Power Module Cooling Manifold for Turbulent Fin-Channel Flow
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Solution Overview
Problem
Conventional cooling apparatuses for power modules in electric vehicles have low cooling efficiency due to simple tube or fin structures, which also degrade the flowability of cooling fluids, leading to reduced cooling performance.
Innovation Solution
A cooling apparatus that generates a vertical turbulent flow of the cooling fluid by perpendicularly spraying it onto a heating surface through a cooling fin, using a manifold cover with a guide wall that forms channels and blocks to ensure direct contact with cooling fins, enhancing flowability and heat exchange efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple tube structure or fin structure is used for cooling, then the device complexity is reduced, but the cooling efficiency is not high
Solution Approach 1:
The cooling apparatus is divided into multiple functional components: a manifold cover with multiple cooling holes, a fin plate with multiple fins, and guide walls forming multiple channels. This segmentation allows the cooling fluid to be distributed through multiple pathways simultaneously, increasing cooling efficiency without requiring a single complex structure
Solution Approach 2:
The guide walls create localized flow channels with specific geometries (first channels with first closed ends, second channels with second closed ends) that direct the cooling fluid to specific regions. The fin plate provides localized heat dissipation surfaces at strategic positions, ensuring efficient cooling where heat generation occurs
2Ease of manufacture
If conventional tube or fin structures are used, then the manufacturing is simpler, but the flowability of cooling fluid is degraded
Solution Approach 1:
The cooling fluid pathway is segmented into multiple independent channels (first channels and second channels) formed by guide walls. This segmentation prevents flow stagnation and maintains fluid velocity, improving flowability while keeping each individual channel simple to manufacture
Solution Approach 2:
The guide walls extend in the flow direction of the cooling fluid to form three-dimensional channel structures with closed ends. This dimensional arrangement creates pressure differentials that drive fluid flow through the fin plate regions, enhancing flowability without complex pumping mechanisms
3Temperature
If vertical turbulent flow is generated by perpendicularly spraying cooling fluid, then cooling efficiency is improved, but flow quantity loss increases
Solution Approach 1:
The guide walls are positioned to preliminarily direct the cooling fluid flow before it reaches the fin plate. The channels with closed ends create pressure buildup that pre-accelerates the fluid, ensuring it impinges perpendicularly on the fin plate with optimal velocity for turbulent flow generation, maximizing cooling efficiency while minimizing wasted flow
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 apparatus improves cooling efficiency and minimizes flow quantity loss by creating a vertical turbulent flow, ensuring effective heat dissipation and maintaining the performance and durability of power modules.
Implementation Method 1
generates a vertical turbulent flow of the cooling fluid by perpendicularly spraying the cooling fluid onto a heating surface
Implementation Method 2
creates a jet collision cooling effect with vertical turbulent flow
Implementation Method 3
a cooling fluid flows to the cooling apparatus to cool the power module
Data Source
AI summary
An embodiment cooling apparatus for a power module includes a manifold cover provided with an inner space that defines a flow path for a cooling fluid and in which the power module can be embedded, a fin plate embedded in the manifold cover so as to contact the power module and including a plurality of cooling fins on a surface facing an inner surface of the manifold cover, and a guide wall extending from the inner surface of the manifold cover in a flow direction of the cooling fluid to define a plurality of first channels having first closed ends and second channels having second closed ends, the guide wall overlapping the cooling fins and having an end portion in contact with the cooling fins to allow the cooling fluid to flow to the first channels and the second channels between the cooling fins in the manifold cover.