Toroidal Power Electronics Cooling via Flow-Cooled Circuit Boards
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Solution Overview
Problem
Existing power electronic systems for controlling electric machines, such as superchargers, face challenges in heat management due to the complexity and cost of cooling systems like water cooling circuits and fans, which are difficult to design and incorporate, especially in thermally restrictive environments like internal combustion engines.
Innovation Solution
A power electronic system with planar or toroidal circuit boards and a mechanical housing that utilizes an air intake hose for cooling, incorporating a heat sink with fins and a fan to maximize heat removal, allowing for compact and cost-effective integration near the electric machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If water cooling circuits or fans are used to cool power electronic components, then cooling effectiveness is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The power electronic components are mounted directly on the electric machine housing, which serves as a heat sink. The housing itself provides the cooling function by conducting heat away from the components, eliminating the need for separate cooling systems. This self-service approach resolves the contradiction by making the structure perform both mechanical support and thermal management functions.
Solution Approach 2:
The cooling function is merged with the electric machine housing structure. Instead of adding separate cooling devices, the housing is designed to directly contact and cool the power electronic components, combining structural support and thermal management into a single integrated solution.
2Loss of substance
If power electronic components are mounted directly on the electric machine, then wiring costs are reduced, but heat management becomes more difficult
Solution Approach 1:
The power electronic components are mounted directly on the electric machine housing, merging the electrical connection structure with the thermal management structure. This eliminates the need for separate wiring while using the housing as a heat sink to manage heat, thus resolving both the cost and heat management issues simultaneously.
Solution Approach 2:
The electric machine housing acts as an intermediary between the power electronic components and the cooling system. It provides both the mechanical mounting surface and the thermal conduction path to dissipate heat, serving dual functions that resolve the contradiction between reduced wiring and heat management.
3Adaptability or versatility
If power components are arranged close to the internal combustion engine, then integration is improved, but temperature resistance requirements increase cost
Solution Approach 1:
The electric machine housing serves as a self-service cooling solution for the power electronic components mounted on it. By using the housing's thermal mass and surface area for heat dissipation, the system can integrate components close to the engine without requiring expensive high-temperature resistant components.
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 solution provides efficient and cost-effective heat management, reducing the need for additional cooling devices and minimizing material costs while ensuring optimal performance and compactness of the power electronic system.
Implementation Method 1
The effect of such a configuration permits the use of the flow from a hose to cool power electronic components. The components, are placed on the boards, and benefit from the removal of heat by the flow.
Implementation Method 2
a heat sink with fins and a fan to maximize heat removal
Implementation Method 3
The power electronic system comprises a heat sink that is connected thermally to at least one of the circuit board and the power electronic components
Data Source
AI summary
The invention is a power electronic system comprising at least one power electronic component implemented at least partly on at least one circuit board. The circuit boards are planar and circular or toroidal in shape with the center thereof comprising a circular opening having a diameter D cooperating with a hose for circulating a flow.