Power Conversion System Compact Spatial Arrangement
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Solution Overview
Problem
The existing power conversion systems face challenges in downsizing due to the increasing size of components like smoothing capacitors, which require efficient spatial utilization and positioning of filter capacitors, DC-DC converters, and refrigerant flow channels to minimize heat and optimize wiring.
Innovation Solution
A power conversion system design where the filter capacitor partially overlaps with the DC-DC converter in the Z direction, the smoothing capacitor does not overlap in the Z direction but partially overlaps in the X direction, and the refrigerant flow channel is positioned between the housing and a flow channel cover, allowing for close placement of components and reduced wiring inductance, thereby enabling compact sizing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the smoothing capacitor is upsized to satisfy high output demand, then the power conversion system can generate higher output, but the system size increases and space utilization becomes problematic
Solution Approach 1:
The patent applies three-dimensional spatial arrangement by allowing the filter capacitor to overlap with the DC-DC converter in the Z direction (vertical stacking), while the smoothing capacitor overlaps in the X direction (horizontal arrangement). This multi-dimensional positioning enables compact packaging of large-capacity capacitors without increasing overall system volume, resolving the contradiction between high output power requirement and system size constraint.
2Loss of energy
If the filter capacitor and DC-DC converter are positioned to optimize wiring, then wiring inductance is reduced, but the positional relationship becomes complex and space utilization is compromised
Solution Approach 1:
The patent merges the filter capacitor and DC-DC converter into an overlapping spatial configuration where the filter capacitor is positioned to partially overlap with the DC-DC converter in the Z direction. This merging approach allows both components to share the same spatial envelope while maintaining optimal electrical connection, reducing wiring inductance without creating complex external positioning requirements.
3Temperature
If the refrigerant flow channel is positioned to cool the DC-DC converter effectively, then heat dissipation is improved, but the available space for other components is reduced
Solution Approach 1:
The refrigerant flow channel is nested within the housing structure and positioned to face the DC-DC converter through the overlapping configuration of the filter capacitor. The flow channel utilizes the vertical space (Z direction) created by the stacked arrangement, allowing effective cooling of the DC-DC converter without occupying additional horizontal space that would interfere with other components.
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 allows for a compact power conversion system by reducing the size of the system in both the Z and X directions, minimizing the need for additional space and optimizing cooling and wiring efficiency.
Implementation Method 1
a refrigerant flow channel to cool the DC-DC converter
Data Source
AI summary
A power conversion system at least includes a filter capacitor, a DC-DC converter, a smoothing capacitor, a housing and a refrigerant flow channel. The refrigerant flow channel is disposed between the housing and a flow channel cover. The refrigerant flow channel includes a converter facing portion at least partially facing the DC-DC converter. The filter capacitor at least partially overlaps with the DC-DC converter when viewed in a first direction from an opposite side of the refrigerant flow channel to the converter facing portion. The smoothing capacitor does not overlap with the DC-DC converter when viewed in the first direction and partially overlaps with the DC-DC converter when viewed in a second direction. At least two fastening sections fasten the flow channel cover to the housing and do not overlap with the smoothing capacitor when viewed in the first direction.