Single-Layer Liquid Cooling Plate for Uniform Power Module Cooling
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Solution Overview
Problem
The existing motor controllers using silicon carbide power modules face issues with non-uniform cooling, large volume, and inefficient assembly processes due to the use of two layers of liquid cooling plates.
Innovation Solution
A single-layer liquid cooling plate design with parallel liquid passages and installation grooves for power modules, featuring strip-shaped holes and ports, enhances cooling uniformity and reduces installation space, allowing for a one-time assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If two layers of liquid cooling plates are used to cool silicon carbide power modules, then the cooling coverage is improved, but the cooling uniformity deteriorates and the volume increases
Solution Approach 1:
The patent transitions from a vertical two-layer cooling plate structure to a horizontal single-layer design with parallel liquid passages. By arranging cooling channels in parallel within a single plane rather than stacking layers vertically, the design achieves uniform cooling across multiple power modules while reducing the overall volume of the cooling plate assembly.
Solution Approach 2:
The liquid cooling plate is segmented into multiple parallel liquid passages, each serving specific power modules. This segmentation allows the coolant to flow through separate parallel channels, ensuring uniform heat dissipation across different regions of the cooling plate without requiring multiple stacked layers.
2Power
If two layers of liquid cooling plates are used, then the cooling capacity is improved, but the installation space increases
Solution Approach 1:
The patent merges the cooling functions of what would traditionally require two separate cooling plates into a single integrated cooling plate with parallel passages. This consolidation maintains the necessary cooling capacity for multiple power modules while eliminating the space required for a second layer, thereby reducing the overall installation footprint.
3Reliability
If two layers of liquid cooling plates are used, then the cooling effect is improved, but the assembly process complexity increases
Solution Approach 1:
By combining the cooling functions into a single-layer plate with parallel passages, the patent reduces the number of assembly steps from two separate assembly operations (one for each layer) to a single assembly process. This simplification maintains effective cooling while reducing manufacturing complexity and improving production efficiency.
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
Improves cooling efficiency and temperature uniformity of power modules, reduces the overall volume of the motor controller, and enhances production efficiency by simplifying the assembly process.
Implementation Method 1
The coolant cools multiple power modules simultaneously during its flow process from the first strip-shaped holes to the second strip-shaped holes, thereby improving the cooling effect of the power modules and keeping the temperature rise of the power modules uniform
Implementation Method 2
a first liquid passage, wherein an inlet end of the first liquid passage is communicated with the inlet port, and an outlet end of the first liquid passage is communicated with the first strip-shaped hole; and a second liquid passage, wherein an inlet end of the second liquid passage is communicated with the second strip-shaped hole, and an outlet end of the second liquid passage is communicated with the outlet port
Data Source
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AI summary
A liquid cooling plate and a motor controller are provided. The liquid cooling plate comprises: a liquid cooling plate body (1000) laid flat inside the motor controller, wherein several installation grooves (103) for installing power modules are provided on an outer surface of the liquid cooling plate body (1000), and a first strip-shaped hole (104) and a second strip-shaped hole (105) are provided in each of the installation grooves (103); an inlet port (101) and an outlet port (102); a first liquid passage (131), wherein an inlet end of the first liquid passage (131) is communicated with the inlet port (101), and an outlet end of the first liquid passage (131) is communicated with the first strip-shaped hole (104); and a second liquid passage (132), wherein an inlet end of the second liquid passage (132) is communicated with the second strip-shaped hole (105), and an outlet end of the second liquid passage (132) is communicated with the outlet port (102). In the liquid cooling plate according to the present disclosure, by providing installation grooves (103) on the liquid cooling plate body (1000) and providing first and second strip-shaped holes (105) in the installation grooves (103), the liquid passages under power modules form a parallel structure. The coolant cools multiple power modules simultaneously during its flow process from the first strip-shaped holes (104) to the second strip-shaped holes (105), thereby improving the cooling effect of the power modules and keeping the temperature rise of the power modules uniform.