Injection-Molded Cooling Base for Variable Speed Drives
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Solution Overview
Problem
Variable speed drives (VSDs) for HVAC&R systems face high costs due to expensive metal cooling blocks and impractical injection molding of large, complex plastic cooling blocks, which are not suitable for mass production.
Innovation Solution
A base with a tub and passageway for fluid cooling, manufactured through injection molding, is used to cool components in VSDs, allowing for cost-effective production and efficient heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If metal cooling blocks are used for thermal management, then cooling effectiveness is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive metal cooling blocks with injection-molded plastic cooling blocks. The plastic material is significantly cheaper than metal, and the injection molding process enables cost-effective mass production. The cooling blocks are designed as disposable or replaceable components that can be manufactured at low cost and replaced when needed, eliminating the high material and machining costs associated with metal blocks.
Solution Approach 2:
The patent changes the material parameter from metal to plastic, fundamentally altering the manufacturing approach. This material substitution enables the use of injection molding instead of machining, dramatically reducing manufacturing costs while maintaining adequate cooling performance for the application requirements.
2Temperature
If large plastic cooling blocks with multiple tubs are manufactured, then cooling capacity for multiple modules is improved, but injection molding becomes impractical
Solution Approach 1:
The patent divides the cooling system into separate modular cooling blocks, each designed for a specific number of modules (2, 4, or 6 tubs). Rather than attempting to injection mold a single large block with all possible configurations, the system uses multiple smaller blocks that can be selectively assembled. Each block is sized and configured to be injection molded with high quality, and the modular approach allows flexibility in matching cooling capacity to actual requirements.
Solution Approach 2:
The patent creates a family of cooling block designs that can serve multiple applications. By producing separate blocks for 2-tub, 4-tub, and 6-tub configurations, the system can universally address different VSD power ratings and module arrangements. This universal approach through modular design is more economically viable than creating a single large block that must accommodate all configurations.
3Temperature
If custom-sized cooling blocks are produced for different VSD applications, then application-specific cooling performance is improved, but production quantity per size decreases
Solution Approach 1:
The patent segments the cooling block offerings into discrete size categories (2-tub, 4-tub, 6-tub blocks). This segmentation allows each size to be produced as a standardized item with sufficient market demand to justify production runs. The modular nature of the segments enables efficient manufacturing of each size category while maintaining the ability to mix and match to meet various application requirements.
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 solution reduces manufacturing costs and enables efficient cooling of VSD components, making it feasible for mass production while maintaining effective thermal management.
Implementation Method 1
A portion of the fluid flowing through the passageway is diverted to the tub and the fluid provides cooling to the component
Data Source
AI summary
A cooling member for a variable speed drive. The variable speed drive has a component that generates heat during operation of the drive and a base. The base has a surface that receives the component, a channel formed in the surface of the base and a passageway formed in the base and receiving fluid therethrough. Fluid flowing through the passageway provides cooling to the component and the base is manufactured from an injection molding process.