Power Conversion Apparatus Thermal Coupling via Insulated Sheet
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Solution Overview
Problem
Current power conversion apparatuses for electric vehicles have low power density and inefficient heat dissipation, leading to a large overall volume and reduced performance.
Innovation Solution
The power conversion apparatus optimizes component layout, using a heat-dissipation module with insulated heat-conducting sheets and elastic clamps to thermally couple power devices directly to heat-dissipation walls and coolant passages, reducing interface thermal resistance and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional power conversion module design is used, then assembly is simple, but heat dissipation capability is poor and overall volume is large
Solution Approach 1:
The patent merges the heat dissipation function directly into the housing structure by integrating coolant passages into the housing body. The housing simultaneously serves as structural enclosure and heat dissipation device, eliminating the need for separate heat dissipation components and reducing overall volume while improving heat dissipation capability.
Solution Approach 2:
The patent utilizes the three-dimensional space within the housing by creating internal coolant passages that traverse through the housing structure. This allows heat dissipation surfaces to be distributed throughout the volume rather than confined to external surfaces, increasing effective heat dissipation area without increasing external dimensions.
2Power
If traditional heat dissipation design is used, then structure is simple, but power density is low
Solution Approach 1:
The patent combines multiple functions into the housing: structural support, heat dissipation via integrated coolant passages, and component mounting. This multi-functionality reduces the number of separate components needed, decreasing overall volume and increasing power density.
Solution Approach 2:
The housing is designed as a multi-functional component that provides mechanical support, thermal management, and component accommodation. This universal design approach maximizes the utility of each component, reducing total system volume and improving power density.
3Reliability
If multiple components are assembled traditionally, then assembly is flexible, but assembly structure is complex and costs are high
Solution Approach 1:
The patent integrates the heat dissipation module directly into the housing structure, forming a unified assembly. This reduces the number of separate components that need to be assembled and connected, simplifying the assembly structure while improving reliability by reducing connection interfaces.
Solution Approach 2:
The power conversion components are nested within the housing that contains integrated coolant passages. This nested arrangement allows compact integration of multiple functional elements, reducing assembly complexity while maintaining reliable thermal coupling between components and the cooling 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
This design enhances heat-dissipation capability, reduces the overall volume, and increases power density while simplifying assembly and reducing costs.
Implementation Method 1
The first insulated heat-conducting sheet is adhered to the corresponding first heat-dissipation wall... the first power device is thermally coupled to the first heat-dissipation wall and the coolant passage via the first insulated heat-conducting sheet
Implementation Method 2
The housing includes at least one first heat-dissipation wall and a coolant passage, wherein the first heat-dissipation wall is thermally coupled to the coolant passage
Implementation Method 3
The heat-dissipation module includes at least one first insulated heat-conducting sheet and at least one first elastic clamp... the first elastic clamp is fixed to the housing and opposite to the first insulated heat-conducting sheet
Data Source
AI summary
A power conversion apparatus is provided, which comprises a housing, a mother board, an electromagnetic filter board, a signal board, and a heat-dissipation module. The housing includes a first heat-dissipation wall and a coolant passage. The mother board is disposed upon the housing, and comprises a first surface facing the housing and a first power device. The heat-dissipation module includes a first insulated heat-conducting sheet adhered to the corresponding first heat-dissipation wall and a first elastic clamp. When the first surface of the mother board approaches the housing to clamp the first power device within the accommodating space, the first power device is pressed against by the first elastic clamp and thus adhered to the first insulated heat-conducting sheet, so that the first power device is thermally coupled to the first heat-dissipation wall and the coolant passage via the first insulated heat-conducting sheet.