Resin Fixed Base Thermal Isolation for Power Control Unit
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In electric vehicles, hybrid vehicles, and fuel cell vehicles, the power control unit (PCU) with a step up converter and inverter housed in a single case faces challenges in maintaining efficient cooling, as the temperature of the reactor and power elements rises due to heat conduction and convection, leading to decreased performance during heavy-load operations.
Innovation Solution
A power control unit is designed with a resin-based fixed base that inhibits heat conduction from the motor case, featuring a cooler with a power module, a control substrate, and a metal thin plate that forms an insulating chamber to prevent convection heating, along with a metal cover to reduce heat transfer from the motor case, ensuring effective cooling and preventing temperature rises.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If the step up converter and inverter are housed together with the motor in a single case, then the device integration is improved, but the temperature control deteriorates due to heat conduction and convection
Solution Approach 1:
The housing is divided into a motor housing and a separate power control unit housing. The power control unit is mounted on the motor case but maintains thermal isolation through the use of a resin-based fixed base and insulating structures, allowing integrated housing while preventing heat transfer from the motor to the power elements.
Solution Approach 2:
A resin-based fixed base is introduced as an intermediary material between the motor case and the power control unit mounting structure. This resin material acts as a thermal insulator, blocking heat conduction pathways while maintaining the mechanical connection and integration of the housings.
2Temperature
If cooling fins and coolant systems are added to the reactor, then the heat release ability is improved, but the device complexity increases
Solution Approach 1:
The reactor is extracted from the integrated housing arrangement and given a separate housing chamber. This allows the reactor to be cooled by lubricating oil circulation independent of the power element cooling system, simplifying the overall cooling architecture by separating the cooling needs of different components.
3Temperature
If a resin-based fixed base is used to inhibit heat conduction, then the temperature control is improved, but the structural strength may deteriorate
Solution Approach 1:
The fixed base is constructed from resin-based composite material that provides both thermal insulation properties and sufficient mechanical strength for mounting the power control unit. The composite structure achieves a balance between heat conduction inhibition and structural integrity requirements.
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 configuration effectively prevents heat conduction and convection heating, maintaining the cooling ability of the power control unit even during heavy-load operations, thereby preventing output decreases and ensuring efficient vehicle performance.
Implementation Method 1
a fixed base made of resin that inhibits conduction of heat from the motor case to the power control unit
Implementation Method 2
a metal thin plate that forms an insulating chamber to prevent convection heating
Implementation Method 3
a cooler that is arranged on the fixed base and that includes a power module
Implementation Method 4
a metal cover to reduce heat transfer from the motor case
Data Source
AI summary
A power control unit that controls a rotary electric machine that drives a vehicle, and that is mounted onto a motor case in which the rotary electric machine is housed, includes a fixed base that is made of resin; a cooler that is arranged on the fixed base and that includes a power module; and a control substrate that is arranged on the cooler. The fixed base inhibits conduction of heat from the motor case to the power control unit.