Stacked Power Module Assembly with Interleaved Coolant Chambers
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Solution Overview
Problem
Current power-module assemblies for electric drivetrains in vehicles face challenges in efficiently managing heat dissipation across stacked power stages, leading to potential thermal gradients and reduced performance.
Innovation Solution
The design incorporates a power-module assembly with stacked power stages that include interleaved coolant chambers, a manifold cavity, and a manifold insert with strategically positioned apertures to facilitate coolant flow, ensuring uniform temperature distribution and enhanced cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If power stages are stacked in an array to increase power density, then productivity and power output are improved, but heat dissipation becomes more difficult and thermal gradients increase
Solution Approach 1:
The patent segments the cooling system by creating individual coolant chambers between each power stage and introducing a manifold insert with multiple apertures to distribute coolant independently to each chamber. This segmentation allows targeted cooling of each power stage, preventing thermal gradients while maintaining high power density through the stacked configuration.
2Temperature
If coolant chambers are interleaved with power stages to improve cooling, then heat dissipation is improved, but device complexity increases
Solution Approach 1:
The patent merges the manifold structure with the housing by forming the manifold as an integrated component that extends between power stages. The coolant chambers are formed by the interaction of the manifold and housing features, combining multiple cooling functions into a single integrated structure rather than separate components, thereby reducing overall device complexity while maintaining effective heat dissipation.
3Temperature
If manifold cavity is made larger to improve coolant flow, then heat dissipation is improved, but volume of power module increases
Solution Approach 1:
The patent applies local quality by positioning the manifold insert with strategically placed apertures to direct coolant flow precisely where heat generation occurs in each power stage. This localized cooling approach ensures efficient heat dissipation through targeted coolant delivery rather than requiring a uniformly large manifold cavity, thereby maintaining compact power module volume while achieving effective cooling.
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 configuration effectively manages heat dissipation, maintaining a uniform temperature gradient along the stack, thereby improving the performance and reliability of power-module assemblies in electric drivetrains.
Implementation Method 1
coolant flow from the cavity and into the chambers
Implementation Method 2
heat dissipation, maintaining a uniform temperature gradient along the stack
Data Source
AI summary
A power inverter includes a plurality of power modules each having a power stage encased in a frame that defines an opening. The power modules are stacked in an array with the power stages being spaced apart to define coolant chambers interleaved with the power stages. The openings cooperate to form a manifold cavity extending along a length of the stack and in fluid communication with the chambers. A manifold insert is disposed in the cavity and extends through the openings.