Integrated Filter Cooling Structure in Power Converters
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Solution Overview
Problem
The challenge lies in downsizing power conversion devices while maintaining or improving cooling efficiency and reliability, particularly in suppressing electromagnetic noise and managing heat generated by components.
Innovation Solution
A power conversion device configuration that integrates a filter case portion with a flow path, where a thermally conductive resin fills the gap between the filter case and the filter circuit unit, allowing refrigerant to flow for cooling and fixing components, thus reducing the need for additional fixing components and enhancing heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a noise filter circuit is added to suppress electromagnetic noise, then electromagnetic compatibility is improved, but device volume increases and cooling performance deteriorates
Solution Approach 1:
The patent combines the filter case portion housing the noise filter circuit with the flow path including body for refrigerant circulation into a single integrated structure. This merging eliminates the need for separate housing and cooling system components, thereby suppressing electromagnetic noise while preventing device volume increase
Solution Approach 2:
The integrated structure serves multiple functions simultaneously: the filter case portion both houses the noise filter circuit components (capacitor, core) and acts as part of the refrigerant flow path for cooling. This multi-functionality allows electromagnetic compatibility improvement without sacrificing cooling performance or increasing device volume
2Object-affected harmful factors
If a noise filter circuit is added to suppress electromagnetic noise, then electromagnetic compatibility is improved, but cooling performance deteriorates
Solution Approach 1:
The patent merges the filter case portion with the flow path including body, creating an integrated structure where the noise filter components are housed within the cooling system itself. This ensures that components such as the capacitor and core are directly exposed to refrigerant flow, maintaining effective cooling performance while suppressing electromagnetic noise
Solution Approach 2:
The integrated filter case portion acts as an intermediary structure that simultaneously provides electromagnetic noise suppression housing and refrigerant flow pathways. This mediator structure ensures that cooling refrigerant can efficiently reach the noise filter components without requiring separate cooling mechanisms
3Volume of moving object
If device size is reduced for downsizing, then device volume decreases, but component fixing reliability deteriorates
Solution Approach 1:
The patent integrates the filter case portion and flow path including body into a single molded structure, eliminating the need for separate fixing components. The noise filter components are securely housed within the integrated structure through precise molding, achieving reliable component fixation while maintaining compact device size
Solution Approach 2:
The patent employs resin material filling in gaps between components and the integrated structure to secure component positions. This resin fixation method provides reliable component mounting without requiring additional mechanical fixing components, enabling device downsizing while maintaining fixing reliability
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 both downsizing and improved cooling efficiency, leading to enhanced reliability by effectively managing heat and noise suppression within the power conversion device.
Implementation Method 1
a flow path including body 10 for letting a refrigerant for cooling the power conversion circuit unit flow
Implementation Method 2
a gap between the filter case portion and the filter circuit unit is filled with a first resin
Data Source
AI summary
Provided is a power conversion device that achieves both downsizing and improvement in cooling efficiency to have improved reliability. The power conversion device includes a power conversion circuit unit which converts DC power into AC power, a flow path including body for letting a refrigerant for cooling the power conversion circuit unit flow, a filter circuit unit which suppresses electric noise from a wire for transmitting the DC power, and a filter case portion which houses the filter circuit unit, where the filter case portion is formed integrally with the flow path including body, and a gap between the filter case portion and the filter circuit unit is filled with a first resin.