Power Module Cooling Insert for Uniform Temperature Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power modules suffer from uneven cooling, with sections closer to the outlet experiencing lower cooling than those closer to the inlet, leading to non-optimal operation and high temperatures.
Innovation Solution
A cooling system for power modules featuring a base plate with dissipation means and an insert that includes staggered openings for dissipation pins, where the insert's central channel has a varying thickness to enhance cooling fluid flow and distribute heat evenly across the module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If known dissipation means (fins or pins) are used in power modules, then heat dissipation is achieved, but uneven cooling occurs with temperature difference greater than 10°C between inlet and outlet sections
Solution Approach 1:
The base plate incorporates heating elements at specific locations corresponding to outlet sections where cooling is insufficient. This local addition of heat creates a compensatory effect that balances the temperature distribution across the power module, addressing the uneven cooling caused by the cooling fluid's temperature drop along its flow path
Solution Approach 2:
The system dynamically adjusts the temperature parameter by introducing controlled heating at specific zones. The heating elements modify the local thermal conditions in outlet sections, changing the overall temperature distribution pattern from uneven to uniform across different sections of the power module
2Power
If power ranges increase to meet higher power demands, then power output is improved, but cooling adequacy deteriorates with sections closest to outlet experiencing lower cooling
Solution Approach 1:
Heating elements are strategically placed at outlet sections where cooling becomes inadequate at higher power levels. This localized heating compensation allows the system to maintain adequate cooling performance across all sections even when operating at increased power ranges
Solution Approach 2:
The heating elements operate continuously or periodically to maintain temperature balance, ensuring that cooling adequacy is sustained throughout the power module's operation at various power levels, particularly compensating for the cumulative temperature drop in outlet sections
3Productivity
If dissipation means are positioned to maximize heat transfer, then cooling efficiency is improved, but temperature difference between inlet and outlet sections increases
Solution Approach 1:
Heating elements are added specifically at outlet sections to compensate for the temperature difference created by efficient cooling at inlet sections. This localized counter-heating maintains overall temperature uniformity while allowing high cooling efficiency at the inlet where it is most needed
Solution Approach 2:
The system creates thermal equipotential conditions across different sections by using heating elements to raise temperatures in cooler outlet sections to match the temperature level of inlet sections, thereby eliminating harmful temperature gradients while maintaining high cooling efficiency
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 achieves balanced temperature distribution and improved cooling performance, ensuring consistent temperature across all sections of the power module, enhancing scalability and efficiency.
Implementation Method 1
The dissipation means are hit, i.e. lapped, by the cooling fluid (typically water, like for example in US2012175094A1, or air) and dissipate (i.e. dispose of) the heat produced
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A cooling system (1) for a power module (100) comprising a base plate (2) and an insert (3). The base plate (2) comprises a path (P) for a cooling fluid extending between an inlet (I) and an outlet (U). The base plate (2) is provided with a plurality of heat dissipation means (6), which project from a surface (5) of the base plate (2) in a direction transverse, in particular orthogonal, to the path (P) of the cooling fluid. The insert (3) is arranged on the base plate (2). The insert (3) comprises two side sectors (7), which are parallel to and spaced apart from one another and laterally delimit a central channel (8), which is interposed between them and is configured to convey the cooling fluid. The two side sectors (7) are provided with a plurality of openings (9), each configured to be at least partially engaged by a respective dissipation means (6) of the base plate (2).