Single Radiator Cooling Hybrid Vehicle Electronics
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Solution Overview
Problem
Current hybrid vehicle electronics cooling systems require multiple radiators, leading to increased cost, weight, and thermal resistance, which cannot effectively maintain junction temperatures below 175°C using standard coolant systems.
Innovation Solution
A compact system utilizing subcooled boiling with a single radiator to cool both internal combustion engines and electronics, eliminating the need for multiple radiators by using pressurized traditional vehicle coolants that remain in a single phase throughout the cooling cycle, thereby reducing thermal resistance and maintaining junction temperatures below 175°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple radiators are used to cool hybrid vehicle electronics, then the junction temperature can be maintained below 175°C, but the system weight, cost, and complexity increase
Solution Approach 1:
The patent combines the cooling functions for both the internal combustion engine and power electronics into a single radiator system. The electronics are cooled by directing coolant flow through channels in direct contact with the semiconductor devices, eliminating the need for separate radiators while maintaining effective heat dissipation for both components
Solution Approach 2:
The single radiator is designed to perform multiple cooling functions simultaneously - cooling both the engine and the power electronics. The system uses a universal coolant circulation path that can serve different thermal management needs, reducing the overall number of cooling components required
2Temperature
If multiple radiators are used to cool hybrid vehicle electronics, then the junction temperature can be maintained below 175°C, but the system cost increases
Solution Approach 1:
The patent merges the electronics cooling function into the existing engine cooling system, eliminating the need for a second radiator and its associated plumbing. This consolidation reduces component count, material requirements, and assembly complexity, thereby lowering overall system cost
3Temperature
If multiple radiators are used to cool hybrid vehicle electronics, then the junction temperature can be maintained below 175°C, but the available space for other components is reduced
Solution Approach 1:
The patent integrates the electronics cooling pathway into the engine cooling system, allowing both cooling functions to share the same radiator and coolant circulation infrastructure. This space-efficient design eliminates duplicate components and frees up vehicle packaging space for other systems
4Temperature
If traditional coolant systems are used with multiple radiators, then the electronics can be cooled, but the thermal resistance is too high to maintain junction temperatures below 175°C
Solution Approach 1:
The patent implements localized cooling by placing coolant flow channels in direct contact with the semiconductor devices. This creates a high-heat-transfer zone at the electronics interface, reducing thermal resistance where it is most critical while using standard coolant temperatures throughout the rest of the system
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 system achieves 25% more efficient cooling, reduces weight and cost, and accommodates high power densities up to 250 W/cm² without the need for cooling fins, using existing components and minimizing pumping power requirements.
Implementation Method 1
A compact system utilizing subcooled boiling with a single radiator to cool both internal combustion engines and electronics
Implementation Method 2
using pressurized traditional vehicle coolants that remain in a single phase throughout the cooling cycle
Implementation Method 3
using pressurized traditional vehicle coolants that remain in a single phase throughout the cooling cycle
Implementation Method 4
The system achieves 25% more efficient cooling, reduces weight and cost, and accommodates high power densities up to 250 W/cm²
Data Source
AI summary
The invention provides a single radiator cooling system for use in hybrid electric vehicles, the system comprising a surface in thermal communication with electronics, and subcooled boiling fluid contacting the surface. The invention also provides a single radiator method for simultaneously cooling electronics and an internal combustion engine in a hybrid electric vehicle, the method comprising separating a coolant fluid into a first portion and a second portion; directing the first portion to the electronics and the second portion to the internal combustion engine for a time sufficient to maintain the temperature of the electronics at or below 175° C.; combining the first and second portion to reestablish the coolant fluid; and treating the reestablished coolant fluid to the single radiator for a time sufficient to decrease the temperature of the reestablished coolant fluid to the temperature it had before separation.