Power Conversion Device Sealing Base Plate Height Differential
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Solution Overview
Problem
Existing power conversion devices for electric vehicles face challenges in preventing coolant leakage from the coolant channel into the circuit board accommodation space, which can lead to reduced reliability and performance.
Innovation Solution
The power conversion device incorporates a design where the circuit board base plate and coolant channel base plate have height differences, with the coolant channel base plate fluidly sealing the coolant channel and the circuit board base plate sealing the circuit board accommodation space, preventing coolant leakage and ensuring reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the coolant channel and circuit board accommodation space are arranged adjacently to save space, then the device compactness is improved, but the risk of coolant leakage into the circuit board area increases
Solution Approach 1:
The device is divided into functionally independent sealed compartments: the coolant channel is separated from the circuit board accommodation space through distinct base plates and subsidiary walls. This segmentation ensures that even if coolant leaks, it cannot cross into the circuit board area, resolving the contradiction between compact arrangement and leakage prevention.
Solution Approach 2:
The first base plate and second base plate act as intermediary sealing elements between the coolant channel and circuit board accommodation space. These base plates with integrated sealing structures serve as protective mediators that physically block coolant migration while allowing the spaces to remain adjacent for compact design.
2Reliability
If the circuit board base plate and coolant channel base plate are positioned at different heights to prevent coolant flow, then the reliability is improved, but the structural complexity increases
Solution Approach 1:
The sealing function and height differential structure are merged into the base plates themselves. The first base plate and second base plate are designed with integrated sealing structures and height differences, combining multiple protective functions into single components rather than adding separate complex mechanisms.
Solution Approach 2:
The height difference and sealing structures are applied locally at critical interfaces where coolant leakage risk exists, rather than throughout the entire device. The first and second base plates have localized sealing features at their peripheries and interfaces with subsidiary walls, providing targeted protection without overall structural 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
This design effectively prevents coolant leakage into the circuit board accommodation space, enhancing the reliability and performance of the power conversion device by ensuring the coolant does not flow into the critical electronic components.
Implementation Method 1
the coolant channel base plate fluidly sealing the coolant channel
Implementation Method 2
the circuit board base plate sealing the circuit board accommodation space
Data Source
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AI summary
A power conversion device includes a casing, an isolation wall, a first circuit board unit, a converter module, a coolant channel base plate, a circuit board plate and a top cover. The casing includes a base plate which has a base surface and a recessed space. The isolation wall partitions the recessed space into a circuit board accommodation space and a coolant channel. The isolation wall has a circuit board subsidiary wall and a coolant channel subsidiary wall. The circuit board subsidiary wall and the coolant channel subsidiary wall have a height difference. The first circuit board unit is located in the circuit board accommodation space. The converter module is located opposite to the recessed space. The coolant channel base plate fluidly seals the coolant channel. The circuit board base plate seals the first circuit board unit. The top cover seals the converter module.