US 12,484,200 B2
Systems and methods for cooling module with progressive cooling fins
Edward Choi, Lake Orion, MI (US); and Todd George Nakanishi, Cicero, IN (US)
Assigned to BorgWarner US Technologies LLC, Wilmington, DE (US)
Filed by BorgWarner US Technologies LLC, Wilmington, DE (US)
Filed on Mar. 22, 2023, as Appl. No. 18/187,894.
Prior Publication US 2024/0324150 A1, Sep. 26, 2024
Int. Cl. H05K 7/20 (2006.01); B60L 50/51 (2019.01); F28F 13/06 (2006.01)
CPC H05K 7/209 (2013.01) [B60L 50/51 (2019.02); F28F 13/06 (2013.01); H05K 7/20845 (2013.01); B60L 2210/40 (2013.01)] 14 Claims
OG exemplary drawing
 
1. A system comprising:
an inverter configured to convert DC power from a battery to AC power to drive a motor, wherein the inverter includes:
a power module; and
a heat sink system configured to cool the power module, the heat sink system including:
a container including a cavity;
a housing connecting to the container to cover the cavity, wherein one or more of the container or the housing includes an inlet port, and one or more of the container or the housing includes an outlet port; and
a cooling module in the cavity between the container and the housing, the cooling module in a flow of coolant from the inlet port to the outlet port, wherein the cooling module includes:
first cooling fins with a first cooling fin geometry,
second cooling fins with a second cooling fin geometry,
a first transition zone with first transition cooling fins with a first transition cooling fin geometry, wherein the first transition cooling fin geometry is a flat wave inclined at an angle, and
a second transition zone, wherein the first cooling fins are upstream of the second cooling fins along the flow of coolant from the inlet port to the outlet port, wherein the first transition cooling fins connect and are between the first cooling fins and the second cooling fins, and the second transition zone is downstream from the second cooling fins along the flow of coolant from the inlet port to the outlet port,
wherein the second transition zone includes second transition cooling fins with a second transition cooling fin geometry, wherein the second transition cooling fin geometry is a sinusoidal wave having a uniform wavelength that is shorter than a wavelength of the flat wave.