Power Module Cooling Plate with Baffled Flow for Uniform Temperature
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Solution Overview
Problem
Current cooling solutions for complex, high power density power modules are insufficient, leading to cooling inhomogeneity and temperature variations that affect performance and reliability.
Innovation Solution
A cooling system with a cooling plate and enclosure that includes a baffle and cutouts to create a fluid distribution pathway, distributing cooling fluid uniformly across protruding bodies to reduce temperature variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling solutions are used for high power density power modules, then the cooling system is simple and cost-effective, but cooling inhomogeneity occurs leading to temperature variations
Solution Approach 1:
The cooling system is segmented into multiple functional components: an enclosure defining a chamber, a cooling plate with protruding bodies, and a complex insert with baffles and cutouts. This segmentation allows each component to perform a specific function in the fluid distribution pathway, achieving uniform cooling through structured division rather than a monolithic design.
Solution Approach 2:
The insert introduces local variations in the cooling system through baffles that create distinct inflow and outflow distribution volumes, and cutouts that direct fluid flow through specific cooling volumes. This local differentiation of fluid distribution characteristics ensures that cooling fluid is delivered uniformly to different regions of the power module, addressing the temperature uniformity requirement.
2Temperature
If a complex insert with baffles and cutouts is added to achieve uniform cooling, then temperature uniformity improves, but manufacturing complexity and integration difficulty increase
Solution Approach 1:
The insert merges multiple functions into a single integrated component: it defines the fluid distribution pathway, creates inflow and outflow distribution volumes through baffles, directs fluid flow through cutouts, and encloses the cooling volume. This consolidation of functions into one manufacturable part simplifies the overall manufacturing process compared to assembling multiple separate components.
Solution Approach 2:
The insert serves multiple functions simultaneously: it acts as a fluid distributor, a structural support, a flow director through baffles and cutouts, and an enclosure element. This multi-functionality reduces the total number of components needed in the cooling system, thereby improving ease of manufacture and integration despite the geometric complexity of the insert itself.
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 ensures uniform cooling across the power module, improving performance and reliability by minimizing temperature differences between different parts of the module.
Implementation Method 1
a cooling plate comprising a plurality of protruding bodies; an enclosure coupled to the cooling plate such that the enclosure and the cooling plate delimit a chamber that encloses the protruding bodies
Implementation Method 2
an insert vertically aligned with the cooling plate and defining a fluid distribution pathway through the chamber between an inlet and an outlet of the enclosure
Data Source
AI summary
A cooling system for a power module includes a cooling plate, an enclosure, and an insert. The enclosure is coupled to the cooling plate such that the enclosure and the cooling plate delimit a chamber that encloses a plurality of protruding bodies of the cooling plate. The insert is vertically aligned with the cooling plate and defines a fluid distribution pathway through the chamber between an inlet and an outlet of the enclosure. The insert includes a baffle that delimits an inflow distribution volume of the fluid distribution pathway from an outflow distribution volume of the fluid distribution pathway, and a plurality of cutouts that direct the fluid distribution pathway from the inflow distribution volume through a cooling volume and into the outflow distribution volume. A profile of the inflow distribution volume changes inversely proportional to a profile of the outflow distribution volume from the inlet to the outlet.