Segmented Cooling Housing for Power Components in Vehicle Control Units
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Solution Overview
Problem
Power components in vehicle control units face challenges in spatial arrangement for electrical connection and heat dissipation, leading to inductance and thermal issues due to the need for efficient cooling and compact installation.
Innovation Solution
A cooling device with a double-walled housing featuring multiple cooling channels and plates made from high thermal conductivity materials, allowing for efficient heat dissipation and easy installation, with separate cooling plates for adaptable thermal conductivity and encapsulation for electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power components are arranged spatially to satisfy electrical connection requirements, then electrical connection is improved, but thermal dissipation deteriorates due to heat accumulation
Solution Approach 1:
The cooling housing is segmented into multiple independent cooling channels (first, second, third, and fourth cooling channels) positioned at different locations. Each channel independently cools specific power components, allowing spatial separation of cooling functions while maintaining effective thermal management across the entire assembly.
Solution Approach 2:
Different regions of the cooling housing are equipped with cooling channels according to the specific thermal requirements of power components in those locations. The cooling structure is tailored to match the heat generation distribution, providing localized cooling where needed most while maintaining electrical connection integrity.
2Temperature
If cooling structures are added to dissipate heat from power components, then thermal dissipation is improved, but device complexity increases
Solution Approach 1:
The cooling housing integrates multiple cooling channels, mounting surfaces for power components, and structural support functions into a single unified structure. This merging eliminates the need for separate cooling plates and mounting brackets, reducing the total number of parts while maintaining effective cooling and electrical connection capabilities.
Solution Approach 2:
The cooling housing serves multiple functions simultaneously: it provides structural support, establishes electrical connections through integrated mounting surfaces, dissipates heat through multiple cooling channels, and positions power components in optimal locations. This multi-functionality reduces overall system complexity by eliminating the need for separate components for each function.
3Volume of moving object
If compact installation is implemented to save space, then installation space is improved, but thermal management deteriorates due to reduced cooling capacity
Solution Approach 1:
The cooling channels are arranged in a three-dimensional configuration around the power components, utilizing vertical and lateral spaces efficiently. This spatial arrangement provides extensive cooling surface area within a compact footprint, maintaining thermal management effectiveness while minimizing installation space 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
The cooling device provides improved cooling performance, enabling compact and efficient installation of power components in vehicle control units with enhanced electrical connections and reduced thermal issues, ensuring rapid power activation and low inductance.
Implementation Method 1
a base and four housing surfaces which are provided as a one-piece component and are preferably made from a metallic material with high thermal conductivity, in particular aluminum
Implementation Method 2
an inlet for supplying a cooling medium and an outlet for discharging the heated cooling medium are provided on the cooling housing
Data Source
Figure 1
Figure 2
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AI summary
The invention relates to a cooling device for cooling a power component (2), comprising a one-piece cooling housing (3) with a base (10), a first end face (11), a second end face (12), a first lateral face (13), and a second lateral face (14), which define a receiving area (15) designed to receive the power component; an inlet (16) for supplying a cooling medium; an outlet (17) for discharging a cooling medium; a first cooling channel (101); a second cooling channel (102); a third cooling channel (103); and a fourth cooling channel (104), wherein the first cooling channel (101) is arranged on the first end face (11), the second cooling channel (102) is arranged on the second end face (12), the third cooling channel (103) is arranged on the first lateral face (13), the fourth cooling channel (104) is arranged on the second lateral face (14), and the first and the second cooling channel (101, 102) are each fluidically connected to the third and fourth cooling channel (103, 104); a separate first cooling plate (4) and a separate second cooling plate (5), the first cooling plate (4) being arranged on the first lateral face (13) and the second cooling plate (5) being arranged on the second lateral face (14) in order to delimit the third and fourth cooling channel (103, 104) from the exterior; a third cooling plate (6) which is arranged on the first end face (11); a fourth cooling plate (7) which is arranged on the second end face (12), said third cooling plate delimiting the first cooling channel (101) from the exterior and the second cooling plate (7) delimiting the second cooling channel (102) from the exterior; and a cover (8) which closes the cooling housing (3).