Plastic Water-Cooled Heat Dissipation Module Assembly

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing water-cooled heat dissipation module assemblies for vehicle inverter systems are heavy and costly due to metallic materials and complex manufacturing processes, which negatively impact energy efficiency and manufacturability.

Innovation Solution

A water-cooled heat dissipation module assembly using a housing unit and cooling unit made of nonmetallic materials, specifically plastic, with the housing unit and cooling unit integrated via plastic welding using a laser, reducing weight and manufacturing costs while improving manufacturability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If metallic materials such as aluminum are used for the housing unit and cooling unit, then cooling performance is improved, but weight increases and manufacturing cost increases

Engineering Contradiction:

Improvecooling performanceVSAvoidweight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The patent changes the material parameter from metallic to plastic, specifically using plastic materials for the housing unit and cooling unit. This material substitution maintains the cooling function through proper thermal design while significantly reducing weight, as plastic materials are lighter than metallic materials like aluminum.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite material construction by combining plastic materials with metallic cooling fins. The housing unit and cooling unit are made of plastic, while cooling fins remain metallic to provide effective heat exchange surfaces. This composite approach optimizes both weight reduction and cooling performance.

Inventive Principle:

Principle #40Composite materials

2Temperature

If metallic materials such as aluminum are used for the housing unit and cooling unit, then cooling performance is improved, but manufacturing cost increases

Engineering Contradiction:

Improvecooling performanceVSAvoidmanufacturing cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent changes the material parameter from metallic to plastic, which enables the use of cost-effective plastic injection molding processes. This manufacturing process change reduces production costs compared to metallic casting processes while maintaining adequate cooling performance through proper thermal design.

Inventive Principle:

Principle #35Parameter changes

3Temperature

If metallic materials are used for the housing unit and cooling unit, then cooling performance is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvecooling performanceVSAvoidmanufacturing process complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent changes the material parameter from metallic to plastic, simplifying the manufacturing process by enabling the use of plastic injection molding. This process change reduces manufacturing complexity compared to metallic casting and joining processes, while maintaining cooling performance through proper thermal design.

Inventive Principle:

Principle #35Parameter changes

4Weight of moving object

If plastic materials are used for the housing unit and cooling unit, then weight is reduced and manufacturing cost is reduced, but joining difficulty increases

Engineering Contradiction:

ImproveweightVSAvoidjoining difficulty

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

The patent replaces mechanical joining methods with laser welding technology for connecting plastic components. The laser welding apparatus uses optical energy to melt and fuse plastic materials, creating strong joints without mechanical fasteners. This substitution of mechanical joining with optical/thermal joining simplifies the manufacturing process and improves joining reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 use of nonmetallic materials and plastic welding techniques results in a lighter, more energy-efficient, and cost-effective heat dissipation module assembly with improved manufacturability.

Implementation Method 1

the housing unit and the cooling unit are joined to each other by plastic welding using a laser

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Implementation Method 2

a plurality of cooling fins is formed on one surface of the cooling unit that seals the housing unit. The plurality of cooling fins performs heat exchange while coming into contact with the coolant flowing in the housing unit

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

The plurality of cooling fins performs heat exchange while coming into contact with the coolant flowing in the housing unit

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS12238903B2Water-cooled heat dissipation module assembly

Publication Date: 2025.02.25 DONG YANG PISTON CO LTD

AI summary

A water-cooled heat dissipation module assembly capable of cooling a power module of a vehicle driving inverter system using a battery or fuel cell. The water-cooled heat dissipation module assembly includes a housing unit provided in the form of a housing having an opening portion at least partially opened at one side thereof. The housing unit and at least a part of a rim region of the cooling unit are made of a plastic material, and the housing unit and the cooling unit are joined to each other by plastic welding using a laser.