Interlocking Vehicle Power Module Assembly for Sealed Coolant Stacking
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Solution Overview
Problem
Existing vehicle power module assemblies face challenges in securely stacking and aligning power modules while maintaining a sealed relationship to facilitate coolant flow and prevent leakage.
Innovation Solution
The vehicle power module assembly incorporates interlocking lock features on opposing sides of power modules, including loop elements and wedge elements, which secure the modules together and create a sealed relationship. Additionally, coolant channels are aligned through extensions and grooves, ensuring fluid communication without external fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If lock features are used to secure power modules together, then the stacking stability is improved, but the device complexity increases
Solution Approach 1:
The lock feature combines multiple functions into a single integrated structure: the loop element provides both the locking mechanism and the alignment feature, while the wedge element simultaneously secures the modules and directs coolant flow. This merging reduces the number of separate components needed, thereby improving stacking stability without proportionally increasing device complexity.
Solution Approach 2:
The lock feature is designed as a multi-functional element that performs locking, alignment, and sealing functions simultaneously. The loop element's through-hole serves both as a mechanical interlock with the wedge and as an alignment reference, while the overall structure creates a sealed relationship for coolant flow. This multi-functionality addresses the contradiction by achieving multiple goals with a single feature.
2Manufacturing precision
If extensions and grooves are used to align coolant channels, then the coolant flow alignment is improved, but the manufacturing complexity increases
Solution Approach 1:
The extensions and grooves are pre-formed as integral features of the power module housing during the molding process. The extensions protrude from the lower surface with predetermined geometry, and the grooves are formed on the upper surface to receive these extensions. This preliminary formation ensures precise alignment of coolant channels when modules are stacked, while the integration into the molding process minimizes additional manufacturing steps.
Solution Approach 2:
The extension from one module nests into the groove of the adjacent module, creating a precise mechanical interfit that aligns the coolant channels. The extension fits within the groove boundaries, ensuring that the coolant flow path is continuously aligned across module interfaces without requiring additional adjustment or assembly steps.
3Reliability
If a sealed relationship is created between power modules, then the coolant leakage prevention is improved, but the device complexity increases
Solution Approach 1:
The seal is integrated into the lock feature structure itself rather than being a separate component. The mating surfaces of the lock features and the engaged geometry of the loop and wedge elements create the sealed relationship, combining the mechanical locking function with the sealing function in a single integrated feature, thereby preventing leakage without adding separate sealing components.
Solution Approach 2:
The seal is formed as a thin film or membrane integrated into the lock feature structure. This thin film seal conformally follows the mating surfaces, creating an effective barrier against coolant leakage while maintaining the compact integrated structure of the lock feature, thus achieving reliable sealing without significant increase in device complexity.
Data Source
AI summary
A vehicle power module assembly including first and second power modules is provided. The first power module may include a first lock feature extending from a lower portion of a first minor side at a first central axis. The second power module may include a second lock feature at an upper portion of a second minor side at a second central axis. The lock features may be sized for interlock with one another to secure the power modules to one another. The first lock feature may be a loop element defining a through-hole and the second lock feature may be a wedge. The through-hole may be sized for the wedge to extend therein and to interlock the first power module and the second power module to one another. The first lock feature may be a flexible hook element and the second lock feature may be a slot.