Power Module Stack Sealing for Watertight Thermal Management
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Solution Overview
Problem
Existing power module assemblies for automotive vehicles face challenges in creating a reliable and watertight connection between power modules, which can lead to coolant leakage and reduced efficiency in thermal management.
Innovation Solution
A power inverter design featuring a stack of power modules with interleaved seals between engaging surfaces, forming a watertight connection and utilizing endplates with tension members for compression, along with a thermal management system that includes coolant chambers and manifolds for uniform temperature distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If power modules are stacked to form a compact assembly, then space utilization is improved, but the risk of coolant leakage increases due to connection reliability issues
Solution Approach 1:
Seals are pre-installed on the engaging surfaces of power modules before stacking, ensuring that the sealing interface is prepared in advance. This preliminary action prevents coolant leakage at the connection interfaces between stacked modules, resolving the reliability issue while maintaining compact assembly design
Solution Approach 2:
Seals act as intermediary elements between adjacent power module frames, creating a watertight barrier at the engaging surfaces. This intermediary component prevents direct contact between coolant and the interface gaps, eliminating leakage risks in the compact stacked configuration
2Reliability
If seals are installed between engaging surfaces to prevent leakage, then connection reliability is improved, but assembly complexity increases
Solution Approach 1:
Seals are pre-installed on the engaging surfaces of individual power modules before stacking. This preliminary installation simplifies the overall assembly process by eliminating the need for complex seal installation procedures during the stacking operation, reducing assembly complexity while ensuring watertight connections
Solution Approach 2:
The seal installation is integrated into the power module manufacturing process itself, where seals are attached to the engaging surfaces during module assembly. This self-service approach eliminates the need for separate seal installation steps during power module stacking, reducing overall assembly complexity
3Reliability
If tension members are used to compress the stack, then seal effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The endplates are designed to integrate both the compression function (through integrated fasteners) and the sealing support function into single components. This merging reduces the number of separate manufacturing steps and components, simplifying manufacturing while maintaining seal effectiveness through proper compression
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 solution ensures a reliable, watertight assembly that prevents coolant leakage and enhances thermal management, improving the efficiency and durability of power module assemblies in automotive vehicles.
Implementation Method 1
assembling the modules into a stack such that engaging surfaces adjacent to each other abut and compress the seal forming a water tight connection
Implementation Method 2
a thermal management system that includes coolant chambers and manifolds for uniform temperature distribution
Data Source
AI summary
A power inverter includes a plurality of power modules that each have a frame defining a cavity, and a power stage disposed within the cavity. Each of the frames have a pair of engaging surfaces. The frames are arranged in a stack such that the engaging surfaces adjacent to each other abut. A plurality of seals are interleaved with the modules such that each of the seals is disposed between engaging surfaces of the frames abutting each other.