Power Electronics Cooling With Swappable Series-Parallel Blocks

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Solution Overview

Problem

Calibrating cooling systems for power electronics units with different cooling capacities requires multiple parts, increasing inventory, costs, and manufacturing time.

Innovation Solution

A heatsink arrangement with interchangeable blocks that allow switching between series and parallel coolant flow configurations, using a first and second heatsink with flow regulation features to selectively route coolant flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple parts are used to calibrate cooling systems for different cooling capacities, then the cooling system can be adapted to different applications, but inventory, costs, and manufacturing time increase

Engineering Contradiction:

Improvecooling capacity calibrationVSAvoidparts inventory

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The cooling system uses a universal heatsink design with multiple configurable flow paths that can accommodate different cooling capacities through software configuration rather than requiring different physical parts. The same heatsink hardware can be calibrated for various cooling capacities by adjusting flow path activation, eliminating the need for multiple specialized heatsink variants.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The cooling system implements dynamic flow path selection where different coolant flow configurations (single-pass, multi-pass, series, parallel) can be activated based on the required cooling capacity. This dynamic reconfiguration allows a single heatsink to adapt to different thermal loads without requiring multiple static designs.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If multiple parts are used to calibrate cooling systems for different cooling capacities, then the cooling system can be adapted to different applications, but manufacturing time increases

Engineering Contradiction:

Improvecooling capacity calibrationVSAvoidmanufacturing time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

A single universal heatsink design serves multiple cooling capacity requirements, eliminating the need to manufacture and assemble different heatsink variants. This reduces manufacturing steps and assembly time while maintaining the ability to calibrate for different applications through flow path configuration.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The heatsink is pre-designed with all possible flow paths and mounting configurations built-in during manufacturing. This preliminary inclusion of multiple flow path options allows for rapid post-manufacturing calibration without requiring additional manufacturing steps or specialized assembly procedures for different cooling capacities.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If multiple parts are used to calibrate cooling systems for different cooling capacities, then the cooling system can be adapted to different applications, but costs increase

Engineering Contradiction:

Improvecooling capacity calibrationVSAvoidparts inventory

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

The patent describes a universal heatsink design that can be configured for different cooling capacities using the same physical components. By eliminating the need for multiple specialized heatsink variants, the system reduces parts inventory requirements and associated costs while maintaining adaptability to different applications.

Inventive Principle:

Principle #6Universality (Multi-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

Enables efficient heat dissipation with flexible cooling system configurations, reducing inventory and manufacturing time by allowing easy switching between series and parallel coolant flows.

Implementation Method 1

Each of the first heatsink and the second heatsink is configured to receive a coolant flow and dissipate heat from one or more power modules

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

Each of the first heatsink and the second heatsink is configured to receive a coolant flow and dissipate heat

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20250331138A1Cooling system for power electronics units

Publication Date: 2025.10.23 CATERPILLAR INC

AI summary

A cooling system for a power electronics unit includes a heatsink arrangement and multiple blocks. The heatsink arrangement includes first and second heatsinks to receive a coolant flow. The first heatsink includes first openings and the second heatsink includes second openings. Blocks are positioned between the heatsinks. Each block defines a flow regulation feature such that coolant flows between the first and second openings is selectively routed and restricted. One block is swappable with another block to interchange locations of flow regulation features to switch the cooling system between first and second configurations. In the first configuration, the heatsinks are fluidly connected to each other to receive the coolant flow according to a series flow. In the second configuration, the heatsinks are fluidly connected to each other to receive the coolant flow according to a parallel flow.