Stacked Air-Duct Power Module for Insulated Direct Cooling
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Solution Overview
Problem
Existing power modules face challenges such as large size and depth, making them difficult to move, heavy weight and high cost due to solid shielding insulation, and poor heat dissipation capabilities, particularly in medium voltage applications.
Innovation Solution
The power module is designed with separate air ducts for high-voltage and low-voltage components, using insulating material for the isolating part and semi-conductive layers to prevent heat transfer while ensuring air circulation, which includes a fan assembly for enhanced heat dissipation and reduces the need for solid insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solid shielding insulation is used to isolate high-voltage and low-voltage cavities, then electrical insulation is improved, but weight and cost increase
Solution Approach 1:
The case is segmented into a high-voltage cavity and a low-voltage cavity that are physically separated and stacked in different spatial layers. This segmentation allows each cavity to be independently designed and cooled without requiring heavy solid insulation between them, thus reducing weight while maintaining electrical insulation.
Solution Approach 2:
An isolating part made of insulating material is introduced as an intermediary component between the high-voltage and low-voltage cavities. This isolating part provides the necessary electrical insulation with minimal weight compared to solid shielding, and it also serves as a structural support for the air duct system.
2Reliability
If solid shielding insulation is used to isolate high-voltage and low-voltage cavities, then electrical insulation is improved, but cost increases
Solution Approach 1:
The case is segmented into a high-voltage cavity and a low-voltage cavity that are physically separated and stacked in different spatial layers. This segmentation allows each cavity to be independently designed and cooled without requiring heavy solid insulation between them, thus reducing weight while maintaining electrical insulation.
Solution Approach 2:
An isolating part made of insulating material is introduced as an intermediary component between the high-voltage and low-voltage cavities. This isolating part provides the necessary electrical insulation with minimal weight compared to solid shielding, and it also serves as a structural support for the air duct system.
3Reliability
If high-voltage and low-voltage power units are arranged side by side with cable connections, then electrical connection is achieved, but heat dissipation deteriorates
Solution Approach 1:
The high-voltage and low-voltage cavities are arranged in different spatial layers (stacked vertically) rather than side by side horizontally. This dimensional change allows for independent air duct systems in each cavity, enabling effective heat dissipation through forced convection while maintaining electrical connections between components.
Solution Approach 2:
Air ducts with fans are introduced into each cavity to create forced convection airflow. The air ducts guide cool air to the power units and transformer, and the fans drive the air circulation to efficiently remove heat from the components, solving the heat dissipation problem in the stacked configuration.
4Temperature
If air ducts are provided for air circulation, then heat dissipation is improved, but heat transfer between cavities may occur
Solution Approach 1:
The case is segmented into a high-voltage cavity and a low-voltage cavity that are physically separated and stacked in different spatial layers. This segmentation allows each cavity to be independently designed and cooled without requiring heavy solid insulation between them, thus reducing weight while maintaining electrical insulation.
Solution Approach 2:
An isolating part made of insulating material is introduced as an intermediary component between the high-voltage and low-voltage cavities. This isolating part provides the necessary electrical insulation with minimal weight compared to solid shielding, and it also serves as a structural support for the air duct system.
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
This design improves heat dissipation efficiency, reduces size and weight, and increases power density by preventing heat transfer between components and allowing direct air cooling, thus addressing the limitations of existing power modules.
Implementation Method 1
the isolating part is formed of insulating material
Implementation Method 2
a fan assembly, including a fan having an air inlet/outlet in communication with both a front portion of the first air duct and a front portion of the second air duct
Implementation Method 3
semi-conductive layers, disposed on both sides of the isolating part, wherein the high-voltage portion and the low-voltage portion are respectively in contact with the semi-conductive layers on both sides of the isolating part
Data Source
Figure 1
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AI summary
The present disclosure relates to the field of power electronics technology, and proposes a power module, including: a case (10) and an isolating part (50) disposed in the case; a first air duct (11) and a second air duct (12) stacked to each other, separated by the isolating part, and penetrated in a front-to-rear direction in the case; a high-voltage power unit; a low-voltage power unit (30); and a transformer (40), including a high-voltage portion (41) and a low-voltage portion (42), wherein the high-voltage portion includes a first magnetic core (411) and a high-voltage coil (412) disposed on the first magnetic core, and the low-voltage portion includes a second magnetic core and a low-voltage coil disposed on the second magnetic core, wherein the high-voltage power unit and the high-voltage portion are disposed in the first air duct, and the low-voltage power unit and the low-voltage portion are disposed in the second air duct.