Stacked Power Module Cooling Channels to Prevent Thermal Overlap
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Solution Overview
Problem
Power modules in electric power conversion devices generate heat, leading to reduced durability and potential damage due to excessive temperature, necessitating effective cooling systems to support high-power and high-efficiency operation.
Innovation Solution
A stack structure with power modules arranged in layers and cooling channels disposed between and outside the modules, featuring internal and outermost channels with opposing medium flow directions, and specific inlets and outlets for efficient cooling medium circulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If power modules are stacked in multiple layers to achieve high-power output, then the power conversion capacity is improved, but thermal overlap and cooling difficulty increase
Solution Approach 1:
The cooling system is segmented into multiple independent cooling channels corresponding to each power module layer. Each cooling channel is independently configured with inlet and outlet passages, allowing separate cooling control for each stacked module. This segmentation prevents thermal overlap by ensuring each module receives dedicated cooling flow.
Solution Approach 2:
The cooling channels are arranged in a vertical dimension corresponding to the stacked power modules, with cooling medium flowing through multiple levels. The cooling system transitions from a single-plane approach to a multi-dimensional vertical arrangement, enabling effective heat removal from each layer while maintaining compact structure.
2Temperature
If cooling channels are added to cool power modules, then temperature control is improved, but device complexity increases
Solution Approach 1:
Multiple cooling channels are merged into a single integrated cooling assembly that can be collectively controlled. The cooling medium flows through a unified system with common inlet and outlet connections, reducing the number of separate control mechanisms while maintaining effective cooling across all power modules.
3Loss of energy
If cooling medium flow direction is reversed in outermost channels, then cooling efficiency is improved, but flow control complexity increases
Solution Approach 1:
The cooling medium flow direction is inverted in the outermost cooling channels compared to the inner channels. While inner channels flow from left to right, the outermost channels flow from right to left, creating a counter-flow arrangement that enhances cooling efficiency by maintaining optimal temperature gradients throughout the cooling path.
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 solution effectively cools power modules, preventing thermal overlap and ensuring high-efficiency, high-output performance without performance deterioration.
Implementation Method 1
cooling channels configured to cool the power modules
Implementation Method 2
a cooling medium from outside is introduced into internal cooling channels disposed between the power modules
Data Source
AI summary
Disclosed is an electric power conversion device including a plurality of power modules stacked in one direction, and a plurality of cooling channels disposed between or outside the power modules such that at least one surface of each of the plurality of cooling channels is in contact with one surface or a remaining surface of one of the power modules, wherein a cooling medium from outside is introduced into internal cooling channels disposed between the power modules, and the cooling medium discharged from the internal cooling channels is introduced into outermost cooling channels disposed outside the power modules.