Interleaved Coolant Channels in Power Electronics Stacks
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Solution Overview
Problem
Current power-electronics assemblies for electric vehicle drivetrains face challenges in efficiently cooling power stages within power inverters, leading to potential thermal management issues and reduced performance.
Innovation Solution
The design incorporates a power-electronics assembly with interleaved coolant channels and passageways between power modules, allowing for effective fluid communication and circulation to cool the power stages, enhancing thermal management and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If power stages are densely packed in the power-electronics assembly, then the power density and compactness are improved, but the cooling efficiency deteriorates due to insufficient coolant flow and increased thermal resistance
Solution Approach 1:
The patent transitions from planar cooling channels to three-dimensional interleaved coolant channels that pass through the power stages in alternating layers. This dimensional change allows coolant to access thermal hotspots from multiple directions, improving cooling efficiency while maintaining high power density through better thermal management of compact power stage arrangements.
Solution Approach 2:
The coolant channels are nested within and between the power stages, with channels defined in the bodies of power modules interleaved with the power stages themselves. This nesting arrangement allows the cooling system to be integrated within the power stage structure, enabling effective cooling of densely packed power stages without requiring additional external cooling space.
2Device complexity
If coolant channels are defined within power module bodies, then the integration and compactness are improved, but the manufacturing complexity increases due to precise channel formation requirements
Solution Approach 1:
The power module bodies serve multiple functions: they house the power stages, define the interleaved coolant channels, and provide structural support for the stacked assembly. This multi-functionality reduces the need for separate cooling components, simplifying the overall system integration while maintaining compact design, though manufacturing precision remains critical.
3Temperature
If passageways are extended between adjacent channels to connect them, then the fluid communication and cooling uniformity are improved, but the thermal resistance increases due to longer coolant flow paths
Solution Approach 1:
The interleaved coolant channels with connecting passageways create continuous coolant flow paths that systematically traverse all power stages in the stack. This continuous action ensures uniform cooling distribution across all power modules, preventing localized hotspots while maintaining efficient thermal management through optimized flow continuity rather than isolated cooling zones.
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 improves cooling efficiency by ensuring uniform coolant flow across power stages, reducing thermal resistance and enhancing the overall performance and reliability of the power-electronics assembly.
Implementation Method 1
a coolant channel defined in the body at a location adjacent to one of the major sides. The modules are arranged in a stack such that the coolant channels are interleaved with the power stages
Implementation Method 2
improves cooling efficiency by ensuring uniform coolant flow across power stages, reducing thermal resistance
Data Source
AI summary
A power-electronics assembly includes a plurality of power modules each having a body, a power stage disposed in the body and having opposing major sides, and a coolant channel defined in the body at a location adjacent to one of the major sides. The modules are arranged in a stack such that the coolant channels are interleaved with the power stages. At least one of the bodies defines a passageway extending between adjacent channels to connect the adjacent channels in fluid communication.