Integrated Vehicle Control Module Housing for Heat Dissipation
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Solution Overview
Problem
Existing control modules for vehicles with electric motors and transmissions are inefficient in heat dissipation, leading to the need for expensive, low-loss construction elements and increased production costs.
Innovation Solution
A compact control module design with a housing comprising a heat sink integrated between housing parts, thermally conductive connections, and a plastic casing to efficiently dissipate heat generated by electronics, reducing the number of components and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional control module design is used, then component reliability is maintained, but heat dissipation efficiency is poor and production costs increase
Solution Approach 1:
The patent combines multiple control units (transmission control unit, motor control unit, converter control unit) into a single integrated control module housing. This merging of previously separate components into one unified structure improves heat dissipation efficiency by consolidating heat-generating electronics into a single thermally managed environment, while reducing the total number of discrete components and assembly points.
Solution Approach 2:
The patent introduces a heat sink as an intermediary thermal management component between the electronic control units and the external environment. This heat sink acts as a mediator that efficiently transfers heat away from the densely packed electronics, solving the heat dissipation problem without requiring separate cooling systems for each control unit.
2Ease of manufacture
If separate control modules are used for transmission and inverter, then functional reliability is maintained, but production costs and component quantity increase
Solution Approach 1:
The patent merges separate transmission control modules and inverter control modules into a single integrated control module. This consolidation reduces production costs by decreasing the number of individual components, assemblies, and manufacturing steps required. The integrated design maintains functional reliability through proper thermal management and electrical isolation within the unified housing.
Solution Approach 2:
The control module housing serves multiple functions simultaneously: it provides mechanical protection for electronics, acts as a thermal management system through integrated heat sinks, serves as an electrical isolation barrier, and functions as a mounting structure. This multi-functionality reduces the need for separate protective housings and cooling systems for each control unit.
3Loss of energy
If expensive low-loss construction elements are used, then heat dissipation performance is improved, but production costs increase
Solution Approach 1:
The patent employs cost-effective heat sink materials and construction methods that provide adequate thermal management without requiring expensive specialized components. The heat sinks are designed as standard thermal management components rather than custom high-performance cooling solutions, reducing material costs while maintaining sufficient heat dissipation for the application.
Solution Approach 2:
The patent optimizes heat sink parameters such as surface area, fin density, and thermal conductivity to achieve effective heat dissipation at lower cost. By carefully selecting thermal management parameters within acceptable ranges rather than maximizing performance at all costs, the design achieves adequate heat dissipation using more economical materials and construction approaches.
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 minimizes the number of components, reduces production costs, and enhances heat dissipation efficiency, allowing for both attached and standalone use in vehicles.
Implementation Method 1
a heat sink (3) in order to dissipate the heat generated by the electronic construction elements (1.1, 5.1) via a coolant
Implementation Method 2
dissipate the heat generated by the electronic construction elements (1.1, 5.1) via a coolant
Implementation Method 3
The inverter electronics unit (1) is connected to the heat sink (3) in a thermally conductive manner
Data Source
AI summary
A control module for a vehicle with at least one electric motor and a transmission is provided. The control module has a housing for receiving a transmission control electronics unit and an inverter electronics unit for controlling an electric motor, and a heat sink. The heat sink is disposed between a housing upper part and a housing lower part in such a manner that the heat sink forms part of the housing. The housing lower part and the heat sink form a medium-tight cavity for receiving the inverter electronics unit. The transmission control electronics unit is surrounded by a plastic casing. The transmission control electronics unit with the plastic casing forms the housing upper part. The housing upper part is connected to the heat sink in a thermally conductive manner such that a heat transport from the transmission control electronics unit to the heat sink takes place.