Modular Plastic Cooling Members for Low-Cost VSD Thermal Control
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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 labor-intensive machining, while plastic cooling blocks reduce material costs but not labor, and injection molding is not feasible for large, low-volume components.
Innovation Solution
A cooling member system with multiple channels and passageways for fluid flow, connected via connectors, allowing for efficient cooling of electrical components and reducing manufacturing costs through injection molding of plastic materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If metal cooling blocks are used for mounting and cooling IGBT semiconductor switches, then cooling effectiveness is improved, but material costs and manufacturing costs increase significantly
Solution Approach 1:
The patent replaces expensive metal cooling blocks with plastic cooling blocks that are cheaper to manufacture. The plastic material allows for cost-effective production while maintaining the necessary cooling function through integrated fluid passages, effectively using a less expensive material to achieve the same thermal management goal.
Solution Approach 2:
The patent changes the material parameter from metal to plastic, which fundamentally alters the manufacturing process and cost structure. This material substitution enables the use of injection molding or similar processes instead of expensive machining operations, thereby reducing manufacturing costs while preserving cooling effectiveness.
2Ease of manufacture
If injection molding is used for plastic cooling blocks, then manufacturing cost is reduced, but large size and low volume make the process infeasible
Solution Approach 1:
The patent divides the cooling system into modular cooling members that can be produced individually through injection molding. Each cooling member is designed as a separate unit with standardized features, allowing for cost-effective production even at low volumes. The modular approach enables assembly of larger cooling systems from smaller, economically manufacturable units.
Solution Approach 2:
The patent modifies the design parameters of the cooling blocks to be compatible with injection molding processes. This includes optimizing the geometry, wall thicknesses, and feature integration to suit mold-based manufacturing, thereby making the process feasible for the required production volume and size constraints.
3Adaptability or versatility
If a single cooling block is designed to mount multiple modules, then versatility is improved, but the number of channels required increases complexity
Solution Approach 1:
The patent divides the cooling function into separate cooling members, each with a limited number of channels optimized for specific module configurations. This segmentation allows each cooling member to be simpler in design while the system as a whole maintains versatility through modular assembly. Each cooling member can be independently manufactured with optimized channel layouts.
Solution Approach 2:
The cooling members are designed with universal features and standardized interfaces that allow them to be used in various configurations. The modular design enables the same basic cooling member type to serve multiple mounting scenarios, achieving system versatility without increasing individual component 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 system provides effective temperature regulation for VSDs with reduced material and labor costs, enabling efficient cooling of multiple components using interconnected plastic cooling members.
Implementation Method 1
a first passageway configured to provide fluid to the at least two channels through the at least one inlet of each channel, a second passageway configured to receive fluid from the at least one outlet of each channel
Implementation Method 2
cooling member for a component of a variable speed drive including at least two channels... configured to provide fluid to the at least two channels... configured to receive fluid from the at least one outlet
Data Source
AI summary
A cooling member for a variable speed drive is disclosed. The cooling member includes including at least two channels, each channel including at least one inlet and at least one outlet, a first passageway configured to provide fluid to the at least two channels through the at least one inlet of each channel, a second passageway configured to receive fluid from the at least one outlet of each channel the at least two channels, and a connector to connect the cooling member to a second cooling member.