Vehicle Power Conversion Module Integrated Cooling
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Solution Overview
Problem
The installation of inverter and LDC devices in electric vehicles results in inefficient space organization and increased manufacturing costs due to excessive heat generation in the capacitor module, which affects the operation and lifetime of the circuit.
Innovation Solution
A power conversion module that integrates a housing with a power conversion unit, a water-cooling-type cooling unit, an air-cooling-type cooling fin, and a radiator blower, which reduces heat generation through efficient cooling methods, improving the efficiency and durability of the devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the inverter and LDC are installed within the engine compartment, then the vehicle can operate with essential power conversion functions, but the space organization efficiency decreases and manufacturing costs increase
Solution Approach 1:
The patent combines the inverter and LDC into a single integrated power conversion unit that shares a common housing and capacitor module. This merging of previously separate devices reduces the number of components in the engine compartment, improves space organization efficiency, and lowers manufacturing costs while maintaining all essential power conversion functions.
2Device complexity
If the inverter and LDC share a common capacitor module, then the device complexity is reduced, but excessive load causes substantial heat generation
Solution Approach 1:
The patent segments the cooling system into two independent subsystems: a water-cooling system for the power modules (inverter and LDC) and an air-cooling system for the capacitor module. This segmentation allows each component to be cooled according to its specific thermal requirements, preventing excessive heat generation despite the shared capacitor module and reduced device complexity.
3Power
If the capacitor module handles excessive load from parallel-connected power modules, then the power conversion capability is maintained, but the capacitor module generates substantial heat
Solution Approach 1:
The patent introduces a water-cooling intermediary system between the power modules and the environment. This water-cooling unit acts as a heat transfer mediator, absorbing heat from the power modules and transferring it to a coolant, thereby maintaining power conversion capability while preventing excessive heat generation in the capacitor module and power components.
4Temperature
If separate cooling systems are used for inverter and LDC, then the thermal management is effective, but the device complexity and manufacturing costs increase
Solution Approach 1:
The patent implements a dual-cooling system where the water-cooling unit serves multiple functions: it cools both the inverter and LDC power modules through a shared coolant circuit. The air-cooling fan simultaneously cools the capacitor module and provides ventilation for the housing. This multi-functional approach achieves effective thermal management while reducing overall device complexity compared to completely separate 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
The module enhances heat dissipation efficiency, reduces electromagnetic compatibility issues, and decreases production costs by minimizing the distance between components, thereby improving the overall performance and longevity of the power conversion system.
Implementation Method 1
a water-cooling-type cooling unit installed on an outside surface of the bottom panel of the housing and arranged in a corresponding position to the power module of the inverter and the LDC
Implementation Method 2
an air-cooling-type cooling fin installed on the outside surface of the bottom panel of the housing and arranged in a corresponding position to a capacitor module
Implementation Method 3
a radiator blower disposed to be adjacent to a radiator of a vehicle and configured to generate cooling-air wind that simultaneously cools the radiator and the air-cooling-type cooling fin
Data Source
AI summary
A power conversion module for a vehicle is provided. The module includes a housing and a power conversion unit installed on an inside surface of a bottom panel of the housing. The power conversion unit includes a capacitor module, a power module of an inverter and a LDC. A water-cooling-type cooling unit is installed on an outside surface of the bottom panel of the housing and is in a corresponding position to the power module of the inverter and the LDC, with the bottom panel of the housing interposed therebetween. An air-cooling-type cooling fin is installed on the exterior surface of the bottom panel and is in a corresponding position to a capacitor module, with the bottom panel of the housing interposed therebetween. A radiator blower adjacent to a radiator of a vehicle is configured to generate cooling-air wind to cool the radiator and the air-cooling-type cooling fin.