Power Module Assembly with Embedded Coolant Chambers
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Solution Overview
Problem
Existing power inverter designs for automotive vehicles face challenges in efficiently cooling and housing power stages, leading to potential thermal management issues and increased complexity in manufacturing.
Innovation Solution
A method of forming a power-module assembly by arranging power stages in a cavity with spacing, inserting a core to create coolant chambers, and pouring resin to form a housing, which includes removing the core to reveal these chambers and installing a manifold for fluid communication, thereby creating a structured cooling system within the power inverter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If power stages are arranged in a cavity with spacing between them, then thermal management is improved through dedicated coolant chambers, but device complexity increases due to the need for cores and manifolds
Solution Approach 1:
The core is inserted into the cavity and positioned between power stages, then resin is poured around it. After curing, the core is removed to create coolant chambers. This nesting approach allows the coolant chamber formation to be integrated into the housing manufacturing process itself, reducing overall device complexity despite the multi-step process.
Solution Approach 2:
The core is installed beforehand to define the shape and position of coolant chambers before the resin is poured. This preliminary action ensures proper thermal management pathways are created during the housing formation process, rather than requiring post-assembly modifications.
2Ease of manufacture
If resin is poured into the cavity to form a housing, then manufacturing is simplified through integrated housing formation, but manufacturing precision requirements increase to ensure proper spacing and alignment
Solution Approach 1:
The core acts as an intermediary object that defines the precise geometry and position of coolant chambers. By using this physical mediator during the resin pouring process, the system achieves high manufacturing precision for thermal pathways without requiring complex tooling or post-processing operations.
3Temperature
If power stages are spaced apart from walls of the container, then thermal management efficiency is improved through dedicated coolant access, but volume utilization decreases
Solution Approach 1:
Coolant chambers are created in specific locations between power stages rather than uniformly throughout the entire housing. This local quality approach provides targeted thermal management where heat generation occurs, while maintaining efficient space utilization in other areas of the housing.
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 approach enhances thermal management by creating dedicated coolant chambers and simplifies the manufacturing process through a structured housing formation, improving the efficiency and reliability of power inverter performance in automotive applications.
Implementation Method 1
pouring resin into the cavity to form a housing of the power-module assembly
Implementation Method 2
coolant chambers between each of the power stages
Implementation Method 3
coolant chambers between each of the power stages
Data Source
AI summary
A method of forming a power-module assembly includes arranging power stages in a cavity of a container such that the power stages are spaced apart from walls of the container. The method further includes inserting a core between each of the power stages, and installing a manifold on top of the power stages. The method also includes putting resin into the cavity to form a housing of the power-module assembly, and removing the core to reveal coolant chambers between each of the power stages.