Integrated Power Electronics Cooler for Cooling and Coolant Heating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power electronics coolers in electric vehicles are not sufficiently flexible to manage heat generation efficiently, necessitating a more adaptable cooling solution.
Innovation Solution
A cooler system with an integrated heating element that controls coolant temperature independently, positioned downstream in the coolant flow path, allowing for both cooling and heating functions based on packaging requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional cooler is used for power electronics, then cooling function is provided, but the system lacks flexibility for both cooling and heating needs
Solution Approach 1:
The patent combines a cooler and a heater into a single integrated power electronics temperature management system. The cooler includes a cooling plate with coolant flow passages, while the heater includes a heating element positioned within the same housing. This merging allows the system to provide both cooling and heating functions through a unified structure, improving versatility without proportionally increasing complexity.
Solution Approach 2:
The integrated system serves multiple functions: the cooler portion cools power electronics when they generate excessive heat, while the heater portion provides supplementary heating when needed. The single system can adapt to different thermal requirements of the power electronics and other vehicle systems, making it a universal temperature management solution.
2Adaptability or versatility
If separate cooler and heater systems are used, then cooling and heating functions are provided, but space utilization is inefficient
Solution Approach 1:
By merging the cooler and heater into a single integrated housing with shared structural components and mounting features, the system eliminates the need for separate installations. The cooler plate and heating element are positioned within the same housing, allowing both temperature management functions to be provided in a compact footprint that optimizes vehicle space utilization.
3Temperature
If the heating element is positioned upstream in coolant flow, then heating occurs early in the cycle, but cooling efficiency is reduced
Solution Approach 1:
The heating element is strategically positioned downstream in the coolant flow path, specifically within the outlet manifold or near the outlet of the cooling plate. This localized positioning ensures that coolant is fully cooled by the cooling plate first, then heated only to the extent needed for supplementary heating applications. This spatial differentiation of heating and cooling zones maintains optimal cooling efficiency while enabling heating functionality.
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 system effectively manages temperature by cooling power electronics and providing supplementary heat to other vehicle systems, optimizing space utilization and efficiency.
Implementation Method 1
a heating element mounted to the housing and configured to heat the coolant
Implementation Method 2
a housing having a cooling surface configured for contacting the power electronics
Data Source
AI summary
A cooler for power electronics comprises: a housing having a cooling surface configured for contacting the power electronics; an inlet and an outlet coupled to the housing; a manifold inside the housing providing a flow of coolant in the cooler, the manifold coupled to the inlet and the outlet; and a heating element mounted to the housing and configured to heat the coolant, the heating element controlled independently of the power electronics.