Power Converter Cooling Wall Deformation Control
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Solution Overview
Problem
Existing electric power conversion apparatuses face challenges during assembly due to deformation of the cooling wall portion under the load of the electronic component, leading to coolant leakage and damage to the sealant, especially when fins and partition walls are involved, due to difficulties in achieving high dimensional accuracy and proper abutment of these components.
Innovation Solution
The electric power conversion apparatus includes a case with a cooling wall portion and a flow passage cover, featuring a standing portion that is easily inserted into an opening, allowing for the use of a jig to support the cooling wall portion and prevent deformation, with a sealant filling gaps to prevent coolant leakage, simplifying the assembly process and enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the cooling wall portion is directly assembled without support, then the assembly process is simple, but the cooling wall portion deforms under the load of the electronic component
Solution Approach 1:
The patent introduces a jig that is attached to the standing portion before the final assembly of the cooling wall portion. This preliminary support structure maintains the dimensional accuracy of the cooling wall portion during assembly, preventing deformation under the load of electronic components while keeping the assembly process straightforward
2Reliability
If high dimensional accuracy is required for the standing portion, then the structural integrity is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent introduces a jig as an intermediary tool that temporarily supports the cooling wall portion during assembly. This allows the standing portion to have relaxed dimensional tolerances while still achieving the required structural integrity, as the jig compensates for any dimensional variations during the assembly process
3Reliability
If the sealant is applied to seal gaps, then coolant leakage is prevented, but the sealant is damaged due to deformation of the cooling wall portion
Solution Approach 1:
The patent applies the cooling wall portion to the jig in advance before final assembly, maintaining dimensional accuracy and preventing deformation. This preliminary positioning ensures that the sealant applied to seal gaps between components remains undamaged, as the cooling wall portion does not deform under subsequent assembly loads
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 effectively suppresses deformation of the cooling wall portion during assembly, reduces damage to the sealant, and allows for reliable coolant flow, facilitating efficient heat transfer and assembly precision without the need for precise dimensional control of the standing portion.
Implementation Method 1
a sealant that seals both a gap between the cooling wall portion and the flow passage cover at a periphery of the coolant flow passage and a gap between the standing portion and the flow passage cover
Implementation Method 2
a coolant flow passage surrounded by the cooling wall portion, the flow passage cover and the flow-passage side wall portion
Implementation Method 3
a case having a cooling wall portion on which the heat-generating element is held
Data Source
AI summary
An electric power conversion apparatus includes: a heat-generating element; a case having a cooling wall portion on which the heat-generating element is held and accommodating the heat-generating element; a flow passage cover having an opening formed therein and covering a surface of the cooling wall portion on the opposite side to the heat-generating element; a standing portion standing from the cooling wall portion and inserted in the opening; a flow-passage side wall portion formed in one of the cooling wall portion and the flow passage cover to protrude toward the other; a coolant flow passage surrounded by the cooling wall portion, the flow passage cover and the flow-passage side wall portion; and a sealant that seals both a gap between the cooling wall portion and the flow passage cover at a periphery of the coolant flow passage and a gap between the standing portion and the flow passage cover.