Traction Drive Inverter Cooling with Submerged Liquid Jet Impingement on Microfinned Enhanced Surfaces (Presentation): NREL (National Renewable Energy Laboratory)

Jet impingement is one means to improve thermal management for power electronics in electric-drive traction vehicles. Jet impingement on microfin-enhanced surfaces further augments heat transfer and thermal performance. A channel flow heat exchanger from a commercial inverter was characterized as a baseline system for comparison with two new prototype designs using liquid jet impingement on plainand microfinned enhanced surfaces. The submerged jets can target areas with the highest heat flux to provide local cooling, such as areas under insulated-gate bipolar transistors and diode devices. Low power experiments, where four diodes were powered, dissipated 105 W of heat and were used to validate computational fluid dynamics modeling of the baseline and prototype designs. Experiments andmodeling used typical automotive flow rates using water-ethylene glycol as a coolant (50%-50% by volume). The computational fluid dynamics model was used to predict full inverter power heat dissipation. The channel flow and jet impingement configurations were tested at full inverter power of 40 to 100 kW (output power) on a dynamometer, translating to an approximate heat dissipation of 1 to 2 kW. With jet impingement, the cold plate material is not critical for the thermal pathway. A high-temperature plastic was used that could eventually be injection molded or formed, with the jets formed from a basic aluminum plate with orifices acting as nozzles. Long-term reliability of the jet nozzles and impingement on enhanced surfaces was examined. For jet impingement on microfinned surfaces,thermal performance increased 17%. Along with a weight reduction of approximately 3 kg, the specific power (kW/kg) increased by 36%, with an increase in power density (kW/L) of 12% compared with the baseline channel flow configuration.