Parallel Cooling Flow Channel Module for Power Conversion Devices
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Solution Overview
Problem
The existing cooling flow channel modules for power conversion devices in hybrid and electric vehicles have complex structures that complicate manufacturing and assembly, leading to defects and inefficiencies, particularly in the water cooling type where the inverter and LDC housings are bonded using a sealant.
Innovation Solution
A cooling flow channel module with a simplified structure featuring parallel intake and discharge flow channels connected by multiple copper cooling pipes, which are welded to prevent coolant leakage and enhance cooling efficiency, and a cooling plate that facilitates easy installation and stable welding of the pipes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the cooling flow channel is shared by two LDCs and an inverter with separate housings bonded using sealant, then the size is reduced and cooling efficiency is enhanced, but the configuration becomes too complicated to manufacture and assemble
Solution Approach 1:
The patent merges the LDC housing and inverter housing into a single integrated housing structure. The cooling flow channels are formed directly within this unified housing, eliminating the need for separate housings and sealant bonding. This integration simplifies the overall structure while maintaining the shared cooling function across multiple devices.
Solution Approach 2:
The cooling flow channel is divided into multiple independent channels that can be separately formed and assembled. The housing includes multiple cooling flow channels that are independently configurable, allowing for simplified manufacturing of each channel while maintaining the complex overall cooling network when assembled.
2Ease of manufacture
If the inverter housing and LDC housing are bonded using a sealant, then the devices can be assembled, but there is a high possibility of generating defects
Solution Approach 1:
The patent extracts and eliminates the sealant bonding step from the assembly process. By forming the cooling flow channels directly within the integrated housing structure, the design removes the external sealant layer that was previously required to bond separate housings, thereby eliminating the associated defect risks.
Solution Approach 2:
The housing structure is merged into a single integrated component where the cooling flow channels are formed as integral parts. This eliminates the interface between separate housings that would require sealant bonding, thereby removing the source of bonding defects while maintaining assembly capability.
3Temperature
If a complex cooling flow channel configuration is used to cool multiple heating elements, then cooling efficiency is improved, but manufacturing and assembly become difficult
Solution Approach 1:
The cooling system is segmented into multiple independent cooling flow channels, each capable of serving specific heating elements. This segmentation allows for simplified manufacturing of individual channels while maintaining the complex overall cooling network when assembled, thereby improving both cooling efficiency and manufacturability.
Solution Approach 2:
The integrated housing structure serves multiple functions simultaneously: it provides structural support, contains multiple cooling flow channels for cooling various heating elements, and eliminates the need for separate bonding operations. This multi-functionality reduces manufacturing steps while maintaining effective cooling across all components.
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 complexity, minimizes weight and volume, and improves cooling efficiency by stabilizing the assembly process and increasing contact area with heating elements, thus enhancing the overall performance and reliability of the power conversion device.
Implementation Method 1
a cooling pipe configured to connect the intake flow channel and the discharge flow channel and cool the heating element disposed thereabove or therebelow
Implementation Method 2
an intake flow channel; a discharge flow channel disposed to be parallel to the intake flow channel
Data Source
AI summary
Provided are a cooling flow channel module for a power conversion device, in which a structure of a cooling flow channel for cooling a power conversion device including an inverter or an LDC is simplified to facilitate manufacturing and assembling, and a power conversion device including the same. The cooling flow channel module includes an intake flow channel, a discharge flow channel disposed to be parallel to the intake flow channel, and a cooling pipe configured to connect the intake flow channel and the discharge flow channel and cool the heating element disposed thereabove or therebelow, wherein a plurality of cooling pipes are provided and connect a side portion of the intake flow channel and a side portion of the discharge flow channel disposed to be parallel to each other.