Nickel-Plated Aluminum Radiator for EV Drive Controller Thermal Management
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Solution Overview
Problem
The existing electric vehicle drive controllers experience excessive temperature rise due to heat generation in high power MOS transistors, affecting their service life and reliability.
Innovation Solution
A heat dissipating system for electric vehicle drive controllers using high power MOS transistors with a nickel-plated aluminum alloy radiator and a silicon fabric for improved thermal conductivity, reducing contact resistance and enhancing heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a radiator made of aluminum alloy is used to dissipate heat from MOS transistors, then heat dissipation performance is improved, but contact resistance increases and additional heat is generated at the contact interface
Solution Approach 1:
A nickel layer is introduced as an intermediary between the aluminum alloy radiator and the MOS transistor bodies. This nickel plating layer serves as a mediator that reduces contact resistance at the interface, preventing the generation of additional heat while maintaining the heat dissipation function of the aluminum alloy radiator.
Solution Approach 2:
The radiator structure is transformed from a single aluminum alloy material to a composite structure consisting of an aluminum alloy base material combined with a nickel plating layer. This composite material approach leverages the high thermal conductivity of aluminum alloy while adding the low contact resistance properties of nickel at the interface.
2Power
If MOS transistors are connected in parallel to handle large current, then power control capability is improved, but heat generation increases
Solution Approach 1:
The power handling capability is segmented across multiple MOS transistors connected in parallel. Each transistor handles a portion of the total current, enabling high power control capability. However, this segmentation results in multiple heat generation sources that require effective heat dissipation management.
Solution Approach 2:
The nickel plating layer acts as an intermediary that facilitates efficient heat transfer from the MOS transistor bodies to the radiator while minimizing heat generation at the contact interface through reduced contact resistance.
3Ease of manufacture
If the radiator surface is left as aluminum alloy without plating, then manufacturing cost is reduced, but electrical conductivity at contact interface deteriorates
Solution Approach 1:
The surface properties of the radiator are modified by changing the material parameter at the contact interface. A nickel plating layer is applied to alter the electrical and thermal contact properties, improving conductivity and reducing contact resistance while maintaining cost-effectiveness through the use of thin plating layers.
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 system effectively lowers the operating temperature by at least 30°C compared to existing solutions, improving the reliability and service life of the electric vehicle drive controllers.
Implementation Method 1
a nickel layer is plated on the surface of the radiator made of aluminum alloy, thereby reducing the heat generation caused by the high contact resistance
Implementation Method 2
a radiator with large heat exchange area is mounted on the bodies of the MOS transistors. For a good overall performance in heat dissipation, economical efficiency and manufacturability, the radiator is generally made of aluminum or aluminum alloy
Implementation Method 3
the radiator which is connected with the MOS transistors can also be pressed on another heat dissipating base plate, with a silicon fabric having good thermal conductivity padded between the radiator and the heat dissipating base plate
Data Source
AI summary
The present invention provides a heat dissipating system for an electric vehicle drive controller. The heat dissipating system for electric vehicle drive controller includes: high power MOS transistors for controlling magnitude of power supplied to an electric vehicle drive motor and for switching current direction, and a radiator connected to bodies of the MOS transistors, the radiator being made of aluminum alloy material, and a surface of the radiator being plated with a metallic nickel layer. Compared with existing electric vehicle drive controller, the electric vehicle drive controller of the present invention has advantages of low operating temperature, high reliability and long service life.