Modular Power Converter Stack Design for Scalable Thermal Management

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Solution Overview

Problem

Existing power converters require individual design and specialized modules for specific power ranges and applications, leading to high costs, inflexibility, and inefficient cooling, making it difficult to adapt to changing power needs or use in various applications.

Innovation Solution

A modular power converter design comprising standardized power stack units with identical electrical interfaces, allowing for easy combination and adaptation of power range by adding or removing modules, along with efficient thermal management using separate cooling units and bus bars for low inductivity connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If individual specialized power modules are designed for specific power ranges and applications, then the power converter can be optimized for a particular application, but the manufacturing cost and engineering effort increase significantly

Engineering Contradiction:

Improveapplication optimizationVSAvoiddesign complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The power converter is divided into multiple identical modular power stack units, each containing the same standardized power modules. This segmentation allows the system to be scaled by simply adding or removing modules rather than redesigning the entire system for different power ranges.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs universal standardized power modules and control circuits that can be used across all power stack units regardless of the total power range. This multi-functionality eliminates the need for specialized designs for each application, reducing engineering effort while maintaining optimization benefits.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If individual specialized power modules are designed for each power range, then the power converter can be optimized for specific applications, but the manufacturing cost per item increases

Engineering Contradiction:

Improveapplication optimizationVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The system is segmented into standardized power stack units that can be manufactured using the same production processes and components. This allows for economies of scale in manufacturing, as the same power modules and control circuits are produced in larger volumes for different power ranges.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of changing the design parameters for different power ranges, the patent changes the quantity of identical modules. The power range is adjusted by varying the number of power stack units rather than modifying the design parameters of individual components, thereby maintaining consistent manufacturing processes.

Inventive Principle:

Principle #35Parameter changes

3Temperature

If forced cooling systems are used to manage thermal power loss, then the components can be cooled effectively, but the power converter size and weight increase

Engineering Contradiction:

Improvethermal managementVSAvoidconverter weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The cooling system is merged with the power stack unit structure itself, with cooling channels integrated into the housing that contains the power modules. This integration eliminates the need for separate external cooling systems, reducing overall size and weight while maintaining effective thermal management.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cooling channels are nested within the housing structure of the power stack unit, with the cooling system embedded inside the same space that contains the power modules. This nesting approach maximizes space utilization and eliminates additional external cooling components.

Inventive Principle:

Principle #7Nested doll (Nesting)

4Reliability

If the power converter is designed for a specialized power range with specialized power modules and control circuits, then the converter is optimized for a predetermined application, but the ability to adapt to changing power needs is lost

Engineering Contradiction:

Improveapplication optimizationVSAvoidpower range adaptability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The power converter is segmented into discrete, identical power stack units that can be independently added or removed. This segmentation enables flexible reconfiguration of the system to match changing power requirements without requiring redesign or replacement of individual components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system is designed to be dynamically reconfigurable by adding or removing power stack units based on changing power needs. The standardized interfaces and modular architecture allow the system to adapt its power range dynamically rather than being fixed to a predetermined configuration.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentEP3161954B2Power converter and assembly method for assembling a power converter

Publication Date: 2023.01.18 HUAWEI DIGITAL POWER TECH CO LTD

Figure 1~3
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AI summary

The present invention provides a concept for a power converter build-up by modular power stack design. The functionality and the power range of the power converter can be individually adapted by combining a plurality of modular power stack units 1. In order to adapt the power range of the power converter, a plurality of modular power stack units 1 can be combined in parallel.