Thermal Analysis and Structural Optimization of Dual IGBT Module Heat Sink under Forced Air Cooling Condition

Using Icepak, a thermal analysis software, the fin heat sink with dual IGBT module under forced air cooling conditions is analyzed. According to the problems of insufficient ventilation and poor heat dissipation of the heat sink, this paper proposed an optimization measure by adding a deflector to change the distribution of cooling airflow among fins. Through calculation, it is found that the deflector can effectively balance the uniformity of airflow distribution among fins, fully utilize the heat dissipation capability of each fin. The results show that the maximum temperature of heat source after the installation of deflector is 79.56 °C, which is significantly lower than 95.34 °C before installation. On this basis, the influence of deflector installation size on improving heat dissipation effect is further studied. The temperature field of the cooling structure is calculated when the deflector installation size is 80 mm, 70 mm, 60 mm and 50 mm. Results show that the maximum and minimum temperature of heat source increase with the deflector installation size, that is, when the size is 50 mm, both the maximum and minimum temperatures of the heat source reach the lowest, and the maximum temperature of heat source is 74.37 °C, which is nearly 21 °C lower than the original structure, the cooling effect is remarkable.