Power Module Coolant Channels for Thermal Management
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Solution Overview
Problem
Current thermal management systems for power module assemblies in electrified vehicles are inadequate in efficiently managing thermal conditions, leading to potential overheating and reduced performance.
Innovation Solution
The proposed solution involves a vehicle power module assembly design with a series and parallel coolant flow path configuration, utilizing frames with defined cavities and pass-throughs to facilitate effective coolant circulation and thermal communication with power stages, along with endplates that direct and compress the frames to optimize coolant flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional thermal management system is used for power module assemblies, then the system structure is simple, but thermal management efficiency is inadequate leading to potential overheating
Solution Approach 1:
The coolant flow path is segmented into multiple cavities (first cavity, second cavity, third cavity, fourth cavity) within the frame, each serving specific thermal management functions. This segmentation allows independent optimization of coolant flow through different regions, improving overall thermal management efficiency while maintaining manageable system complexity through modular cavity design.
Solution Approach 2:
The patent introduces a three-dimensional coolant flow path configuration with cavities positioned at different spatial locations and orientations within the frame. The coolant flows through multiple cavities in sequence, utilizing vertical and horizontal dimensions to maximize heat dissipation surface area and improve thermal management efficiency without significantly increasing overall system footprint.
2Temperature
If coolant cavities are positioned to maximize thermal communication with power stages, then heat dissipation efficiency improves, but manufacturing precision requirements increase
Solution Approach 1:
The coolant cavities are merged with the frame structure itself rather than being separate components. The frame defines multiple cavities (first cavity, second cavity, third cavity, fourth cavity) that are integrally formed, which improves thermal communication between coolant and power stages while reducing manufacturing complexity and positioning requirements compared to separate cavity components.
Solution Approach 2:
The frame serves multiple functions: it provides structural support for the power module assembly and simultaneously defines the coolant cavities that enable thermal management. This multi-functionality reduces the need for separate cavity components and simplifies manufacturing while maintaining effective thermal communication between coolant and power stages.
3Reliability
If frames are stacked to create serial coolant paths, then thermal management coverage improves, but assembly complexity increases
Solution Approach 1:
The power module assembly is divided into multiple frames (first frame, second frame) that can be stacked independently. Each frame contains its own coolant cavities (first cavity, second cavity in first frame; third cavity, fourth cavity in second frame), allowing modular assembly and simplified manufacturing while achieving comprehensive thermal management coverage through stacking.
Solution Approach 2:
The coolant cavities and flow paths are pre-configured within each frame during manufacturing, with inlet and outlet channels positioned to enable automatic serial connection when frames are stacked. This preliminary configuration of coolant paths within individual frames simplifies the assembly process, as the thermal management coverage is achieved simply by stacking frames without complex alignment procedures.
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 enhances thermal management by ensuring efficient heat dissipation from power stages, improving the reliability and performance of power module assemblies in electrified vehicles.
Implementation Method 1
coolant flowing through the cavities is in thermal communication with the power stages
Implementation Method 2
coolant flowing through the cavities to define a serial coolant path
Data Source
AI summary
A vehicle power module assembly is provided. The assembly may include a first frame, a second frame, and power stages. The first frame may define a first pair of coolant cavities. The second frame may define a second pair of coolant cavities in communication with the first pair of cavities to define a serial coolant path. Each of the frames may house one of the power stages disposed between the respective pairs of cavities such that coolant flowing through the cavities is in thermal communication with the power stages. The assembly may further include a pair of endplates, one of which defines a channel to divert coolant from a last of the pair of coolant cavities to the outlet cutouts in substantial registration with one another. Each of the first frame and second frame may further define a pass-through fluidly connecting the pair of coolant cavities.