Power Inverter Extrusion Cooler Layout for Multi-Module Heat Dissipation
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Solution Overview
Problem
Existing power inverters for vehicles face inefficiencies in cooling multiple power modules, which can lead to reduced performance and reliability due to inadequate heat management systems.
Innovation Solution
A power inverter design featuring a housing with separate cooling spaces and a refrigerant circulation system, including a first and second cooling space, an extrusion cooler, and a control board to manage the operation of power modules, ensuring efficient heat dissipation through controlled refrigerant flow and modular cooling architecture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple power modules are mounted in a single power inverter to improve power output and driving efficiency, then the power and driving efficiency are improved, but the heat generation increases and cooling becomes more difficult
Solution Approach 1:
The cooling system is segmented into multiple independent cooling spaces (first cooling space, second cooling space) that can be separately controlled. Each cooling space is associated with specific power modules, allowing targeted cooling of high-heat-generation areas without affecting other components, thus effectively managing heat from multiple power modules.
Solution Approach 2:
A refrigerant is introduced as an intermediary cooling medium that circulates through the cooling spaces and cooling passages. The refrigerant absorbs heat from power modules indirectly through thermal conduction via cooling plates, preventing direct thermal interference between multiple power modules while efficiently removing heat.
2Device complexity
If a single cooling space is used to cool all power modules, then the device complexity is reduced, but the cooling efficiency and temperature control precision deteriorate
Solution Approach 1:
The cooling system is divided into multiple cooling spaces (first cooling space for first and second power modules, second cooling space for third power module) with independent refrigerant circulation paths. This segmentation allows each power module to be cooled according to its specific heat generation characteristics, improving cooling efficiency and reliability.
Solution Approach 2:
Different cooling spaces are provided with different cooling capacities and configurations according to the specific heat generation needs of each power module. The first cooling space is designed for modules generating higher heat, while the second cooling space is optimized for the third power module, achieving localized optimal cooling.
3Volume of moving object
If power modules are arranged in a compact configuration to improve space utilization, then the space utilization is improved, but the heat dissipation performance deteriorates due to limited cooling space
Solution Approach 1:
The cooling system utilizes three-dimensional space by forming cooling spaces above and below the capacitor arrangement space. The first cooling space is positioned above the capacitor, and the second cooling space is positioned below it, effectively utilizing vertical space without increasing the horizontal footprint, thus maintaining compact configuration while ensuring adequate heat dissipation.
Solution Approach 2:
The cooling spaces are nested around the capacitor arrangement space, with the first cooling space positioned above and the second cooling space positioned below the capacitor. This nested configuration allows the cooling system to be integrated within the compact inverter housing without requiring additional external space.
4Reliability
If a complex cooling system with multiple independent systems is designed to cool each power module separately, then the cooling efficiency is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
Multiple cooling functions are merged into a single integrated refrigerant circulation system. The refrigerant flows sequentially through the first cooling space, first cooling passage, second cooling space, and extrusion cooler in a unified circulation path, achieving efficient cooling of all power modules through one system rather than multiple independent systems.
Solution Approach 2:
The refrigerant circulation system serves multiple functions simultaneously: it cools the first power module, second power module, and third power module through different cooling spaces and passages. The extrusion cooler also serves dual functions by cooling the second power module while enabling refrigerant circulation between cooling spaces.
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 design enhances cooling efficiency by circulating refrigerant through multiple power modules, maintaining optimal operating temperatures and improving the reliability and performance of the power inverter, especially during varying power inversion states.
Implementation Method 1
a first cooling plate coupled to the first cooling space to seal the first cooling space... a second cooling plate coupled to the second cooling space... an extrusion cooler mounted to contact with an external side of the second power module, the extrusion cooler having opposite end portions thereof connected to a pair of flow holes, allowing the refrigerant to flow in from the second cooling space through one of the pair of flow holes
Implementation Method 2
a pair of cooling spaces formed on opposite sides of the arrangement space to be separated from the arrangement space and allow a refrigerant to flow therein... a cooling passage separated from the arrangement space and fluidically communicating first ends of the pair of cooling spaces with each other
Data Source
AI summary
A power inverter may include a housing including an arrangement space having a capacitor, a pair of cooling spaces formed on opposite sides of the arrangement space and include first and second cooling spaces, a cooling passage communicating first ends of the pair of cooling spaces with each other, and a pair of through holes respectively fluidically-connecting second ends of the pair of cooling spaces to outside of the power inverter apparatus; a first cooling plate coupled to the first cooling space to seal the first cooling space thereby; a second cooling plate coupled to the second cooling space and provided with a pair of flow holes; a first power module contacting with the first cooling plate; a second power module contacting with the second cooling plate; an extrusion cooler contacting with the second power module; and a third power module contacting with the extrusion cooler.