Inverter Capacitor Cooling Bar Thermal Management
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Solution Overview
Problem
Inverter system controller modules in hybrid electric vehicles generate significant heat due to increased power output, necessitating effective thermal management solutions to prevent overheating and maintain performance.
Innovation Solution
The implementation of a coolant-based cooling system within the inverter system, which includes a power module with a coolant channel and a capacitor assembly featuring a thermally conductive potting material and a cooling bar that extends into the power module to facilitate heat transfer, ensuring efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If increased power output is achieved in the inverter system controller module, then the power conversion capability is improved, but heat generation increases requiring thermal management
Solution Approach 1:
The patent extracts the heat management function from the main power conversion system by introducing a separate cooling bar that extends into the coolant channel. This cooling bar is specifically designed to conduct heat away from the power sources and IGBTs, separating the thermal management function from the power conversion function while allowing both to operate effectively together.
Solution Approach 2:
The cooling bar acts as an intermediary thermal conductor between the heat-generating components (power sources and IGBTs) and the coolant system. It provides a dedicated thermal pathway that mediates heat transfer from the high-power components to the circulating coolant, enabling high power output while maintaining acceptable temperature levels.
2Temperature
If thermal management is implemented with cooling channels and cooling bars, then heat dissipation is improved, but device complexity increases
Solution Approach 1:
The patent merges the cooling function directly into the existing power module structure by integrating the cooling bar within the housing and positioning it to contact both the power sources and the coolant channel. This integration combines thermal management with the power conversion system in a unified design, reducing the need for separate cooling components and simplifying the overall device architecture.
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 cooling system effectively manages heat generated by the inverter system controller modules, preventing overheating and ensuring reliable operation by maintaining optimal temperatures, thus enhancing the performance and longevity of the vehicle's powertrain components.
Implementation Method 1
a cooling bar extending within the potting material between the power sources, and further extending out of the potting material and into the power module
Implementation Method 2
a power module defining a coolant channel for receiving a coolant
Data Source
AI summary
An inverter system control (ISC) module is provided. The ISC module includes a power module defining a coolant channel for receiving a coolant, and a capacitor assembly disposed adjacent to the power module. The capacitor assembly includes a housing, a potting material disposed within the housing, and a plurality of power sources disposed within the potting material. The capacitor assembly further includes a cooling bar extending within the potting material between the power sources, and further extending out of the potting material and into the power module.