Power Module Cooling Structure With Meander-Like Chamber Walls
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Solution Overview
Problem
Existing cooling structures for power modules, such as those in automotive vehicles, face inefficiencies in heat transfer between the cooling structure and coolant, as the coolant may follow direct paths without contacting the chamber walls, limiting effective heat dissipation.
Innovation Solution
A cooling structure comprising multiple layers with a network of local chambers and meander-like structures that force the coolant to contact the chamber walls, enhancing heat transfer by blocking direct paths between apertures and utilizing overlapping chambers to create impingement flows, thereby improving thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a simple chamber structure with direct paths between apertures is used, then the device complexity is reduced, but the heat transfer efficiency deteriorates because coolant follows direct paths without contacting chamber walls
Solution Approach 1:
The patent introduces meander-like structures with curved paths instead of straight lines within the chamber. These curved meander structures force the coolant to follow a longer, more tortuous path that increases contact area with the chamber walls, thereby improving heat transfer efficiency while maintaining manufacturing feasibility through standardized curved geometry
Solution Approach 2:
The patent transitions from a two-dimensional direct path between apertures to a three-dimensional meander structure that utilizes vertical and lateral dimensions. By stacking chambers vertically and incorporating horizontal meander paths, the coolant flow is redirected through multiple spatial dimensions, increasing wall contact time and area without significantly increasing overall device footprint
2Temperature
If meander-like structures are added to block direct paths, then the heat transfer efficiency is improved, but the device complexity increases
Solution Approach 1:
The patent divides the cooling structure into multiple stacked chambers, each containing simplified meander structures. This segmentation allows complex heat transfer functionality to be achieved through repetition of modular units, reducing overall design complexity while maintaining high heat transfer efficiency across the entire cooling structure
Solution Approach 2:
The patent implements nested chamber structures where multiple layers of chambers are stacked vertically, with each layer containing meander structures. The nested arrangement allows compact packaging of extended cooling pathways within a limited footprint, achieving high heat transfer efficiency without proportionally increasing device complexity
3Ease of operation
If local chambers are made separate within layers, then the coolant flow control is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent segments each layer into separate local chambers that are connected vertically through overlapping chambers in adjacent layers. This segmentation provides independent flow control for each chamber while using standardized connection interfaces that simplify manufacturing through modular assembly
Solution Approach 2:
The overlapping chambers serve multiple functions: they provide vertical communication between layers, act as flow control elements, and serve as manufacturing alignment features. This multi-functionality reduces the need for additional manufacturing steps while achieving precise coolant flow control
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 enhanced cooling structure effectively increases heat transfer from the power module to the coolant, improving the thermal management of power modules and converters, particularly in automotive applications, by ensuring that the coolant consistently interacts with the meander-like structures, leading to improved cooling efficiency.
Implementation Method 1
heat may be relatively easily transferred from wall of the meander-like structure to the coolant
Implementation Method 2
the coolant flowing between the two apertures is forced to get in contact with at least one meander-like structure, so that heat may be relatively easily transferred from wall of the meander-like structure to the coolant
Data Source
AI summary
A cooling structure including several layers and a network of local chambers distributed between the several layers stacked one on another according to a stacking direction. Each local chamber includes at least two apertures, of which at least one is in communication with a local chamber of another of the layers. Each local chamber includes one or several meander-like structures blocking any direct path in the local chamber between the two apertures.