Sinusoidal Cooling Fin Layout for Low-Pressure EV Inverter Cooling
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Solution Overview
Problem
Existing cooling modules in electric vehicle systems have limited thermal performance optimization capabilities and high pressure drop, leading to uneven temperature distribution among power modules and increased energy consumption.
Innovation Solution
A cooling module design featuring varying sinusoidal wave geometries in cooling fins along the coolant flow direction, with changing wavelengths to optimize thermal performance and reduce pressure drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional cooling module designs are used, then the structure is simple and easy to manufacture, but the thermal performance is limited and pressure drop is high
Solution Approach 1:
The cooling fins are designed with varying wavelengths along their length, with different sections having different geometric characteristics. The first section has a first wavelength, the second section has a second wavelength different from the first, and the third section has a third wavelength different from the previous sections. This local variation in geometry optimizes heat transfer in different regions while managing pressure drop, resolving the contradiction between thermal performance and structural simplicity.
2Temperature
If cooling modules with optimized thermal performance are designed, then temperature distribution improves, but pressure drop increases leading to higher energy consumption
Solution Approach 1:
The cooling fin wavelength parameter is varied along the flow direction to optimize both thermal performance and pressure drop. By changing the wavelength from the first section to the second and third sections, the design achieves more uniform temperature distribution while controlling the pressure drop to reduce energy consumption of the coolant pump, thus resolving the contradiction between temperature uniformity and energy usage.
3Temperature
If conventional cooling fin geometries are used, then manufacturing is easy, but thermal performance optimization capability is limited
Solution Approach 1:
The cooling fin is divided into multiple sections along its length, with each section having a distinct wavelength characteristic. This segmentation allows each portion to be optimized for specific thermal performance requirements while maintaining a manufacturable structure. The first, second, and third sections can be manufactured using standard processes with appropriate tooling, balancing cooling efficiency with ease of manufacture.
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 design achieves uniform temperature distribution among power modules, reduces parasitic losses, and enhances the performance and reliability of electric vehicle inverters by minimizing energy consumption and improving thermal management.
Implementation Method 1
a cooling module in the cavity between the container and the housing, the cooling module in a flow of coolant from the inlet port to the outlet port
Implementation Method 2
first cooling fins with a first cooling fin geometry, second cooling fins with a second cooling fin geometry, the second cooling fins downstream of the first cooling fins along the flow of coolant
Data Source
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AI summary
A cooling module includes: first cooling fins with a first cooling fin geometry, second cooling fins with a second cooling fin geometry, the second cooling fins downstream of the first cooling fins along a flow of coolant from an inlet port to an outlet port, and third cooling fins with a third cooling fin geometry, the third cooling fins downstream of the second cooling fins along the flow of coolant from the inlet port to the outlet port, wherein the first cooling fin geometry is a first sinusoidal wave having a first uniform wavelength, the second cooling fin geometry is a second sinusoidal wave having a second uniform wavelength that is shorter than the first uniform wavelength, and the third cooling fin geometry is a third sinusoidal wave having a third uniform wavelength that is longer than the second uniform wavelength.