Power Module Endcap With Recessed Manifold Cavities
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Solution Overview
Problem
Current power-module assemblies for electric vehicles lack efficient cooling solutions, leading to non-uniform temperature distribution and potential thermal management issues in power inverter systems.
Innovation Solution
The power-module assembly incorporates a stack design with interleaved coolant chambers and axial manifold channels, utilizing endcaps with recessed inlet and outlet cavities to enhance fluid communication and thermal management, allowing for flexible port placement to accommodate various vehicle configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional power-module assemblies are used without enhanced cooling structures, then the device complexity is reduced, but non-uniform temperature distribution and thermal management issues occur
Solution Approach 1:
The cooling system is merged with the power module structure itself. The coolant chambers are formed within the power module housing, and the manifold channels are integrated into the endcaps, eliminating the need for separate external cooling components and achieving uniform temperature distribution through this integrated design
Solution Approach 2:
The cooling architecture transitions from traditional external cooling to an internal three-dimensional cooling system. Multiple coolant chambers are arranged in different spatial dimensions within the power module, with manifold channels extending axially along the stack, creating a multi-dimensional cooling network that efficiently distributes coolant
2Adaptability or versatility
If fixed port placement is used in endcaps, then manufacturing is simplified, but adaptability to different vehicle configurations is reduced
Solution Approach 1:
The endcap is designed as a universal component with multiple inlet and outlet ports that can accommodate different vehicle configurations. The manifold cavities are positioned to align with various channel arrangements, allowing the same endcap design to serve multiple cooling layouts and vehicle packaging requirements
Solution Approach 2:
The port configuration in the endcap is designed to be adaptable rather than fixed. The manifold cavities can align with different channel positions depending on the specific power module arrangement, enabling dynamic adaptation to various vehicle configurations without requiring custom endcap designs
3Reliability
If coolant chambers are not interleaved with power modules, then manufacturing is simpler, but cooling efficiency is reduced
Solution Approach 1:
The power module stack is segmented into alternating layers of power modules and coolant chambers. This segmentation creates a modular assembly where each layer can be independently manufactured and then stacked together, simplifying the overall manufacturing process while achieving efficient interleaved cooling
Solution Approach 2:
The coolant chambers and manifold channels are pre-formed within the power module housing and endcaps before final assembly. This preliminary action allows the cooling structures to be integrated into the stack during assembly rather than requiring complex post-assembly modifications, improving thermal management reliability
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 provides improved thermal uniformity and flexibility in power inverter systems, enabling efficient cooling and adaptability to different vehicle packaging constraints, thus enhancing the reliability and performance of electric vehicle powertrains.
Implementation Method 1
coolant chambers interleaved with power modules
Implementation Method 2
manifold channels extending axially along the stack
Data Source
AI summary
According to one embodiment, a power-module assembly includes a power-module stack having coolant chambers interleaved with power modules and supply and return manifold channels extending axially along the stack. An endcap has a major side defining recessed inlet and outlet manifold cavities aligned with the channels and inlet and outlet ports disposed on one or more minor sides that are perpendicular to the major side.