Power Converter Heat Pipe Thermal Coupling

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Solution Overview

Problem

Power converters, such as AC-to-DC and/or DC-to-DC converters, generate heat, which becomes challenging to manage in densely packed arrangements where heat transfer between closely located converters is inefficient.

Innovation Solution

The implementation of heat pipes within power converters to extract heat from internal components like inductors and semiconductors, and transfer it to external heat sinks, enhancing heat dissipation and allowing for increased power draw.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If power converters are densely packed to increase productivity, then power density is improved, but heat transfer efficiency deteriorates

Engineering Contradiction:

Improvepower densityVSAvoidheat transfer efficiency

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

Heat pipes are introduced as intermediary thermal coupling components between the power converter components and the heat sink. These heat pipes act as highly efficient thermal mediators that conduct heat away from densely packed converters, enabling high power density while maintaining effective heat transfer despite limited space and thermal coupling challenges.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If heat is transferred to external heat sinks, then heat dissipation is improved, but device complexity increases

Engineering Contradiction:

Improveheat dissipationVSAvoidstructural complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The heat sink is integrated directly with the power converter housing, merging two previously separate components into a unified structure. This integration maintains effective heat dissipation through the heat pipe thermal coupling while reducing overall device complexity by eliminating the need for separate heat sink mounting structures and brackets.

Inventive Principle:

Principle #5Merging (Combining)

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 solution effectively manages heat dissipation in power converters, improving their operational efficiency and allowing for higher power output by efficiently transferring heat away from internal components.

Implementation Method 1

a heat pipe thermally coupling the heat generating devices within the housing to the external heat sink

Methodology Applied

Scientific EffectHeat pipe: Heat Pipe

Implementation Method 2

transfer that heat to one or more external heat sinks for more efficiently extracting heat

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

external heat sink mounted to the housing

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20250151232A1Power converter with integrated heat pipe

Publication Date: 2025.05.08 VERTIV CORP

AI summary

A power supply system can include a case, a plurality of sets of power converter connections within the case, and a plurality of power converters configured to be removably coupled to corresponding ones of the sets of connections. A power converter can include a housing, a plurality of power connectors configured to be removably coupled to corresponding ones of the connections, a plurality of heat generating devices within the housing, an external heat sink, and a heat pipe that thermally couples the heat generating devices to the external heat sink.