3D Annular Cold Plate Stack for Motor Drive Thermal Management
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Solution Overview
Problem
Existing high power density electric drive train systems face challenges in reducing overall weight and achieving effective thermal management, as thermal management components contribute significantly to system weight, impacting power density and efficiency.
Innovation Solution
A three-dimensional stack-up design incorporating annular cold plates with integrated fluid pathways and supporting structures for power electronic components, enabling compact integration and efficient coolant distribution, thereby reducing weight and enhancing thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermal management components are added to ensure safe operation of power electronic components, then thermal management capability is improved, but system weight increases significantly
Solution Approach 1:
The patent combines the thermal management function with the structural support function by integrating cold plates into the supporting structures. The cold plates serve dual purposes: providing mechanical support for power electronic components and acting as heat sinks with internal fluid pathways for coolant flow. This merging eliminates the need for separate thermal management components, thereby improving thermal management capability without significantly increasing system weight.
Solution Approach 2:
The supporting structures are designed to perform multiple functions simultaneously: mechanical support, thermal management, and fluid distribution. The cold plates integrated into the supporting structures contain internal fluid pathways that distribute coolant to multiple power electronic components, making the supporting structures universal components that address both structural and thermal management requirements.
2Weight of moving object
If component packages are made compact to reduce overall weight, then weight is reduced, but thermal management effectiveness may be compromised
Solution Approach 1:
The patent transitions from traditional two-dimensional planar layouts to a three-dimensional stacked architecture. Multiple cold plates are stacked vertically with power electronic components mounted on each plate, allowing efficient heat dissipation through multiple surfaces. The internal fluid pathways extend through the thickness of each cold plate, enabling effective thermal management in the vertical dimension while maintaining compact horizontal footprint.
Solution Approach 2:
The cold plates are nested within the supporting structures, with internal fluid pathways embedded within the solid material. The coolant flow pathways are nested inside the cold plates, allowing the thermal management function to be integrated within the structural components rather than adding external cooling systems.
3Power
If integration among components is increased to achieve higher power density, then power density is improved, but device complexity increases
Solution Approach 1:
The integrated motor drive architecture is segmented into modular cold plates, each capable of supporting power electronic components. Each cold plate functions as an independent module with its own internal fluid pathways, allowing for standardized replication and assembly. This segmentation enables high power density through integration while maintaining manageable complexity through modularity.
Solution Approach 2:
The patent changes the geometric parameters of the cold plates, specifically using annular shapes with internal fluid pathways. The annular configuration allows coolant to flow through the center and distribute heat evenly across the mounting surface. By optimizing these geometric parameters, the system achieves high power density without proportionally increasing complexity.
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 achieves reduced weight, improved thermal efficiency, and increased power density by minimizing parasitic losses and ensuring uniform coolant distribution, optimizing performance across varying operational conditions.
Implementation Method 1
Each cold plate has an annular shape with internal fluid pathways extending therethrough. At least one supporting structure defines an internal cavity bifurcated into an internal inlet fluid pathway configured to direct fluid into the internal fluid pathways of each cold plate and an internal outlet fluid pathway receptive of the fluid from the internal fluid pathways of each cold plate.
Implementation Method 2
The internal inlet fluid pathway is configured to direct fluid into the internal fluid pathways of each cold plate... ensuring uniform coolant distribution
Data Source
Figure 1A~1B
Figure 2
Figure 3~5
AI summary
A motor drive architecture is provided. The motor drive architecture includes a three-dimensional (3D) stack of cold plates (320) on which power electronic components for an electric machine are mountable and supporting structures. Each cold plate (320) has an annular shape with internal fluid pathways. The supporting structures hold the cold plates (320) in the 3D stack. At least one supporting structure defines an internal cavity (341) bifurcated into an internal inlet fluid pathway configured to direct fluid into the internal fluid pathways of each cold plate (320) and an internal outlet fluid pathway receptive of the fluid from the internal fluid pathways of each cold plate (320).