Stacked EV Inverter Cells with Series Coolant Channels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional automotive inverters are limited in flexibility regarding power ratings and performance due to the use of off-the-shelf modular components, requiring significant engineering rework for modifications and lacking scalability to meet varying vehicle requirements.
Innovation Solution
A modularized, stackable, and scalable inverter architecture comprising combinable inverter cells with dedicated cold plates for effective cooling and multi-phase terminals, allowing for customization of power ratings and package dimensions by combining cells in various configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If off-the-shelf modular components are used in conventional automotive inverters, then ease of manufacture is improved, but adaptability and versatility deteriorate due to limited flexibility in power ratings and performance
Solution Approach 1:
The inverter is divided into multiple modular inverter cells (first inverter cell, second inverter cell, etc.), each capable of independent operation. These cells can be stacked in series to achieve different power ratings and performance levels, providing both manufacturing ease through standardization and adaptability through configurable combinations.
Solution Approach 2:
Each inverter cell is designed as a universal module that can function independently or be combined with other identical cells. The standardized cold plate design with series-connected coolant channels allows the same module to serve multiple power rating requirements by simply changing the number of cells stacked, achieving multi-functionality across different application scenarios.
2Adaptability or versatility
If conventional inverter designs are modified to meet varying vehicle requirements, then adaptability is improved, but device complexity and engineering rework increase
Solution Approach 1:
By segmenting the inverter into standardized cells, the system achieves adaptability through simple numerical scaling rather than complex redesign. Each cell maintains identical internal structure, eliminating the need for engineering rework while meeting varying power requirements through different stacking configurations.
Solution Approach 2:
The inverter system becomes dynamically configurable, allowing the number of active cells to be adjusted based on vehicle requirements. This dynamic adaptability is achieved without increasing device complexity because the modular architecture allows simple addition or removal of identical units rather than complex reconfiguration.
3Adaptability or versatility
If multiple inverter cells are stacked to achieve desired power ratings, then adaptability is improved, but manufacturing precision and assembly difficulty increase
Solution Approach 1:
The segmentation into identical modular cells actually simplifies manufacturing precision requirements compared to custom designs. Each cell is manufactured to the same specifications using the same processes, allowing standardization and quality control. The repetitive nature of manufacturing identical units reduces variability and improves precision consistency across production batches.
4Productivity
If conventional inverters use fixed power ratings, then manufacturing simplicity is maintained, but productivity and time-to-market decrease for customized applications
Solution Approach 1:
The segmented modular cell architecture enables rapid customization for different power ratings by simply changing the number of cells stacked, significantly improving productivity for customized applications. The standardized design of each cell maintains manufacturing simplicity while the flexible configuration capability accelerates time-to-market for various vehicle requirements without proportionally increasing device complexity.
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 approach enables the creation of inverter modules with tailored power ratings and performance for different applications, reducing manufacturing and engineering costs while allowing for faster time-to-market and design flexibility.
Implementation Method 1
The various stacked configurations provide continuous channels for coolant flow to transfer heat generated in the inverter cells away from the inverter cells
Implementation Method 2
a cold plate placed in contact with or proximate to the at least one transistor device
Data Source
AI summary
Provided herein is an inverter module that can include a first inverter cell and a second inverter cell, each including at least one transistor device, and a cold plate placed in contact with or proximate to the at least one transistor device. The cold plate can have a coolant channel through the cold plate. A connector can connect a coolant outlet of the cold plate of the first inverter cell to a coolant inlet of the cold plate of the second inverter cell in series, to form a continuous channel that extends from the first coolant inlet of the cold plate of the first inverter cell into the coolant channel of the cold plate of the second inverter cell. The coolant inlet of the cold plate of the first inverter cell can receive coolant fluid into the continuous channel.