Vehicle Power Converter with Overlapping Cooler and Pressed Assemblies
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Solution Overview
Problem
Existing power converter systems for eco-friendly vehicles are inefficient in integrating and cooling components like capacitors, power modules, and low voltage DC-DC converters, leading to suboptimal performance and space usage.
Innovation Solution
A compact power converter apparatus integrating a power module assembly with overlapping coolers, a capacitor, and a low voltage DC-DC converter, with an LDC assembly plate for electromagnetic wave blocking and heat exchange, and engagement elements for mechanical and electrical connections, reducing size and weight while enhancing cooling and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If power conversion components (capacitor, power module, LDC) are integrated in the form of one assembly, then vehicle mountability and space efficiency are improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The power conversion system is divided into three main segments: capacitor assembly, power module assembly, and LDC assembly. Each segment is designed as a separate unit that can be independently manufactured and assembled, reducing overall assembly complexity while achieving compact integration in the vehicle.
Solution Approach 2:
The power module is nested within the power module assembly structure, which includes integrated cooling channels. The capacitor is nested within its own assembly structure with cooling passages. The LDC is nested within the LDC assembly with integrated cooling features. This nesting approach allows compact integration while maintaining manageable assembly complexity.
2Temperature
If components are integrated in one assembly to efficiently cool each component, then cooling performance is improved, but manufacturing complexity increases
Solution Approach 1:
Each component assembly (capacitor, power module, LDC) is equipped with dedicated cooling channels and cooling plates tailored to its specific thermal requirements. The cooling passages are locally optimized for each component's heat generation characteristics, achieving efficient cooling while allowing standardized manufacturing processes for each module type.
Solution Approach 2:
Cooling plates and cooling passages act as intermediary thermal transfer media between the power conversion components and the external cooling system. These intermediaries facilitate heat dissipation from each component while allowing standardized cooling infrastructure to serve multiple components, simplifying manufacturing.
3Stability of the object's composition
If engagement elements are used to mechanically connect and press components, then assembly stability is improved, but device complexity increases
Solution Approach 1:
Multiple functions are merged into the engagement elements: they provide mechanical connection between assemblies, apply pressing force for thermal contact, and serve as structural support members. This consolidation achieves assembly stability with minimal additional components, reducing overall device complexity.
Solution Approach 2:
The engagement elements are designed as multi-functional components that simultaneously perform mechanical fastening, thermal contact pressure application, and structural support. This multi-functionality reduces the number of separate components needed, achieving stability without proportionally increasing complexity.
4Object-affected harmful factors
If the LDC assembly plate blocks electromagnetic waves and facilitates heat exchange, then electromagnetic interference protection is improved, but device complexity increases
Solution Approach 1:
The LDC assembly plate performs multiple functions simultaneously: it blocks electromagnetic waves generated by the LDC, facilitates heat exchange between the LDC and cooling system, and provides structural support. This multi-functionality achieves EMI protection without adding separate dedicated components, minimizing complexity increase.
Solution Approach 2:
Electromagnetic shielding and thermal management functions are merged into the LDC assembly plate structure. The plate's material composition and geometric design simultaneously provide electromagnetic wave blocking and heat conduction pathways, achieving dual protection with a single component.
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
The solution enables improved mountability, stability, and assembly of power conversion components, achieving reduced size, weight, and increased output density by integrating components in a single assembly with efficient cooling and electromagnetic interference management.
Implementation Method 1
a cooler overlapping with the power module to allow the cooler to cover both sides of the power module
Implementation Method 2
An LDC assembly plate, which is configured to block electromagnetic waves generated in the LDC
Implementation Method 3
facilitate heat exchange between a heater of the LDC and the cooler of the power module assembly
Implementation Method 4
An engagement element may pass through the LDC, the power module assembly, and the capacitor to engage the LDC, the power module assembly, and the capacitor
Data Source
AI summary
A power converter apparatus includes a power module assembly including a power module and a cooler overlapping with the power module to allow the cooler to cover both sides of the power module, and a capacitor and a low voltage direct-current (DC)-DC converter (LDC) which are coupled in a state of pressing the power module assembly on both sides of the power module assembly.