Vehicle Power Converter Cooling Block for Compact Module Integration
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Solution Overview
Problem
Existing power converter systems for eco-friendly vehicles lack a compact and efficient integration of components like capacitors, power modules, and DC-DC converters, which hinders space optimization and effective cooling within the vehicle.
Innovation Solution
A power converter apparatus featuring a cooling block with parallel cooling baths and tubes that merge refrigerant flow, providing a compact assembly for power conversion components and ensuring uniform cooling through strategically positioned cooling fins and surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If power conversion components are integrated into one assembly form, then space utilization and cooling efficiency are improved, but device complexity increases
Solution Approach 1:
The patent combines multiple power conversion components (inverter, DC-DC converter, capacitor) into a single integrated assembly with a unified cooling system. The cooling block serves as a common structure that provides cooling chambers for different components, merging what would traditionally be separate cooling systems into one consolidated unit, thereby reducing overall assembly volume while managing the integration complexity through modular design
Solution Approach 2:
The cooling block performs multiple functions simultaneously: it serves as a structural support for mounting components, provides cooling chambers for thermal management, and acts as a refrigerant distribution system. This multi-functionality allows the same structure to fulfill several roles, reducing the need for additional separate components and thereby reducing overall assembly volume
2Temperature
If separate cooling systems are used for each component, then cooling effectiveness is maintained, but assembly volume increases
Solution Approach 1:
The patent merges multiple separate cooling systems into a single integrated cooling block that serves all power conversion components. The cooling block contains multiple cooling chambers that can be independently configured for different components while sharing common refrigerant flow paths, thereby maintaining component-specific cooling effectiveness while reducing the total volume required for separate cooling systems
Solution Approach 2:
The cooling block is segmented into multiple cooling chambers, each dedicated to a specific power conversion component. This segmentation allows each chamber to be optimized for the thermal characteristics of its associated component, maintaining cooling effectiveness, while the shared outer structure and refrigerant flow paths reduce the overall volume compared to completely separate cooling systems
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
Enables the compact integration of power conversion components while ensuring effective cooling, enhancing vehicle mountability and preventing performance limitations due to thermal issues.
Implementation Method 1
a cooling block provided with a refrigerant inlet and a refrigerant outlet, and with two cooling baths connected to the refrigerant inlet in parallel
Implementation Method 2
the cooling block being configured to allow refrigerants passing through the two cooling baths to be merged prior to being discharged through the refrigerant outlet
Implementation Method 3
includes a plurality of cooling fins protruding into the cooling chamber
Data Source
AI summary
A power converter apparatus for a vehicle includes: a cooling block provided with a refrigerant inlet and a refrigerant outlet, and with two cooling baths connected to the refrigerant inlet in parallel and each having a shape open to an outside, the cooling block being configured to allow refrigerants passing through the two cooling baths to be merged prior to being discharged through the refrigerant outlet; two cooling plates, wherein each of the two cooling plates covers an opening of an associated one of the cooling baths to provide a cooling chamber and includes a plurality of cooling fins protruding into the cooling chamber; and two cooling tubes, wherein each of the cooling tubes is coupled to the cooling block to provide a space for accommodating a power module between the cooling tube and an associated one of the cooling plates.