Layered Liquid Cooling Structure for Compact EV Powertrain Heat Dissipation
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Solution Overview
Problem
Existing liquid cooling heat dissipation apparatuses for electric vehicle powertrains have low heat dissipation efficiency and are large in size, making it difficult to meet the demands of high power density and miniaturization.
Innovation Solution
A compact liquid cooling heat dissipation apparatus design featuring a cover plate, middle partition plate, and bottom plate with integrated cavities and channels, including openings, through holes, and guide racks to facilitate efficient heat exchange and reduce dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If existing liquid cooling heat dissipation apparatus is used, then heat dissipation function is provided, but heat dissipation efficiency is low and device size is large
Solution Approach 1:
The patent implements nesting by placing the second cavity inside the first cavity structure. The middle partition plate divides the first cavity into liquid inlet and outlet channels, while the second cavity is positioned within the first cavity's volume, allowing the heat dissipation apparatus to achieve high heat dissipation efficiency with reduced overall size.
Solution Approach 2:
The patent utilizes three-dimensional spatial arrangement by stacking the cover plate, middle partition plate, and bottom plate in layers. The cavities and channels are arranged in different spatial dimensions, with the first cavity forming upper and lower channels and the second cavity providing additional heat dissipation pathways, achieving compact high-efficiency heat dissipation through dimensional optimization.
2Power
If motor and motor control unit are integrated into all-in-one powertrain, then power density increases, but heat generation becomes more severe
Solution Approach 1:
The patent segments the heat dissipation system into multiple independent cavities and channels. The first cavity is divided into liquid inlet channel and liquid outlet channel by the separator wall, and the second cavity provides additional heat dissipation pathways. This segmentation allows efficient heat removal from high-power density components without requiring excessive cooling system size.
Solution Approach 2:
The patent employs liquid cooling through hydraulic principles, using a heat exchange medium that circulates through the cavities and channels. The liquid flow paths are designed to maximize heat transfer from the power switching transistors, effectively managing the severe heat generation resulting from high power density integration.
3Reliability
If existing liquid cooling heat dissipation apparatus is used, then cooling function is provided, but structure is large and mounting is difficult
Solution Approach 1:
The patent merges multiple functions into a single integrated structure. The cover plate, middle partition plate, and bottom plate are stacked and sealed together to form a compact heat dissipation apparatus that combines cooling channels, heat exchange cavities, and mounting interfaces in one unit. This integration maintains reliable cooling function while simplifying mounting operations.
Solution Approach 2:
The middle partition plate serves multiple functions simultaneously: it divides the first cavity into inlet and outlet channels, provides through holes for liquid communication, and offers mounting surfaces for securing the apparatus. This multi-functionality reduces the number of separate components needed, making the apparatus more compact and easier to mount while maintaining effective cooling.
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 design enhances heat dissipation efficiency, improves compactness, and facilitates easier mounting, leading to improved performance and reliability of the motor control unit and powertrain.
Implementation Method 1
The motor control unit usually uses a liquid cooling heat dissipation apparatus to dissipate heat for the power switching transistors
Implementation Method 2
Heat exchange circulation of a heat exchange medium in the liquid cooling heat dissipation apparatus
Data Source
AI summary
This application discloses a liquid cooling heat dissipation apparatus, a motor control unit, a powertrain, and an electric vehicle. The liquid cooling heat dissipation apparatus includes a cover plate, a middle partition plate, a separator wall, and a bottom plate. The cover plate, the middle partition plate, and the bottom plate are sequentially stacked in a first direction. A gap between the cover plate and the middle partition plate forms a first cavity, and a gap between the bottom plate and the middle partition plate forms a second cavity. The separator wall is configured to separate the first cavity into a liquid inlet channel and a liquid outlet channel. The cover plate includes two openings. One opening communicates with the liquid inlet channel, and the other opening communicates with the liquid outlet channel. The middle partition plate includes at least one group of through holes.