Power Module Manifold Cooling With Vertical Turbulent Flow
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Solution Overview
Problem
Conventional cooling apparatuses for power modules in electric vehicles have low cooling efficiency due to their simplified or fin-based structures, which affect the overall energy efficiency and durability of the power module.
Innovation Solution
A cooling apparatus with a manifold cover and a guide inside it, featuring first and second channels and micro-flow paths that create a vertical turbulent flow of the cooling fluid, enhancing cooling efficiency without the need for external fin plates or nozzle injection devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simplified structure or fin structure is used in the cooling apparatus, then the device complexity is reduced, but the cooling efficiency deteriorates
Solution Approach 1:
The cooling apparatus is segmented into multiple functional components: manifold cover with inlet/outlet channels, guide structure with partition walls, and micro-flow paths. This segmentation allows each component to perform its specific function optimally while maintaining overall system efficiency without excessive complexity
Solution Approach 2:
The invention transitions from conventional 2D fin structures to a 3D multi-channel system with vertical turbulent flow. The manifold cover creates three-dimensional cooling channels that penetrate deeper into the power module, enabling more effective heat removal through volumetric cooling rather than surface-only cooling
2Ease of manufacture
If conventional cooling structures are used, then the manufacturing process is simple, but the heat transfer efficiency is insufficient
Solution Approach 1:
The invention employs hydraulic principles by using cooling fluid flow through engineered channels and micro-flow paths. The fluid dynamics are optimized to create turbulent flow patterns that enhance convective heat transfer, leveraging hydraulic principles to improve cooling efficiency while maintaining manufacturability through injection molding
Solution Approach 2:
The invention changes key flow parameters by creating micro-flow paths that induce turbulent flow regime instead of laminar flow. This parameter change in flow regime significantly enhances heat transfer coefficients, allowing efficient heat removal while the entire structure can still be manufactured through standard injection molding processes
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 by promoting turbulent flow, increasing heat transfer and energy efficiency, and maintaining performance and durability of the power module.
Implementation Method 1
the power module is cooled using a cooling fluid
Implementation Method 2
circulate a cooling fluid to the cooling apparatus
Implementation Method 3
the cooling fluid circulated inside the manifold cover forms a vertical turbulent flow by the guide
Data Source
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AI summary
A cooling apparatus of a power module includes a guide provided inside a manifold cover to control a flow of a cooling fluid, wherein the cooling fluid circulated inside the manifold cover forms a vertical turbulent flow by the guide so that cooling efficiency of the power module is secured only using an internal structure of the manifold cover. Thus, heat dissipation performance is improved without a separate fin plate or a separate nozzle injection device.