Integrated Vehicle Control Module Heat Sink Design
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Solution Overview
Problem
Existing control modules for vehicles with electric motors and transmissions face challenges in minimizing component count and efficiently dissipating heat, leading to increased costs and complexity.
Innovation Solution
A compact control module design featuring a housing with a heat sink integrated between its upper and lower parts, where the transmission control electronics unit is thermally connected to a metal base plate and surrounded by a plastic casing, utilizing thermally conductive materials for effective heat dissipation, and allowing for both attached-to and standalone installations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a compact control module design is implemented with integrated heat sink, then the number of components is minimized and production costs are reduced, but heat dissipation efficiency must be maintained
Solution Approach 1:
The patent combines multiple separate components (control module housing, heat sink, and cooling system) into a single integrated control module. The heat sink is built into the housing structure itself, eliminating the need for separate heat dissipation components while maintaining effective cooling of the inverter electronics unit and transmission control electronics unit.
Solution Approach 2:
The housing structure serves multiple functions simultaneously: it provides mechanical protection for the electronics, acts as a mounting structure for the heat sink, and facilitates heat dissipation through integrated cooling channels. This multi-functionality reduces the overall component count while maintaining thermal management effectiveness.
2Ease of manufacture
If expensive construction elements are dispensed with through efficient heat dissipation design, then production costs are reduced, but thermal management performance must be maintained
Solution Approach 1:
The patent changes the thermal management approach by transitioning from expensive separate cooling components to an integrated heat sink design with optimized thermal conductivity materials. The housing is designed with specific thermal parameters that enable efficient heat dissipation without requiring additional expensive cooling systems.
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 design minimizes the number of components, reduces production costs, and enhances heat dissipation efficiency, making it suitable for use in vehicles as both an attached and standalone control module.
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 (4)
Implementation Method 2
dissipate the heat generated by the electronic construction elements (1.1, 5.1) via a coolant (4)
Implementation Method 3
at least the thermally conductive connection between the inverter electronics unit and the heat sink
Implementation Method 4
the transmission control electronics unit, conjointly with the plastic casing and the base plate, forms the housing upper part, where the housing upper part is connected to the heat sink in a thermally conductive manner such that heat generated by electronic construction elements of the transmission control electronics unit is dissipated via the base plate to the heat sink
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, conjointly with the plastic casing and the base plate, 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 via the base plate to the heat sink takes place.