1:
The patent combines the power module, capacitor module, and coolant flow paths into a single integrated power unit. The housing simultaneously accommodates all three components, with coolant channels directly formed within the housing structure to provide cooling to both the power module and capacitor module, eliminating the need for separate cooling systems and reducing overall system complexity.
Solution Approach 2:
The housing serves multiple functions: it provides structural support, contains the power module and capacitor module, forms coolant flow paths, and acts as a thermal management system. The integrated design allows a single component (the housing) to perform what previously required multiple separate components, reducing device complexity while maintaining ease of manufacture.
2Ease of manufacture
If power module, capacitor module, and coolant flow paths are separately configured, then ease of manufacture is improved, but size increases
Solution Approach 1:
The patent combines the power module, capacitor module, and coolant flow paths into a single integrated power unit. The housing simultaneously accommodates all three components, with coolant channels directly formed within the housing structure to provide cooling to both the power module and capacitor module, eliminating the need for separate cooling systems and reducing overall system complexity.
Solution Approach 2:
The power module and capacitor module are nested within the housing that also contains the coolant channels. The coolant channels are formed within the housing structure itself, creating a nested arrangement where components are arranged concentrically or in overlapping spaces, maximizing space utilization and minimizing the overall volume of the power unit.
3Temperature
If integrated cooling structure is used, then cooling efficiency is improved, but device complexity increases
Solution Approach 1:
The patent combines the power module, capacitor module, and coolant flow paths into a single integrated power unit. The housing simultaneously accommodates all three components, with coolant channels directly formed within the housing structure to provide cooling to both the power module and capacitor module, eliminating the need for separate cooling systems and reducing overall system complexity.
Solution Approach 2:
The housing itself provides the cooling function through integrated coolant channels formed within its structure. The housing serves its own cooling needs and simultaneously cools the power module and capacitor module, eliminating the need for external or separate cooling systems. This self-service approach improves cooling efficiency while avoiding the complexity of additional dedicated cooling components.
4Temperature
If integrated cooling structure is used, then size is reduced, but device complexity increases
Solution Approach 1:
The patent combines the power module, capacitor module, and coolant flow paths into a single integrated power unit. The housing simultaneously accommodates all three components, with coolant channels directly formed within the housing structure to provide cooling to both the power module and capacitor module, eliminating the need for separate cooling systems and reducing overall system complexity.
Solution Approach 2:
The housing itself provides the cooling function through integrated coolant channels formed within its structure. The housing serves its own cooling needs and simultaneously cools the power module and capacitor module, eliminating the need for external or separate cooling components. This self-service approach improves cooling efficiency while avoiding the complexity of additional dedicated cooling components.
5Manufacturing precision
If fixed capacity design is used, then manufacturing precision is improved, but adaptability decreases
Solution Approach 1:
The power unit is designed as a modular segment that can be replicated and stacked to achieve different total capacities. Each power unit module contains standardized components (power module, capacitor module, coolant channels) that can be independently manufactured with high precision, then assembled in series to create systems with various capacity requirements, thus maintaining manufacturing precision while achieving adaptability.
Solution Approach 2:
The standardized power unit module serves as a universal building block that can fulfill different capacity requirements through replication. The same modular design with standardized interfaces and dimensions can be used across multiple applications and capacity levels, achieving both manufacturing precision through standardization and adaptability through scalable configuration.
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 configuration enhances cooling efficiency, reduces size, and allows for flexible capacity handling by improving heat absorption and distribution, while maintaining a simplified and efficient structure.
Implementation Method 1
Coolant channels, which are connected between the coolant supply pipe and the coolant discharge pipe, may be formed in the cooling module, and a coolant passing through the coolant channel may absorb heat generated from the power module
Implementation Method 2
a coolant passing through the coolant channel may absorb heat generated from the power module
Data Source
AI summary
A power unit according to an exemplary embodiment of the present disclosure may include: a power module which is configured by a power conversion switching element, the power module having a first side having gate pins connected to a board, and a second side to which main busbars are connected; cooling modules which are disposed on both surfaces of the power module, respectively; capacitor modules which are disposed on outer surfaces of the cooling modules, respectively, and have capacitors that are electrically connected to the main busbars through connecting busbars, respectively; a coolant supply pipe which is connected to one end portion of each of the cooling modules to supply a coolant to the cooling module; and a coolant discharge pipe which is connected to another end portion of each of the cooling modules to discharge a coolant discharged from the cooling module.