Power Module Manifold for Stacked Array Thermal Management
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Solution Overview
Problem
Current power inverter and thermal management systems in electrified vehicles face challenges in efficiently managing heat dissipation across power stages, leading to potential performance degradation and reduced operational efficiency.
Innovation Solution
A vehicle power module assembly with a stacked array of module frames, a manifold, and endplates that create a coolant path between power stages, utilizing thermal plates for heat dissipation, and a manifold with inlet and outlet chambers to optimize coolant flow and momentum for effective thermal communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a conventional thermal management system is used, then the structure is simple, but the heat dissipation efficiency across power stages is insufficient
Solution Approach 1:
The manifold is integrated directly into the module frame structure, merging the coolant distribution system with the structural framework. This eliminates separate cooling channels and reduces the number of components while maintaining effective heat dissipation across all power stages through the unified manifold design that distributes coolant to multiple thermal plates simultaneously.
Solution Approach 2:
The system transitions from conventional single-plane cooling to a three-dimensional stacked array configuration. Multiple module frames are stacked vertically with manifolds positioned at different levels, creating multi-layer coolant flow paths that efficiently dissipate heat from power stages arranged in three-dimensional space, thereby improving heat dissipation efficiency without proportionally increasing system footprint.
2Manufacturing precision
If coolant flow is not optimized, then the system is simple, but uniform heat dissipation across power stages cannot be achieved
Solution Approach 1:
The manifold incorporates locally optimized features including varying port sizes, strategically positioned flow distributors, and tailored channel geometries at different locations. These local variations in the coolant flow path ensure that each power stage receives appropriate coolant flow rates matched to its specific thermal load, achieving uniform heat dissipation across all modules through localized flow control mechanisms.
Solution Approach 2:
The manifold design uses replicated flow distribution patterns across multiple module frames. Identical coolant flow paths and distributor configurations are copied and stacked vertically, ensuring consistent and uniform heat dissipation performance across all power stages. This replication approach maintains precision while simplifying the overall design through standardization.
3Reliability
If thermal communication between coolant and power stages is insufficient, then the system structure is simple, but performance degradation occurs
Solution Approach 1:
The thermal plates are nested within the module frames, with coolant channels positioned in direct thermal contact with power stages. The manifold is nested within the stacked array structure, creating a compact integrated assembly where cooling components are embedded within the power module structure itself. This nesting arrangement maximizes thermal communication efficiency while maintaining a compact and reliable system.
Solution Approach 2:
Thermal plates serve as intermediary components between the power stages and the coolant flow paths. These thermal plates enhance heat transfer by providing extended thermal contact surfaces that facilitate efficient heat extraction from power stages to the circulating coolant, thereby improving thermal communication and ensuring stable performance under varying operating conditions.
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
Enhances thermal management by ensuring uniform coolant flow and improved heat dissipation across power stages, maintaining performance and efficiency in electrified vehicle systems.
Implementation Method 1
thermal plates in thermal communication with adjacent power stages
Implementation Method 2
coolant path between the endplate inlet and endplate outlet
Data Source
AI summary
A vehicle power module assembly including a stacked array of module frames, a manifold, and a pair of endplates is provided. The stacked array of module frames may each define a passthrough in registration with other of the passthroughs to define a manifold cavity, a power stage cavity, and a plurality of outlets open to the respective passthroughs and oriented relative to the power stage cavities to deliver coolant therebetween. The manifold may be disposed within the manifold cavity and defines a manifold inlet open to an inlet chamber and manifold ports for alignment with the plurality of outlets. One of the endplates may define an inlet open to the manifold inlet and another one of the endplates may define an outlet open to a manifold outlet. The inlets, outlets, and ports are arranged with one another to provide a coolant path between the endplate inlet and endplate outlet.