Power Conversion Device Base Plate Convex Hull Heat Dissipation
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Solution Overview
Problem
Current power conversion devices for electric vehicles face challenges in heat dissipation, which affects their efficiency and reliability, particularly in high-power applications.
Innovation Solution
The design incorporates a power conversion device with a base plate convex hull and coolant channels that allow direct contact between coolant and the base plate, enhancing heat dissipation through the base plate convex hull, along with strategically located fins and an auxiliary circuit board module to optimize heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional cooling structures are used in power conversion devices, then the device complexity is reduced, but the heat dissipation rate is insufficient
Solution Approach 1:
The base plate serves dual functions as both a structural support component and a heat dissipation component. The coolant channels are integrated directly into the base plate structure, merging the cooling system with the mechanical support structure, thereby improving heat dissipation without proportionally increasing device complexity
Solution Approach 2:
The invention introduces a three-dimensional coolant channel network within the base plate, transitioning from traditional two-dimensional surface cooling to volumetric cooling. This dimensional change enables more effective heat removal by distributing coolant throughout the base plate structure
2Power
If high-power converters are used to increase power density, then the power conversion capability is improved, but the heat generation increases and affects reliability
Solution Approach 1:
The coolant acts as an intermediary heat transfer medium between the high-power converter modules and the external environment. The coolant channels provide a dedicated thermal pathway that mediates the heat transfer process, allowing high-power operation while maintaining reliability through effective thermal management
Solution Approach 2:
The invention changes the thermal parameters of the system by introducing active coolant flow with controlled temperature and flow rate. This parameter change enables the system to handle higher power densities by dynamically adjusting the cooling capacity to match the heat generation from high-power converters
3Temperature
If coolant channels are added to improve heat dissipation, then the heat dissipation rate is improved, but the manufacturing complexity increases
Solution Approach 1:
The base plate is segmented into functional zones with coolant channels distributed throughout. This segmentation allows the cooling function to be integrated into the base plate manufacturing process itself, rather than requiring separate assembly of cooling components, thereby reducing overall manufacturing complexity while improving heat dissipation
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
This configuration effectively delivers heat away from the converter module, improving the power conversion device's heat dissipation rate and overall performance, reducing thermal resistance and increasing power density.
Implementation Method 1
since the coolant flowing in the first coolant channel can be directly in contact with the base plate convex hull, when the converter module located in the concave recess operates, the heat generated can be effectively delivered away by the coolant though the base plate convex hull
Implementation Method 2
the coolant flowing in the first coolant channel can be directly in contact with the base plate convex hull... the heat generated can be effectively delivered away by the coolant
Data Source
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AI summary
A power conversion device includes a casing, a middle plate and a converter module. The casing includes a base plate. The base plate has a concave recess therein. The base plate forms a base plate convex hull at a side opposite to the concave recess. The middle plate has a middle plate groove therein. The middle plate groove corresponds to the base plate convex hull. The middle plate and the base plate combine up, such that the base plate convex hull fluidly seals the middle plate groove, making the middle plate groove to form a first coolant channel. The converter module is at least partially located in the concave recess.