Plastic Cooler Layout for Variable Speed Drive and Inductor Heat
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Solution Overview
Problem
Existing cooling systems for variable speed drives and inductors are bulky, heavy, and prone to wirebond failure due to vibration and thermal cycling, with aluminum electrolytic capacitors requiring regular maintenance and posing corrosion risks, and traditional liquid-cooled inductors using de-ionized water for electrical insulation.
Innovation Solution
A plastic cooling system with a base having a cooling well and channels for fluid flow, a coolant system for variable speed drives, and a heat sink for inductors, which reduces size, weight, and cost, using a plastic cooler that directs coolant fluid onto electronic components and absorbs heat generated by the core and coil losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional liquid-cooled inductors use de-ionized water for cooling, then electrical insulation is maintained, but system complexity and maintenance requirements increase
Solution Approach 1:
The patent extracts the cooling function from the electrical insulation function by using a dual-channel design: one channel circulates de-ionized water through the inductor for cooling while maintaining electrical insulation, and another channel handles the coolant circulation. This separation allows each function to be optimized independently.
Solution Approach 2:
The patent introduces an intermediary substance (de-ionized water) that serves dual purposes: it acts as a coolant while simultaneously providing electrical insulation. This intermediary eliminates the need for complex separate insulation systems while maintaining reliable electrical isolation.
2Quantity of substance
If aluminum electrolytic capacitors are used in power assemblies, then capacitance requirements are met, but weight and maintenance requirements increase
Solution Approach 1:
The patent changes the physical parameters of the capacitor by using solid polymer electrolyte instead of liquid electrolyte, and using plastic housing instead of metal. This parameter change reduces weight while maintaining capacitance functionality and eliminating maintenance requirements.
Solution Approach 2:
The patent employs composite materials in the capacitor construction, combining plastic housing with solid polymer electrolyte and aluminum foil electrodes. This composite approach achieves the required capacitance with significantly reduced weight compared to traditional aluminum electrolytic capacitors.
3Temperature
If copper or aluminum heatsinks are used for cooling, then heat dissipation is effective, but corrosion risks and maintenance requirements increase
Solution Approach 1:
The patent uses a plastic cooling system that is inherently corrosion-resistant, eliminating the need for corrosion protection measures. The plastic material accepts gradual degradation without rusting or contaminating the coolant, effectively treating the cooling system as maintenance-free rather than requiring periodic maintenance.
Solution Approach 2:
The patent employs plastic materials for the cooling system components that combine thermal conductivity sufficient for heat dissipation with inherent corrosion resistance. This composite approach maintains effective cooling while eliminating corrosion risks associated with metal heatsinks.
4Strength
If heavy metallic frames and multiple components are used in power assemblies, then structural strength is ensured, but weight and wirebond failure risks increase
Solution Approach 1:
The patent replaces heavy metallic frames with plastic housing that provides sufficient structural strength through optimized geometry and material properties. The plastic construction eliminates weight while maintaining structural integrity and reducing vibration-induced wirebond failures.
Solution Approach 2:
The patent segments the power assembly into integrated modules where capacitors, inductors, and cooling systems are combined into unified plastic-housed assemblies. This segmentation eliminates the need for heavy metallic framing while maintaining structural strength through distributed support structures.
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 plastic cooling system effectively reduces the size, weight, and cost of inductor coils, enhances heat transfer efficiency, and prevents corrosion, while maintaining reliable electrical insulation and reducing maintenance needs.
Implementation Method 1
Coolant is circulated directly through the inductor tubing
Implementation Method 2
The liquid flow in the heat sink in the cooling system absorbs heat generated by the core and coil losses
Implementation Method 3
a plastic cooler configured to receive a plurality of fasteners for engaging and securing an electronic component
Data Source
AI summary
A plastic liquid cooled variable speed drive or inductor provided. The cooler provides lightweight, space conservative, corrosive free cooling to the components as well as provides a mounting area for modules. A cooler can be mounted to the core of an inductor to absorb heat generated by the core losses.