Power Electronics Module Cooling Channel Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Power electronics modules in the automotive industry face challenges with heat management due to high electrical currents in load current lines, leading to reduced performance and service life, and require individual adaptations for different automobile manufacturers, making mass production inefficient.
Innovation Solution
A power electronics module system with a cooling channel running through side walls and a housing design that facilitates thermally conductive contacts, allowing for efficient heat absorption and dissipation, and a unified design compatible with various load current line orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If load current lines are connected directly to the power converter via electrical contacts, then electrical conductivity is achieved, but heat is transferred to the power converter causing reduced performance and service life
Solution Approach 1:
The invention separates the connection module from the power electronics module into two distinct functional units. The connection module handles electrical connections and heat dissipation, while the power electronics module focuses on power conversion. This segmentation prevents heat from the load current lines from being transferred to the power converter, thereby improving reliability and service life.
Solution Approach 2:
The invention introduces a receiving area with thermal insulation between the connection module and the power electronics module. This intermediary structure acts as a thermal barrier, blocking the heat transfer path from the electrical contacts and load current lines to the power converter, thus protecting the power electronics from thermal damage.
2Adaptability or versatility
If individual adaptations are made for different automobile manufacturers, then specific requirements are met, but manufacturing complexity and effort increase
Solution Approach 1:
The connection module is designed as a universal component with a standardized receiving area that can accommodate different load current line configurations from various automobile manufacturers. The modular design allows the same connection module to be adapted to different requirements through configuration rather than redesign, reducing manufacturing complexity while maintaining versatility.
Solution Approach 2:
The invention enables dynamic adaptability where the connection module can be configured for different manufacturers' requirements without changing the fundamental structure. The receiving area is designed to flexibly accommodate various electrical connection arrangements, allowing the system to adapt to different specifications while maintaining a uniform base design for mass production.
3Temperature
If heat is dissipated from the connection module, then temperature control is improved, but additional cooling infrastructure is required
Solution Approach 1:
The invention combines the cooling function with the existing power electronics module cooling system. The receiving area with thermal insulation is integrated into the housing structure, and the cooling channels are merged with the power converter cooling pathways. This unified approach provides effective heat dissipation from the connection module without requiring a completely separate cooling infrastructure.
Solution Approach 2:
The connection module utilizes the cooling system already present in the power electronics module for its thermal management. The thermal insulation in the receiving area directs heat away from the power converter while the existing cooling channels in the housing structure handle the heat dissipation from the connection module, allowing the system to self-regulate temperatures using already-available cooling resources.
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 achieves effective cooling of power converters and connection modules, preventing overheating and enabling a uniform module design suitable for multiple manufacturers, improving performance and longevity while simplifying production.
Implementation Method 1
a cooling channel through which a liquid cooling medium can flow runs within at least one of the side walls (11a, 11b, 11c and 11d) of the receiving area (5) and continues through the power converter cooling area (6)
Implementation Method 2
The first contact elements (9) have a thermally conductive connection with the third side wall (11c) of the receiving area (5)
Data Source
AI summary
The application relates to a power electronics module system (1) having a power electronics module (2) and a connection module (3), wherein the power electronics module has a first converter (4) and a cooling device (7), wherein the cooling device has a converter cooling region (6) and a receiving region (5), wherein the first converter is arranged in the converter cooling region, and the receiving region has side walls (11a, 11b, 11c, 11d), one of said side walls (11d) separating the receiving region from the converter cooling region, wherein the receiving region has electrically conductive first contact elements (9) that have a thermally conductive connection to a side wall (11c) of the receiving region, and the connection module has electrically conductive second contact elements (10) arranged on the connection module such that an electrically conductive contact between the first and the second contact elements (9, 10) is established when the connection module is arranged in the receiving region, wherein a cooling channel, through which a fluid cooling medium can flow, runs inside at least one of the side walls of the receiving region and continues to run through the converter cooling region. The invention provides a power module system that permits efficient cooling of a converter in a power module, and the use of a unified power module.