Power Converter Thermal Management via Segmented Housing
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Solution Overview
Problem
High-power power converters face challenges in managing heat generated during operation, which can lead to overheating and malfunction or failure of heat-sensitive circuitry, especially in environments where thermal management is critical.
Innovation Solution
A power converter assembly that includes a housing with a cold plate, a power converter module conductively coupled to the cold plate, and a thermal composite that insulates the heat-sensitive circuitry from generated heat, allowing heat to be conducted away through the cold plate and maintaining temperatures within safe limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If higher-power converter components are used to increase power conversion capability, then power output is improved, but heat generation increases causing temperature to exceed thermal operating limits of heat-sensitive circuitry
Solution Approach 1:
The housing is divided into a first portion and a second portion separated by a partition wall. The first portion contains heat-producing power converter modules while the second portion contains heat-sensitive circuitry. This segmentation physically isolates the thermal zones, allowing high-power operation in one section without overheating sensitive components in another section.
Solution Approach 2:
A thermal composite is introduced as an intermediary layer between the power converter modules and the heat-sensitive circuitry. This thermal composite includes a thermal barrier that blocks heat transfer to sensitive circuitry while allowing controlled heat management. The partition wall also acts as an intermediary thermal barrier separating the two thermal zones.
2Device complexity
If heat-producing components are placed close to heat-sensitive circuitry to reduce device size, then device complexity is reduced, but temperature of heat-sensitive circuitry rises above thermal operating limits
Solution Approach 1:
The housing is segmented into distinct thermal zones with a partition wall separating heat-producing and heat-sensitive components. This allows close proximity arrangement (reducing overall device size) while maintaining thermal isolation through the partition wall and thermal composite, thus keeping device complexity low while preventing overheating.
Solution Approach 2:
A thermal composite comprising multiple layers including a thermal barrier is used between heat-producing and heat-sensitive components. This composite material structure provides effective thermal isolation in a compact form factor, enabling close component placement without exceeding thermal limits of sensitive circuitry.
3Temperature
If thermal insulation is added between heat-producing and heat-sensitive components, then temperature of heat-sensitive circuitry is maintained within limits, but device complexity increases
Solution Approach 1:
The partition wall and thermal composite are merged into a single integrated thermal management structure. The partition wall serves dual purposes as both a structural divider and a thermal barrier, while the thermal composite is integrated between the power converter modules and the housing. This merging approach provides effective thermal isolation without adding separate complex insulation systems.
Solution Approach 2:
The partition wall is designed to serve multiple functions: structural support, thermal isolation, and physical separation of components. The thermal composite also provides multiple benefits including thermal barrier properties and electrical insulation. This multi-functionality reduces the need for additional dedicated insulation components, thereby limiting the increase in device complexity.
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
Effectively prevents heat-sensitive circuitry from overheating by isolating it from generated heat and removing excess heat through conduction and convection, ensuring reliable operation within predetermined thermal limits.
Implementation Method 1
at least a portion of the generated heat is removed by way of conduction through the cold plate
Implementation Method 2
a thermal composite overlying the power converter module and at least partially thermally insulating the power converter module from the heat sensitive circuitry
Data Source
AI summary
A power converter assembly includes a housing, a cold plate located within the housing, a power converter module coupled with the cold plate, receiving a power input and providing a power output, and a thermal composite overlying the power converter module and at least partially thermally insulating the power converter module.