Electric power converter device

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Solution Overview

Problem

Conventional electric heating devices in vehicles require additional installation space and increase vehicle weight, as they are separate modules designed solely for heating, which is not efficient in hybrid or electric vehicles.

Innovation Solution

An electric power converter device that utilizes waste heat from the power electronics unit to heat a fluid, which is then circulated to warm the vehicle, incorporating a control unit to switch between operation modes to optimize heat generation, eliminating the need for a separate heating device.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a separate electric heating device is used, then heating function is provided, but installation space and vehicle weight increase

Engineering Contradiction:

Improveheating capabilityVSAvoidvehicle weight

Core Design Contradiction:

TemperatureVSWeight of stationary object

Solution Approach 1:

The patent combines the heating function with the existing power converter device by integrating a heating element into the power electronics housing. The power converter device, which already requires installation in the vehicle, is enhanced to provide both power conversion and heating functions, thereby eliminating the need for a separate heating device and reducing overall vehicle weight.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The power converter device is designed to perform multiple functions: power conversion (AC-DC or DC-DC) and heating. By making the power converter device universal, it can serve both its original purpose and provide thermal comfort, thus avoiding additional installation space and weight associated with dedicated heating equipment.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If a separate electric heating device is used, then heating function is provided, but installation space increases

Engineering Contradiction:

Improveheating capabilityVSAvoidinstallation space

Core Design Contradiction:

TemperatureVSArea of stationary object

Solution Approach 1:

The heating element is integrated into the housing of the power converter device, merging two functions into one physical unit. This eliminates the need for separate installation space for a dedicated heating device, as the heating functionality is now housed within the existing power converter enclosure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Temperature

If power electronics unit operates in second operation mode, then waste heat generation is increased, but energy efficiency decreases

Engineering Contradiction:

Improvewaste heat amountVSAvoidenergy efficiency

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The patent converts the harmful waste heat generated by the power electronics unit into a useful resource for heating the vehicle. By operating the power electronics in a mode that generates higher waste heat during cold start phases, the system transforms energy loss into beneficial thermal energy, thereby improving overall system efficiency rather than merely accepting the energy loss.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The power electronics unit can dynamically switch between different operation modes depending on thermal requirements. During cold start phases, it operates in a mode that generates more waste heat for heating purposes, and during normal operation, it switches to a more energy-efficient mode, thus adapting its operation to optimize both heating performance and energy efficiency.

Inventive Principle:

Principle #15Dynamics

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 reduces installation space and vehicle weight by sharing existing electronics components, providing efficient heat distribution during cold start phases and normal operation, while reducing production costs.

Implementation Method 1

waste heat generated by the power electronics unit is used for heating the fluid flowing through the fluid chamber

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

The power electronics unit being electrically connected to an electric power input and an electric power output

Methodology Applied

Scientific EffectElectrical resistance: Electrical Resistance

Implementation Method 3

The plate may be a thermally conductive plate which is as thin as possible for a given fluid pressure in the fluid circuit

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 4

The fluid inlet and the fluid outlet may be fluidically connected to fluid circuit which may comprise a fluid convey unit for conveying a fluid in the fluid circuit

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentEP3870466B1Electric power converter device

Publication Date: 2022.06.15 MAHLE INT GMBH

Figure 1~2

AI summary

An electric power converter device (1) comprising a power electronics unit (2) with an electric power input (3) and an electric power output (4),at least one fluid chamber (5) with a fluid inlet (6) and a fluid outlet (7), wherein the fluid chamber (5) and the power electronics unit (6) are thermally coupled such that waste heat generated by the power electronics unit (6) is used for heating a fluid flowing through the fluid chamber(5),wherein the electric power converter device (1) has a first operation mode and a second operation mode,wherein the amount of waste heat generated by the power electronics unit (2) is increased in the second operation mode compared to the first operation mode.