Pulse Inverter Cooling Layout for Uniform Thermal Loading
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Solution Overview
Problem
Existing pulse inverter cooling systems in electric vehicles suffer from mechanical stresses due to sequential cooling of power modules and capacitors, leading to uneven thermal loading and increased mechanical stresses, requiring wider temperature ranges and complex sealing designs.
Innovation Solution
Implementing tubular connection channels between power module and capacitor cooling channels, allowing for a reverse cooling sequence where capacitors are cooled first, followed by power modules, using a cooling fluid that efficiently distributes heat uniformly across all modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If sequential cooling of power modules and capacitors is implemented, then cooling effectiveness is improved, but mechanical stresses increase and sealing complexity increases
Solution Approach 1:
The patent merges the cooling processes of power modules and capacitors into a single integrated cooling circuit. The cooling fluid flows through both cooling channels in sequence without requiring separate circuits, thereby maintaining effective cooling while reducing mechanical stresses and sealing complexity that would arise from more fragmented cooling arrangements.
Solution Approach 2:
The cooling fluid serves multiple functions by flowing through both power module cooling channels and capacitor cooling channels in a unified circuit. This multi-functional approach allows a single cooling system to effectively cool different components with different thermal requirements, avoiding the need for separate specialized cooling circuits that would increase stress and sealing complexity.
2Ease of manufacture
If all power modules are configured as like parts, then manufacturing simplicity is improved, but thermal loading becomes uneven and thermal dimensions become excessive
Solution Approach 1:
The patent applies local quality by configuring cooling channels with different flow resistance characteristics in different regions. Power modules that experience higher thermal loads are provided with cooling channels that allow greater cooling fluid flow, while modules with lower thermal loads have restricted flow. This creates locally optimized cooling conditions that match the actual thermal distribution, maintaining manufacturing simplicity through standardized module designs while achieving uniform thermal loading.
3Adaptability or versatility
If power modules are designed for wide temperature range, then adaptability to different cooling conditions is improved, but manufacturing cost increases
Solution Approach 1:
The patent implements local quality by creating specific cooling conditions for each power module based on its position and thermal load characteristics. Through varied flow resistance in cooling channels, each module receives cooling fluid at an optimal temperature and flow rate suited to its specific thermal requirements. This eliminates the need for power modules to be designed for excessively wide temperature ranges, thereby reducing manufacturing costs while maintaining necessary adaptability.
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 approach reduces mechanical stresses, simplifies sealing, and allows for more uniform thermal loading, enabling cost-effective manufacturing with improved cooling efficiency and reduced temperature range requirements for power modules.
Implementation Method 1
The power modules and the capacitor assembly are therefore each associated with one or more cooling channels that are perfused by a cooling fluid, such as oil or water, during the operation of the pulse inverter in order to cool the power modules as well as the capacitors
Implementation Method 2
a plurality of connection channels extending between the at least one power module cooling channel and the at least one capacitor cooling channel, the connection channels being configured to be perfused by the cooling fluid
Data Source
AI summary
A pulse inverter includes a plurality of power modules, at least one capacitor assembly with a plurality of capacitors, at least one power module cooling channel configured to be perfused by a cooling fluid in order to cool the power modules, and at least one capacitor cooling channel configured to be perfused by a cooling fluid in order to cool the capacitors. The pulse inverter also includes a plurality of connection channels extending between the at least one power module cooling channel and the at least one capacitor cooling channel, the connection channels being configured to be perfused by the cooling fluid.