Power Conversion Apparatus Thermal Management via Deformable Spacer

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Solution Overview

Problem

Conventional power conversion apparatuses face challenges in effectively absorbing dimensional variations of electric components, leading to stress and reduced cooling efficiency due to the integral formation of refrigerant flow channels with the housing.

Innovation Solution

A power conversion apparatus design featuring a housing, an electric component, and a flow channel formation unit with an elastically deformable spacer between them, allowing for independent thermal connection and adjustment to absorb dimensional variations, thereby reducing stress and enhancing cooling efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the housing is formed integrally with the refrigerant flow channel, then the cooling efficiency is improved, but the stress on electric components increases due to dimensional variations

Engineering Contradiction:

Improvecooling efficiencyVSAvoidstress on electric component

Core Design Contradiction:

TemperatureVSStress or pressure

Solution Approach 1:

The housing is divided into a first housing portion and a second housing portion, with the refrigerant flow channel formed integrally only in the first portion. The electric component is positioned in the second portion, separating the thermal management function from the component mounting function to reduce stress transmission.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A buffer portion is introduced as an intermediary element between the electric component and the refrigerant flow channel. This buffer absorbs dimensional variations and reduces stress transmission to the electric component while maintaining thermal coupling for effective cooling.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If the refrigerant flow channel is formed integrally with the housing, then the manufacturing complexity is reduced, but the adaptability to electric component dimensional variations deteriorates

Engineering Contradiction:

Improvemanufacturing complexityVSAvoidadaptability to dimensional variation

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The housing is segmented into portions with different functions: the first portion contains the integrally formed refrigerant flow channel for manufacturing efficiency, while the second portion provides adaptability for electric component accommodation without requiring complex integral design throughout the entire housing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the housing have different structural characteristics. The first housing portion has integral refrigerant flow channels for ease of manufacture, while the second housing portion has a buffer mechanism for adaptability, allowing each region to optimize its local function.

Inventive Principle:

Principle #3Local quality

3Device complexity

If the electric component is fixed directly to the housing, then the structural simplicity is improved, but the stress concentration increases during thermal expansion

Engineering Contradiction:

Improvestructural simplicityVSAvoidstress concentration

Core Design Contradiction:

Device complexityVSStress or pressure

Solution Approach 1:

The buffer portion serves as an intermediary between the electric component and the housing structure. It maintains the relatively simple overall structure while introducing a stress-absorbing element that prevents stress concentration during thermal expansion and dimensional variations.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The buffer portion allows for parameter changes in the housing structure (dimensional variations, thermal expansion) without transmitting these changes as stress to the electric component. It absorbs the variations while maintaining structural simplicity.

Inventive Principle:

Principle #35Parameter changes

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 effectively absorbs dimensional variations of electric components, reduces stress, and improves cooling efficiency while also sealing the space between components, eliminating the need for separate seals and maintaining the integrity of the electric components.

Implementation Method 1

a refrigerant flow channel through which a refrigerant flows for cooling the electric component

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a refrigerant flow channel through which a refrigerant flows for cooling the electric component

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

an elastically deformable spacer is provided between the flow channel formation unit and the housing

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11432440B2Power conversion apparatus

Publication Date: 2022.08.30 DENSO CORP

AI summary

A power conversion apparatus includes an electric component, a housing, and a flow channel formation unit. The electric component configures at least a part of a power conversion circuit. The housing stores the electric component, and the electric component is fixed to the housing. The flow channel formation unit forms a refrigerant flow channel through which a refrigerant flows, and is thermally connected to the electric component. The flow channel formation unit is a member different from the housing, and an elastically deformable spacer is provided between the flow channel formation unit and the housing.