Interleaved Coolant Chambers for Power Module Thermal Management
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Solution Overview
Problem
Current power-module assemblies for automotive vehicles face challenges in efficiently managing heat dissipation within the power inverter, which can lead to reduced performance and reliability due to inadequate coolant distribution and temperature uniformity.
Innovation Solution
The power inverter is designed with power modules arranged in a stack such that pockets adjacent to each other form coolant chambers, allowing for interleaved coolant flow and improved thermal management through a manifold system that ensures uniform temperature gradients along the length of the stack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If power modules are arranged in a stack with traditional cooling, then the power inverter can process high power, but heat dissipation efficiency is insufficient and temperature uniformity is poor
Solution Approach 1:
The cooling system is segmented into multiple independent coolant chambers, each serving specific power modules. The pockets on opposing sides of each power module are cooled by separate coolant chambers, allowing independent temperature control and improving overall temperature uniformity across the stacked power modules.
Solution Approach 2:
Coolant chambers act as intermediary cooling elements between the power modules and the external environment. These chambers receive coolant through manifolds and transfer heat away from the power modules, serving as a mediating thermal management system that improves heat dissipation efficiency.
2Volume of moving object
If power modules are arranged in a stack, then space utilization is improved, but coolant distribution becomes inadequate leading to poor heat dissipation
Solution Approach 1:
The cooling system transitions from a single-dimension approach to a three-dimensional interleaved structure. Coolant chambers are positioned between power modules in the vertical stack, creating alternating layers of power modules and coolant chambers. This dimensional arrangement improves coolant distribution and heat dissipation efficiency while maintaining compact vertical stacking.
Solution Approach 2:
The system uses hydraulic coolant flow through manifolds and coolant chambers to achieve efficient heat removal. The coolant is pumped through the interleaved chambers, using fluid dynamics to distribute cooling uniformly across all power modules in the stack, thereby improving heat dissipation efficiency.
3Device complexity
If traditional cooling systems are used, then device structure is simpler, but temperature uniformity and cooling efficiency are insufficient
Solution Approach 1:
The cooling system is divided into multiple segmented coolant chambers, each with its own manifold connections. This segmentation allows for more precise temperature control and improved cooling efficiency, as each chamber can be optimized for the specific thermal loads of adjacent power modules.
Solution Approach 2:
The system changes the thermal parameters by introducing multiple coolant chambers with potentially different flow rates, temperatures, or pressures. This allows optimization of cooling parameters for different regions of the power module stack, improving overall cooling efficiency and temperature uniformity.
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 the cooling efficiency of the power modules, maintaining optimal operating temperatures and improving the reliability and performance of the power inverter by ensuring uniform coolant distribution and effective heat dissipation.
Implementation Method 1
coolant chambers interleaved with the modules
Implementation Method 2
interleaved coolant flow and improved thermal management
Data Source
AI summary
A power-module assembly includes a plurality of power modules that each have a power stage with opposing major sides and minor sides surrounded by a frame. The frame extends past the major sides and cooperates with the major sides to define pockets on each side of the power module. The modules are arranged in a stack such that pockets adjacent to each other cooperate to form coolant chambers interleaved with the modules.