Modular Cylindrical Power Inverter Packaging for Uniform Heat Distribution
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Solution Overview
Problem
Existing power inverter systems face challenges in packaging complexity, non-modularity, and scalability, leading to non-uniform power and heat distribution, difficult component access, and limited compatibility with other power systems.
Innovation Solution
A modular packaged power inverter design featuring a cylindrical outer housing with a heatsink core, electronic modules, AC and DC bus bars, and capacitors, allowing for easy assembly and integration with other systems, and enabling scalable and flexible component interchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If non-modular packaging is used, then assembly process is complex and difficult, but component access and interchangeability are limited
Solution Approach 1:
The power inverter is divided into modular functional units (DC link module with capacitors, inverter module with IGBTs, control module, heatsink assembly) that can be independently manufactured, tested, and interchanged. Each module has standardized mounting interfaces allowing flexible reconfiguration and replacement without affecting other components.
Solution Approach 2:
The packaging structure incorporates universal mounting features and standardized connection interfaces that allow the same housing and mounting framework to accommodate different module configurations. The cylindrical housing with flanged ends provides a universal platform for various power inverter applications.
2Volume of stationary object
If compact configuration is used, then space is reduced, but power and heat distribution becomes non-uniform
Solution Approach 1:
The design transitions from planar component layout to a three-dimensional cylindrical configuration with radial arrangement of power components around the central heatsink. This radial-dimensional approach allows uniform heat dissipation in all directions while maintaining compact volume, as the heatsink centrally positions thermal management capabilities equidistant from all power-generating components.
3Manufacturing precision
If specialized parts are used, then packaging precision is improved, but device complexity increases
Solution Approach 1:
Multiple functional elements are merged into integrated assemblies: the heatsink combines thermal management with structural support and mounting functions; the DC link bar integrates electrical connection with mechanical positioning; the cylindrical housing combines enclosure, alignment, and sealing functions. This reduction in separate specialized parts simplifies the overall packaging while maintaining precision through integrated design.
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 provides uniform power and heat distribution, facilitates easy component access and interchange, and supports integration with various power systems, enhancing scalability and performance.
Implementation Method 1
a heatsink core located within the housing and having a longitudinal axis aligned with the longitudinal axis of the outer housing
Implementation Method 2
a heatsink core located within the housing... providing uniform power and heat distribution
Data Source
AI summary
A packaged power inverter including a cylindrical outer housing having a central longitudinal axis, a heatsink core located within the housing and having a longitudinal axis aligned with the longitudinal axis of the outer housing and a plurality of outer planar surface portions. The packaged power inverter further includes a plurality of electronic modules each being coupled to one of the plurality of planar surface portions. A plurality of AC bus bars are coupled to one of the plurality of planar surface portions. A plurality of capacitors and DC bus bars located within the outer housing.