Power Converter Coolant Channel Structure for Lower Weight Cooling
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Solution Overview
Problem
Current power converters and drive devices face challenges in weight reduction while maintaining effective cooling efficiency, as both the coolant case and lid are typically made of metal, limiting further weight reduction opportunities.
Innovation Solution
Incorporating a plastic flow path defining member integrated into a metal plate to form a coolant flow path, which reduces weight and simplifies the structure, while using insert molding or other integration methods to ensure a secure and efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If both coolant case and lid are made of metal to ensure cooling efficiency, then thermal conductivity is improved, but weight increases
Solution Approach 1:
The patent applies composite materials by integrating a plastic flow path defining member with a metal plate to form a hybrid structure. The metal plate provides thermal conductivity for effective cooling, while the plastic portion reduces overall weight. This composite approach allows the coolant case to maintain adequate thermal performance while significantly reducing weight compared to an all-metal construction.
2Ease of manufacture
If coolant case and lid are separately manufactured and assembled, then manufacturing flexibility is improved, but device complexity increases
Solution Approach 1:
The patent merges the flow path defining member with the coolant case into an integrated structure. The plastic flow path defining member is formed as an integral part of the coolant case, eliminating the need for separate assembly steps. This integration simplifies the overall structure, reduces the number of parts, and decreases assembly complexity while maintaining manufacturing feasibility through processes like injection molding.
3Adaptability or versatility
If multiple separate components are used for coolant flow path, then adaptability is improved, but productivity decreases
Solution Approach 1:
The integration of the flow path defining member with the coolant case into a single molded part significantly improves productivity. This unified structure can be manufactured in one production cycle using injection molding or similar processes, eliminating multiple assembly operations. The integrated design maintains adaptability through the ability to customize the flow path geometry within the molded structure, while dramatically reducing manufacturing time and increasing production efficiency.
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 achieves a significant weight reduction in power converters and drive devices while maintaining effective coolant flow and thermal connectivity, enhancing the overall efficiency and reducing vibrations.
Implementation Method 1
a metal plate being in thermal connection with the at least one power semiconductor element
Data Source
AI summary
A power converter disclosed herein may include; a power module comprising at least one power semiconductor element; a metal plate being in thermal connection with the at least one power semiconductor element, and a flow path defining member including a plastic material and defining a coolant flow path together with the metal plate. A coolant may flow through the coolant flow path, and the flow path defining member may be integrated into the metal plate.