Liquid Cooling Module for Motor Controllers

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Solution Overview

Problem

The existing liquid cooling modules for high-power motor controllers, formed by metal casting, have limited channel sizes due to excessive metal material thickness, hindering flow rectification and heat dissipation efficiency.

Innovation Solution

A heat dissipating module design featuring a heat dissipating substrate, a structural plate formed by injection molding or 3D printing, and a heat conductive plate, allowing for finer channel structures and improved flow rectification, enhancing heat dissipation efficiency by using a liquid cooling method.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If metal casting process is used to form liquid cooling module, then structural strength is ensured, but channel size cannot be reduced due to excessive metal material thickness

Engineering Contradiction:

Improvechannel sizeVSAvoidstructural strength

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The liquid cooling module is divided into multiple layers with channel-forming plates inserted between heat dissipation substrates. This segmentation allows the cooling channels to be formed in thin plates rather than requiring thick metal casting, enabling reduced channel size while maintaining structural integrity through the layered assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The module combines heat dissipation substrates with channel-forming plates to create a composite structure. This composite design allows different components to serve different functions - the substrates provide structural strength while the thin channel-forming plates enable fine channel structures that would be impossible with solid metal casting alone.

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If metal casting process is used, then manufacturing simplicity is maintained, but flow rectification of cooling liquid cannot be achieved

Engineering Contradiction:

Improveflow rectificationVSAvoidmanufacturing complexity

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

By segmenting the cooling module into separate channel-forming plates with independent channel structures, flow rectification can be designed into specific plates without redesigning the entire casting. Each plate can be optimized for flow control while maintaining overall manufacturing simplicity through modular assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Flow rectification features are localized to specific channel-forming plates rather than requiring complex features throughout the entire casting. This allows flow control to be implemented in critical areas while keeping other areas simple for manufacturing, resolving the contradiction between flow rectification and manufacturing ease.

Inventive Principle:

Principle #3Local quality

3Power

If channel size is reduced for better heat dissipation, then heat dissipation efficiency improves, but metal material thickness becomes excessively thin

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidmetal material thickness

Core Design Contradiction:

PowerVSVolume of moving object

Solution Approach 1:

Instead of reducing channel size within a single thick metal block, the design transitions to a multi-layered dimensional structure where thin channel-forming plates are stacked between heat dissipation substrates. This dimensional reorganization allows fine channel structures to achieve high heat dissipation efficiency without requiring excessively thin metal walls, as the substrates provide the necessary structural support.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 increases the volume flow rate of the heat dissipating liquid, reduces flow resistance, and significantly improves heat dissipation efficiency, enabling more effective temperature management for motor controllers.

Implementation Method 1

The first heat conductive plate covers the first structural plate. The first heat conductive plate is in contact with a heat generating member for conducting heat energy generated by the heat generating member to the heat dissipating liquid.

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

A heat dissipating liquid flows through the first channel member via the inlet, and flows out of the heat dissipating module via the outlet.

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS11632882B2Heat dissipating module and motor controller thereof

Publication Date: 2023.04.18 LSC ECOSYSTEM CORP

AI summary

A heat dissipating module includes a heat dissipating substrate, a first structural plate, and a first heat conductive plate. The heat dissipating substrate has an inlet, an outlet, and a first container formed on a top surface of the heat dissipating substrate. The inlet and the outlet are communicated with the first container respectively. The first structural plate has a first channel member and is contained in the first container. The first channel member is communicated with the inlet and the outlet respectively. Heat dissipating liquid flows through the first channel member via the inlet, and flows out of the heat dissipating module via the outlet. The first heat conductive plate covers the first structural plate. The first heat conductive plate is in contact with a heat generating member for conducting heat energy generated by the heat generating member to the heat dissipating liquid.