Power Module Coolant Pre-Cooling for Reliable Temperature Control

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing power module cooling systems struggle to effectively manage coolant temperature, which affects the operational performance and reliability of power modules in electrified vehicles.

Innovation Solution

A power module temperature management device that includes a flow path with a first section thermally connected to the power module and a second section connected in series, along with a coolant cooler that adjusts the coolant temperature before it enters the power module, using a combination of fluid tanks and energy-operated cooling units.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If coolant temperature is not actively managed, then the power module structure remains simple, but the operational performance and reliability deteriorate due to inadequate cooling

Engineering Contradiction:

Improveoperational reliabilityVSAvoidcooling system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The coolant cooler is integrated within the flow path structure, with the second cooling unit nested in the second section and the fluid tank positioned to surround the external side of the second section. This nested configuration allows multiple cooling functions to be compactly arranged without significantly increasing overall device complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The coolant cooler proactively cools the coolant before it enters the power module by managing temperature in the second section of the flow path. This preliminary cooling action prevents overheating before it occurs, improving reliability without requiring complex reactive cooling systems.

Inventive Principle:

Principle #10Preliminary action

2Temperature

If a coolant cooler is added to manage temperature, then cooling performance improves, but device complexity increases

Engineering Contradiction:

Improvecoolant temperature controlVSAvoidsystem structure complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The flow path is divided into a first section thermally connected to the power module and a second section connected in series, with the coolant cooler specifically targeting the second section. This segmentation allows temperature management to be applied selectively rather than throughout the entire system, improving cooling efficiency while limiting complexity increase to specific areas.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second section serves multiple functions: it acts as a flow path for coolant circulation, a thermal exchange zone with the fluid tank surrounding it, and a cooling target for the second cooling unit. This multi-functionality reduces the need for separate dedicated components, thereby limiting complexity increase.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Temperature

If the second cooling unit is operated continuously, then coolant temperature is maintained optimally, but energy consumption increases

Engineering Contradiction:

Improvecoolant temperature stabilityVSAvoidenergy consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The control unit operates the second cooling unit periodically or conditionally based on detected coolant temperature or power module operating conditions, rather than continuously. This periodic operation maintains optimal temperature stability while significantly reducing energy consumption compared to continuous operation.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The control unit detects operating conditions and adjusts the second cooling unit operation accordingly, creating a feedback control system. This ensures coolant temperature is maintained optimally only when needed, reducing energy consumption during periods when cooling demand is low or absent.

Inventive Principle:

Principle #23Feedback

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 solution enhances the cooling performance of power modules by reliably managing coolant temperature, thereby improving operational efficiency and reliability without requiring modifications to the power module's structure or materials.

Implementation Method 1

a first cooling unit including a fluid tank filled with a fluid having a boiling point lower than a boiling point of the coolant and connected to an external side of the second section

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 2

a second cooling unit connected to the second section and operated by receiving energy from a power source

Methodology Applied

Scientific EffectPeltier effect: Peltier Effect

Data Source

PatentUS20250159849A1Power module temperature management device

Publication Date: 2025.05.15 HYUNDAI MOTOR CO LTD

AI summary

Introduced is a power module temperature management device including a flow path including a first section thermally connected to the power module and a second section connected in series to the first section for a coolant to flow from the second section to the first section, and a coolant cooler thermally connected to the second section of the flow path and cooling the coolant flowing into the second section according to a predetermined condition.