Power Module Assembly with Direct Coolant Flow Across Cards
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Solution Overview
Problem
Power module assemblies for vehicle power inverters face challenges in efficiently managing heat dissipation, leading to thermal resistance issues that can affect the performance and reliability of electric vehicles.
Innovation Solution
The power module assembly incorporates a housing with opposing end caps and side panels that define a coolant chamber and passages, allowing coolant to directly convey across cards, reducing thermal resistance through efficient heat transfer compared to traditional designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional coolant flow paths are used in power module assemblies, then the structural design is simpler, but thermal resistance increases and heat transfer efficiency decreases
Solution Approach 1:
The coolant channel is segmented into multiple sections by dividing the power module assembly into cards with individual coolant chambers. Each card has its own coolant flow path defined by side panels, allowing independent thermal management for different sections of the power module. This segmentation enables optimized heat transfer across each card while maintaining overall system efficiency.
Solution Approach 2:
The coolant flow path is extended into the third dimension by creating vertical coolant chambers between cards and using side panels that extend between opposing end caps. This multi-dimensional coolant channel configuration allows coolant to flow across and between cards, maximizing heat transfer surface area and efficiency beyond traditional two-dimensional cooling paths.
2Temperature
If coolant is conveyed directly across the cards, then thermal resistance is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
Multiple functional elements are merged into the side panels, which simultaneously serve as structural supports, coolant channel boundaries, and alignment features. The side panels integrate the coolant flow path definition with mechanical card support functions, reducing the number of separate components and simplifying assembly while maintaining precise coolant channel alignment.
Solution Approach 2:
The side panels perform multiple functions: they define coolant chambers, provide structural support for cards, enable coolant flow across cards, and maintain alignment between cards and end caps. This multi-functionality reduces the need for separate precision-machined components while achieving direct coolant-to-card heat transfer.
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 configuration enhances heat transfer efficiency, improving the thermal management of power module assemblies and maintaining the reliability and performance of electric vehicle systems.
Implementation Method 1
allowing coolant to directly convey across cards, reducing thermal resistance through efficient heat transfer
Implementation Method 2
The side panel and row define a channel in fluid communication with the ports and configured to convey coolant directly across the cards
Data Source
AI summary
A power module assembly includes opposing end caps collectively having coolant ports and a row of cards that each have a major side defining a projection extending across the card. A side panel extends between the end caps such that the panel and row define a channel in fluid communication with the ports and configured to convey coolant directly across the cards. The side panel defines a groove that receives the projections.