EV Inverter Cooling Module Assembly for Thermal Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing thermal management methods for double-sided cooled power modules in electric vehicles have limited thermal performance optimization and manufacturability due to design and material selection, leading to issues like galvanic corrosion and high manufacturing complexity.
Innovation Solution
A cooling module assembly system featuring integrated spacers and heat sinks with galvanic compliance, combined with a counter-flow arrangement, to manage thermal performance and reduce manufacturing complexity, using materials like aluminum and copper alloys.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional thermal management methods are used for double-sided cooled power modules, then manufacturing cost is reduced, but thermal performance optimization capability is limited
Solution Approach 1:
The cooling system is segmented into a first heat sink and a second heat sink positioned on opposite sides of the power module, allowing independent optimization of each heat sink's thermal pathways and fin structures. This segmentation enables tailored thermal management for each side without compromising the other, improving overall thermal performance while maintaining manageable design complexity through modular design.
Solution Approach 2:
The spacer is integrated into the second heat sink structure, with the spacer's flange coupled to both heat sinks and its protrusion received by the mounting hole. This nested integration allows the spacer to be part of the heat sink assembly rather than a separate component, reducing assembly steps and design complexity while maintaining precise spacing for optimal thermal performance.
2Manufacturing precision
If conventional cooling module assembly is used, then manufacturing simplicity is maintained, but assembly tolerance control is insufficient
Solution Approach 1:
The spacer is pre-positioned on the second heat sink with its flange and protrusion structure prepared in advance. This preliminary action ensures that when the first heat sink is mounted, the spacing and alignment are already predetermined, enabling tight assembly tolerances without requiring complex adjustment procedures during final assembly.
Solution Approach 2:
The spacer acts as an intermediary component between the first and second heat sinks, providing a mechanical interface that precisely controls the distance and alignment between the two heat sinks. This intermediary structure enables accurate positioning and maintains consistent assembly tolerances while simplifying the overall assembly process through a dedicated positioning mechanism.
3Volume of moving object
If heat sinks are positioned close together for compact design, then space efficiency is improved, but galvanic corrosion risk increases
Solution Approach 1:
The spacer serves as a galvanic isolation intermediary between the first and second heat sinks, preventing direct contact between dissimilar metals. By positioning the heat sinks at a controlled distance apart and eliminating direct metal-to-metal contact, the spacer blocks the galvanic corrosion pathway while maintaining compact overall assembly dimensions through optimized spacer thickness.
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
The system enhances thermal management by improving heat transfer between heat sinks, reduces galvanic corrosion, and simplifies manufacturing processes while maintaining tight assembly tolerances.
Implementation Method 1
a cooling module assembly system featuring integrated spacers and heat sinks with galvanic compliance, combined with a counter-flow arrangement, to manage thermal performance
Implementation Method 2
The system enhances thermal management by improving heat transfer between heat sinks
Data Source
AI summary
A system for an electric vehicle includes: a first heat sink including a cooling pipe extending in an axial direction; a housing including a port to receive the cooling pipe, the port including an alignment feature; and a second heat sink between the first heat sink and the housing, the second heat sink including an opening to cooperate with the alignment feature of the port to align the second heat sink with the housing.