Vehicle Power Electronic Device Integrating Waste Heat Heating

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Solution Overview

Problem

Existing power electronic devices in electric and hybrid vehicles require separate heating systems due to the absence of waste heat energy from internal combustion engines, leading to increased costs and space requirements.

Innovation Solution

Integration of a power electronic device with a heat conductive intermediate unit and a heating device that utilizes waste heat energy to heat vehicle subregions, sharing components to reduce costs and space, with the heating device connected to the power electronic unit via a fluid circuit.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a separate heating device is used in electric and hybrid vehicles, then heating function is provided, but production costs and space requirements increase

Engineering Contradiction:

Improveheating capabilityVSAvoidsystem complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The heating device is integrated into the power electronic device by combining the heating element with the intermediate unit that dissipates waste heat from the power electronic component. The housing of the power electronic device serves as part of the heating system structure, merging two separate functions (power conversion and heating) into a single integrated unit.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The intermediate unit serves dual purposes: it dissipates waste heat from the power electronic component during operation and simultaneously functions as a heating element that provides thermal energy to the vehicle interior. This multi-functional design eliminates the need for a dedicated separate heating device.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If a separate heating device is used in electric and hybrid vehicles, then heating function is provided, but space requirements increase

Engineering Contradiction:

Improveheating capabilityVSAvoidspace occupation

Core Design Contradiction:

TemperatureVSVolume of moving object

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

3Device complexity

If waste heat from power electronic device is utilized for heating, then production costs and space requirements are reduced, but heat transfer efficiency must be optimized

Engineering Contradiction:

Improvesystem integrationVSAvoidheat transfer efficiency

Core Design Contradiction:

Device complexityVSLoss of energy

Solution Approach 1:

A thermal coupling agent or heat transfer medium is introduced between the intermediate unit and the heating element to optimize heat transfer from the power electronic component to the vehicle interior. This intermediary ensures efficient thermal energy transfer while maintaining the integrated design.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 reduces production costs and space requirements by utilizing waste heat for vehicle heating, eliminating the need for a separate heating device and optimizing energy conversion within the power electronic device.

Implementation Method 1

The intermediate unit can be made of a heat conductive material, which has at least a heat conductivity, which is higher than the heat conductivity of air

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

The heating device can have a resistance heating element and/or a thick film heating element, in order to convert electrical energy into heat energy

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 3

The power electronic unit can have a rectifier unit, which is configured to convert alternating voltage into direct voltage or alternating current into direct current, respectively

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS11160198B2Power electric device for a vehicle

Publication Date: 2021.10.26 MAHLE INT GMBH

AI summary

The present disclosure relates to a power electronic device for a vehicle. The power electronic device includes at least one intermediate unit having at least one fluid duct system fluidically connected to a fluid inlet and a fluid outlet, at least one power electronic unit arranged at least at a surface of the at least one intermediate unit, and at least one heating device arranged at least at a surface of the at least one intermediate unit.