Modular Electrical Device Cold Plate with Stepped Bearing
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Solution Overview
Problem
The existing electrical systems used in motor vehicles, which include a cold plate for heat evacuation, face challenges due to the significant thickness required for the cooling system, leading to increased weight and space consumption.
Innovation Solution
An electrical system design featuring a cold plate with a recessed and advanced landing connected by a step, allowing the cooling system to be placed under the advanced bearing while maintaining a thinner profile, and an auxiliary module that can move relative to the main module to accommodate manufacturing clearances and secure attachment to the cold plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the cooling system is placed under the cold plate to evacuate heat from modules, then the cooling effectiveness is improved, but the cold plate thickness increases significantly
Solution Approach 1:
The cold plate is designed with non-uniform thickness, featuring a first bearing surface at a first thickness and a second bearing surface at a second thickness greater than the first. This local variation in thickness allows the cooling system to be positioned only where needed (under the high-heat main module), while maintaining adequate cooling capability for lower-heat areas with reduced plate thickness.
Solution Approach 2:
The invention transitions from a uniform two-dimensional cold plate design to a three-dimensional structure with varying thickness. By introducing vertical dimensionality through the step feature, the cooling system can be strategically positioned in specific zones, optimizing heat evacuation for high-heat modules while minimizing overall plate thickness and weight.
2Temperature
If the cold plate thickness is increased to accommodate the cooling system, then the cooling capability is improved, but the weight and space consumption increase
Solution Approach 1:
Rather than uniformly increasing cold plate thickness throughout, the invention applies increased thickness (and the associated cooling system) only in the specific region where heat evacuation is most critical. This localized approach maintains cooling capability where needed while minimizing unnecessary material usage and weight in other areas.
3Adaptability or versatility
If multiple modules are fixed to the cold plate, then the electrical device functionality is improved, but the manufacturing precision requirements increase due to clearance accommodation
Solution Approach 1:
The auxiliary module is designed with movement capability between a close position (for securing attachment to the cold plate) and a remote position (for accommodating manufacturing clearances). This dynamic design allows the system to adapt to variations in manufacturing precision while maintaining secure attachment when needed.
Solution Approach 2:
The electrical device is divided into separate main and auxiliary modules that can be independently positioned and secured. This segmentation allows each module to be optimized for its specific function while accommodating manufacturing variations through independent adjustment and attachment mechanisms.
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 reduces the thickness of the cold plate, saving space and material while ensuring effective cooling, and allows for secure attachment of the electrical device to the cold plate, addressing the weight and space issues of traditional systems.
Implementation Method 1
a cold plate having a recessed landing and a forward landing, extending in front of the recessed landing, the two landings being connected to each other by a step, in which the main rear face of the main module is pressed against and fixed to the advanced bearing and in which the auxiliary rear face of the auxiliary module is pressed against and fixed to the recessed bearing
Implementation Method 2
it is possible to use a cold plate having two bearings connected to each other by a step. Thus, it is possible to arrange the cooling system under the forward bearing, while keeping a smaller plate thickness under the recessed bearing
Data Source
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AI summary
The electrical device (114) comprises: a main module (116) having, in a front-to-back (Ft-To) direction, a rear face, called the main rear face (120), intended to be pressed and fixed against a bearing of a cold plate (102), called the leading bearing (120); an auxiliary module (118) having a rear face, called the auxiliary rear face (122), intended to be pressed and fixed against another bearing of the cold plate (102), called the retracted bearing (122). The leading bearing (120) extends forward of the retracted bearing (122), the two bearings (120, 122) being connected to each other by a step (108), and the auxiliary rear face (122) extends rear of the main rear face (120).