Vehicle Inverter Cooling Structure with Phase-Change Auxiliary Module
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Solution Overview
Problem
The existing cooling structures for vehicle drive inverters are inadequate in responding to the rapid heat generation and temperature changes of switching elements, leading to frequent exposure to high temperatures due to slow coolant temperature and flow rate control.
Innovation Solution
A cooling structure that includes a heat dissipation fin, a cooling flow path, and an auxiliary cooling module with a refrigerant having a state change temperature within the allowable range, connected through heat conductors to enhance heat exchange and control the temperature changes of the switching element, along with a control system that adjusts the rotational speed of pumps and fans based on motor load or pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a conventional cooling structure with coolant flow rate control is used for the inverter, then the cooling system is simple and easy to control, but the cooling response is slow and cannot keep up with rapid heat generation of the switching element
Solution Approach 1:
The cooling system is divided into two independent parallel paths: a conventional coolant-based cooling path and a new phase-change refrigerant cooling path. Each path operates independently to handle different cooling demands, allowing the system to respond rapidly to heat generation without overhauling the entire cooling architecture.
Solution Approach 2:
The phase-change refrigerant is pre-positioned in the auxiliary cooling module in a liquid state, ready to immediately absorb heat through evaporation when the switching element generates excessive heat. This preliminary preparation enables instant cooling response without waiting for coolant flow rate adjustments.
2Temperature
If the coolant temperature and flow rate are increased to cool the switching element, then the cooling effect is improved, but the control response is delayed and the switching element already reaches high temperature
Solution Approach 1:
The auxiliary cooling module utilizes the phase transition (evaporation) of refrigerant from liquid to gas state to absorb heat directly from the switching element. This phase change occurs rapidly and absorbs large amounts of latent heat, providing immediate temperature control without the time delay associated with adjusting coolant flow rates.
Solution Approach 2:
The phase-change refrigerant acts as an intermediary cooling medium between the switching element and the external environment. It directly contacts the switching element to absorb heat through evaporation, then transfers the absorbed heat to the coolant through heat exchange, providing rapid intermediate cooling action.
3Reliability
If the switching element is cooled using engine-like cooling control, then the cooling system is straightforward to implement, but the switching element is frequently exposed to high temperature due to slow response
Solution Approach 1:
The cooling system is segmented into a primary coolant cooling path and an auxiliary phase-change cooling path. The auxiliary cooling module with refrigerant is added as a separate component that activates when additional cooling is needed, protecting the switching element without requiring complete redesign of the existing cooling system.
Solution Approach 2:
The auxiliary cooling module is nested within or adjacent to the existing inverter structure, with the phase-change refrigerant contained in a compact reservoir that integrates with the switching element housing. This nested arrangement provides enhanced cooling protection without significantly increasing overall system footprint or complexity.
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 solution effectively reduces temperature changes and prevents the switching element from reaching high temperatures by increasing its heat capacity and improving cooling response time, enhancing durability and responsiveness.
Implementation Method 1
a heat dissipation fin connected to and heat-exchangeable with the switching element
Implementation Method 2
a cooling flow path in which a coolant flows and heat-exchanges with the heat dissipation fin
Implementation Method 3
The refrigerant may cool the switching element while being evaporated by the heat generation of the switching element
Implementation Method 4
a refrigerant having a state change temperature within an allowable temperature range of the switching element
Implementation Method 5
the switching element may be connected to and heat-exchangeable with the inverter case through a first heat conductor positioned between the inverter case and the switching element
Implementation Method 6
The second heat conductor may have one end connected to the auxiliary cooling module and the other end connected to the cooling flow path
Data Source
AI summary
A cooling structure of a vehicle drive inverter includes: a switching element disposed in the vehicle drive inverter; a heat dissipation fin connected to and heat-exchangeable with the switching element; a cooling flow path in which a coolant flows and heat-exchanges with the heat dissipation fin; and an auxiliary cooling module connected to and heat-exchangeable with the switching element to be heated by a heat generation of the switching element or to be cooled together with the switching element.