Power Module Cooling Structure With Guide-Wall Turbulent 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 fin plate with a guide wall structure, minimizing flow quantity loss and enhancing 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 deteriorates
Solution Approach 1:
The cooling apparatus is divided into multiple functional components: manifold cover with cooling channels, fin plate with heat dissipation fins, and guide wall with flow direction control portions. This segmentation allows each component to perform its specific function optimally, improving overall cooling efficiency while maintaining manageable complexity
Solution Approach 2:
The guide wall acts as an intermediary component between the manifold cover and fin plate, controlling the flow direction of cooling fluid through its flow direction control portions. This intermediary structure ensures efficient heat transfer from the power module to the cooling fluid without requiring complex integrated designs
2Ease of manufacture
If conventional cooling structures are used, then the manufacturing is simpler, but the cooling performance deteriorates
Solution Approach 1:
The cooling apparatus uses segmented components (manifold cover, fin plate, guide wall) that can be manufactured separately using conventional processes and then assembled. This maintains manufacturing simplicity while achieving improved cooling performance through the optimized flow path and heat dissipation structure
Solution Approach 2:
The guide wall includes flow direction control portions that change the flow parameters of the cooling fluid, directing it to flow between the heat dissipation fins. This parameter change optimizes heat transfer efficiency without requiring complex manufacturing processes
3Ease of operation
If cooling fluid flow is not optimized, then the flowability is maintained, but the cooling performance deteriorates due to flow quantity loss
Solution Approach 1:
The guide wall serves as a flow control intermediary that directs cooling fluid through the cooling channels and between the heat dissipation fins. This intermediary structure minimizes flow quantity loss by ensuring efficient fluid distribution throughout the cooling apparatus
Solution Approach 2:
The flow direction control portions of the guide wall change the flow direction and velocity parameters of the cooling fluid, optimizing its path through the system. This parameter optimization maintains flowability while preventing flow quantity loss that would degrade cooling performance
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 flowability of the cooling fluid, ensuring effective heat dissipation and maintaining the performance and durability of power modules in electric vehicles.
Implementation Method 1
a cooling fluid flows to the cooling apparatus to cool the power module
Implementation Method 2
generates a vertical turbulent flow of the cooling fluid by perpendicularly spraying the cooling fluid onto a heating surface
Implementation Method 3
generates a vertical turbulent flow of the cooling fluid by perpendicularly spraying the cooling fluid onto a heating surface
Data Source
Figure 1
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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.