Modular Liquid Cooling Unit With Voltage Isolation for Power Converters
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Solution Overview
Problem
Existing power flow control systems in modern distributed power generation and distribution systems face high thermal loads due to high current devices, necessitating improved heat dissipation methods beyond air cooling.
Innovation Solution
A liquid cooling system for power flow control systems, incorporating a modular design with voltage isolation, using liquid coolant to directly or indirectly impinge on switching assemblies, and employing insulating materials to prevent ionization at high electric fields, with switching assemblies electrically isolated from the enclosure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air cooling is used for heat dissipation in power flow control systems, then the system structure is simple, but the heat dissipation efficiency is insufficient for high thermal loads
Solution Approach 1:
The patent applies liquid cooling (hydraulic principle) instead of air cooling to efficiently dissipate high thermal loads from power electronic converters. The liquid cooling system circulates coolant through channels in contact with heat-generating components, providing superior heat transfer efficiency compared to air cooling while managing the complexity through structured implementation.
2Temperature
If liquid coolant is used for cooling switching assemblies, then heat dissipation efficiency is improved, but coolant ionization may occur at high electric fields
Solution Approach 1:
The patent introduces electrically insulating materials as intermediaries between the liquid coolant and high-voltage switching assemblies. These insulating barriers prevent direct contact between the conductive coolant and electrical components, eliminating ionization risks while maintaining the superior heat dissipation benefits of liquid cooling.
Solution Approach 2:
The patent employs thin film or shell-like insulating structures that separate the liquid coolant from electrical components. These thin barrier layers effectively prevent electrical breakdown and coolant ionization while allowing efficient thermal transfer, resolving the contradiction between cooling performance and electrical safety.
3Reliability
If switching assemblies are electrically isolated from the enclosure, then voltage isolation and safety are improved, but thermal coupling efficiency may be reduced
Solution Approach 1:
The patent uses thermally conductive but electrically insulating materials as intermediaries between the switching assemblies and the enclosure. These materials simultaneously provide electrical isolation for safety and voltage protection while maintaining effective thermal coupling for heat dissipation, thus resolving the contradiction between electrical isolation and thermal efficiency.
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 effectively manages high thermal loads with efficient heat dissipation, enabling long operational lifetimes and high reactive power injection capabilities while preventing coolant ionization, suitable for diverse converter topologies and ambient temperatures.
Implementation Method 1
Each switching assembly may have a respective baseplate arranged to thermally couple to the liquid coolant
Implementation Method 2
The pump may be configured for circulating liquid coolant from the inlet port to the outlet port of the liquid cooling block
Implementation Method 3
employing insulating materials to prevent ionization at high electric fields, with switching assemblies electrically isolated from the enclosure
Data Source
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AI summary
A liquid cooling power flow control system and related method are described. The system has switching assemblies for power flow control, in an enclosure. A pump circulates liquid coolant through a liquid cooling block to each switching assembly. The switching assemblies are electrically isolated from the enclosure.