Patent Publication Number: US-2022225546-A1

Title: Cooling automotive power electronics

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority from U.S. Provisional Application No. 63/137,366 filed on Jan. 14, 2021, the contents of which are incorporated herein by reference in their entirety. 
    
    
     CONTRACTUAL ORIGIN 
     This invention was made with United States government support under Contract No. DE-AC36-08GO28308 awarded by the U.S. Department of Energy. The U.S. government has certain rights in this invention. 
    
    
     BACKGROUND 
     The power electronics module (or semiconductor power module) is the key power electronics component in most hybrid and electric vehicles. Examples of power electronics modules include insulated-gate bipolar transistors modules (IGBT modules), diodes, or metal-oxide semiconductor field effect transistors modules (MOSFET modules). The power electronics module, found in the inverter, distributes energy throughout the hybrid or electric vehicle. Improving the energy efficiency of these power electronics modules is a key to improving energy efficiency of hybrid and electric vehicles and improving their battery range. 
     According to Oak Ridge National Laboratory, power electronics can account for up to 40% of the total traction drive cost in hybrid vehicles. Increasing vehicle electrification requires making electric drive vehicles (i.e., hybrid and electric vehicles) cost competitive with conventional gasoline and diesel-powered vehicles. One means of reducing cost is improving the energy density of automotive power electronics. Power electronics modules can generate significant amounts of heat, which needs to be removed from the power electronics module for proper functioning of the power electronics module and the vehicle as a whole. Cooling systems can be large and add weight and cost to the vehicle, as well as a point of failure for operations of the vehicle. Thus, there remains a need for smaller and lighter power electronic components. 
     SUMMARY 
     An aspect of the present disclosure is a system for cooling a power electronics module using a fluid, the system including a housing including a thickness and configured to contain the power electronics module, a molding configured to extend through the thickness and contact at least a portion of the power electronics module, an electrical connection configured to extend through the molding and contact at least a portion of the power electronics module, and a manifold positioned within the housing, wherein the power electronics module includes a first side and a second side, the manifold is configured to direct the fluid to contact the first side and the second side, and the fluid is configured to contact the power electronics module and the electrical connection inside the housing. In some embodiments, the system also includes a first port configured to extend through the thickness, and a second port configured to extend through the thickness, in which the fluid is configured to enter the housing through the first port, and the fluid is configured to exit the housing through the second port. In some embodiments, the fluid includes a dielectric fluid. In some embodiments, the dielectric fluid includes a synthetic hydrocarbon. In some embodiments, the synthetic hydrocarbon may be at least one of mineral oil, hexane, heptane, silicone oil, water, benzene, an ester, transformer oil, a perfluoroalkane, or an alkane. In some embodiments, the molding is configured to create a seal with the thickness, and the seal includes interlocking grooves of the molding and the thickness. In some embodiments, the molding is configured to contact the first side and the second side of the power electronics module. In some embodiments, the electrical connection includes a planar surface which extends through the molding, the molding includes at least one slot, and the electrical connection extends through the slot. In some embodiments, the electrical connection includes a cylindrical extension which extends through the thickness, the cylindrical extension is configured to create a seal with the thickness, and the seal includes interlocking grooves of the cylindrical extension and the thickness. In some embodiments, the manifold includes a first channel and a second channel, the first channel is configured to direct the fluid to the first side of the power electronics module, and the second channel is configured to direct the fluid to the second side of the power electronics module. 
     An aspect of the present disclosure is a system for cooling a power electronics module using a fluid, the system including a housing configured to contact the power electronics module, an electrical connection configured to extend through the housing and configured to contact the power electronics module, a manifold contained within the housing having at least one jet, and a plate connected to the power electronics module and oriented substantially parallel to the manifold; wherein, in which the fluid is configured to enter the manifold, exit the jet, and impinge on the plate. In some embodiments, the system also includes a plurality of fins extending from the plate; in which the fluid is configured to contact the plurality of fins after exiting the slot. In some embodiments, the plurality of fins includes at least one fin having an elliptical cross-section. In some embodiments, the plurality of fins includes at least one folded fin, the folded fin includes a first side and a second side joined at an angle, and the first side and the second side contact the plate. In some embodiments, at least one folded fin includes a slot, and the slot includes a cutout in the first side and the second side at the angle. In some embodiments, the system includes a first port connected to the housing, and a second port connected to the housing, in which the fluid is configured to enter the housing through the first port, and the fluid is configured to exit the housing through the second port. 
     An aspect of the present disclosure is a method for cooling a power electronics module using a fluid, the method including positioning the power electronics module within a housing; and directing the fluid to contact the power electronics module, in which the power electronics module includes a first side and a second side, and the directing includes using a manifold to direct the fluid to contact the first side and the second side of the power electronics module. In some embodiments, the housing includes a thickness, and the positioning includes extending a molding through the thickness to contact at least a portion of the power electronics module. In some embodiments, the molding and the thickness create a seal, and the seal includes interlocking groves of the molding and the thickness. In some embodiments, the positioning also includes extending an electrical connection through the molding to contact at least a portion of the power electronics module and extending an electrical connection through the thickness to contact at least a portion of the power electronics module. In some embodiments, the directing also includes allowing the fluid to enter the housing through a first port, contacting the power electronics module with the fluid, and allowing the fluid to exit the housing through a second port. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       Some embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than limiting. 
         FIG. 1  illustrates a first exemplary device for cooling a power electronics module using a fluid, according to some aspects of the present disclosure. 
         FIG. 2  illustrates an internal view of the first exemplary device for cooling a power electronics module using a fluid, according to some aspects of the present disclosure. 
         FIG. 3  illustrates a rear view of the first exemplary device for cooling a power electronics module using a fluid, according to some aspects of the present disclosure. 
         FIG. 4A  illustrates some of the internal components in the first exemplary device for cooling a power electronics module using a fluid of  FIGS. 1-3 , and  FIG. 4B  illustrates a rear view of the molding of the device for cooling a power electronics module using a fluid according to some aspects of the present disclosure. 
         FIG. 5  illustrates some of the internal components in the first exemplary device for cooling a power electronics module using a fluid of  FIGS. 1-3 , according to some aspects of the present disclosure. 
         FIG. 6A  illustrates an isometric view of the manifold in the first exemplary device for cooling a power electronics module using a fluid and  FIG. 6B  illustrates a cross section view of the manifold in the first exemplary device for cooling a power electronic module using a fluid, according to some aspects of the present disclosure. 
         FIG. 7A  illustrates an exploded view of the first exemplary device for cooling a power electronics module using a fluid and  FIG. 7B  illustrates a port in the first exemplary device for cooling a power electronics module using a fluid, according to some aspects of the present disclosure. 
         FIG. 8  illustrates a second exemplary device for cooling a power electronics module using a fluid, according to some aspects of the present disclosure. 
         FIG. 9  illustrates a cross sectional view of the second exemplary device for cooling a power electronics module using a fluid, according to some aspects of the present disclosure. 
         FIG. 10  illustrates a plurality of fins in the second exemplary device for cooling a power electronics module using a fluid, according to some aspects of the present disclosure. 
         FIG. 11  illustrates a manifold in the second exemplary device for cooling a power electronics module using a fluid, according to some aspects of the present disclosure. 
         FIG. 12  illustrates an external view of a third exemplary device for cooling a power electronics module using a fluid, according to some aspects of the present disclosure. 
         FIG. 13  illustrates a cut-away view of the third exemplary device for cooling a power electronics module using a fluid, according to some aspects of the present disclosure. 
         FIG. 14  illustrates a manifold within the third exemplary device for cooling a power electronics module using a fluid, according to some aspects of the present disclosure. 
         FIG. 15  illustrates a cross-sectional view of the internal components the third exemplary device for cooling a power electronics module using a fluid, according to some aspects of the present disclosure. 
         FIG. 16  illustrates the fins within the third exemplary device for cooling a power electronics module using a fluid, according to some aspects of the present disclosure. 
         FIG. 17  illustrates a method for cooling a power electronics module using a fluid, according to some aspects of the present disclosure. 
         FIG. 18  illustrates the improved thermal performance (as shown by lower thermal resistance) of the first exemplary device for cooling a power electronics module using a fluid compared with existing automotive solutions, according to some aspects of the present disclosure. 
         FIG. 19  illustrates the improved thermal performance (as shown by lower thermal resistance) of the second exemplary device for cooling a power electronics module using a fluid compared with existing automotive solutions, according to some aspects of the present disclosure. 
     
    
    
     REFERENCE NUMERALS 
     
         
         
           
               100  . . . first exemplary device 
               105  . . . housing 
               107  . . . external surface 
               110  . . . electrical connections 
               115  . . . port 
               120  . . . molding 
               125  . . . power electronics module 
               130  . . . manifold 
               135  . . . tube 
               140  . . . opening 
               145  . . . groove 
               150  . . . jet 
               155  . . . channel 
               160  . . . slot 
               165  . . . fins 
               300  . . . third exemplary device 
               400  . . . method 
               405  . . . positioning 
               410  . . . directing 
               415  . . . impinging 
           
         
       
    
     DETAILED DESCRIPTION 
     The embodiments described herein should not necessarily be construed as limited to addressing any of the particular problems or deficiencies discussed herein. References in the specification to “one embodiment”, “an embodiment”, “an example embodiment”, “some embodiments”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. 
     As used herein the term “substantially” is used to indicate that exact values are not necessarily attainable. By way of example, one of ordinary skill in the art will understand that in some chemical reactions 100% conversion of a reactant is possible, yet unlikely. Most of a reactant may be converted to a product and conversion of the reactant may asymptotically approach 100% conversion. So, although from a practical perspective 100% of the reactant is converted, from a technical perspective, a small and sometimes difficult to define amount remains. For this example of a chemical reactant, that amount may be relatively easily defined by the detection limits of the instrument used to test for it. However, in many cases, this amount may not be easily defined, hence the use of the term “substantially”. In some embodiments of the present invention, the term “substantially” is defined as approaching a specific numeric value or target to within 20%, 15%, 10%, 5%, or within 1% of the value or target. In further embodiments of the present invention, the term “substantially” is defined as approaching a specific numeric value or target to within 1%, 0.9%, 0.8%, 0.7%, 0.6%, 0.5%, 0.4%, 0.3%, 0.2%, or 0.1% of the value or target. 
     As used herein, the term “about” is used to indicate that exact values are not necessarily attainable. Therefore, the term “about” is used to indicate this uncertainty limit. In some embodiments of the present invention, the term “about” is used to indicate an uncertainty limit of less than or equal to ±20%, ±15%, ±10%, ±5%, or ±1% of a specific numeric value or target. In some embodiments of the present invention, the term “about” is used to indicate an uncertainty limit of less than or equal to ±1%, ±0.9%, ±0.8%, ±0.7%, ±0.6%, ±0.5%, ±0.4%, ±0.3%, ±0.2%, or ±0.1% of a specific numeric value or target. 
     The present disclosure relates to cooling power electronics modules using a fluid. Manifolds may be used for directing fluid flow. At least one heat source, such as a semiconductor, switch, transistor, diode, and/or switching semiconductor, may be enclosed within an exemplary device as described herein. The exemplary devices described herein may direct cooling fluid to contact the power electronics module and/or the busbars of the power electronics module directly. In some embodiments, the cooling fluid may be a dielectric fluid (such as transmission fluid). In other embodiments, the cooling fluid may be a mixture including ethylene glycol. 
       FIG. 1  illustrates a first exemplary device  100  for cooling a power electronics module  125  (not shown in  FIG. 1 ) using a fluid, according to some aspects of the present disclosure.  FIG. 2  illustrates an internal view of the first exemplary device  100  and  FIG. 3  illustrates a rear view of the first exemplary device  100  for cooling a power electronics module using a fluid, according to some aspects of the present disclosure. The first exemplary device  100  may contact both the top side and bottom side of the power electronics module  125  with the fluid. The first exemplary device  100  for using a fluid has a housing  105  which has a thickness  107  and contains the power electronics module  125 . A molding  120  extends through the thickness  107  and contact at least a portion of the power electronics module  125  inside the housing  105 . At least one electrical connection  110   a  extends through the molding  120  and contacts at least a portion of the power electronics module  125 . A manifold  130  is positioned within the housing  105  and contacts both sides of the power electronics module  125  (via an upper manifold  130   a  and a lower manifold  130   b ). The manifold  120  has channels  155  and jets  150  (see  FIG. 6B ) which may direct a fluid to contact at least a portion of the power electronics module  125  on both sides inside the housing  105 . A first port  115   a  and a second port  115   b  may extend through the thickness. The first port  115   a  may act as an inlet and allow the fluid to enter the housing  105  and the second port  115   b  may act as an outlet and allow the fluid to exit the housing  105 . 
     In some embodiments, the molding  120  may create a seal with the thickness  107  of the housing  105 , which may be a substantially fluid seal (i.e., substantially free of leaks when the housing  105  contains a fluid). The seal may be formed through interlocking grooves  145  on the molding  120  and/or the thickness  107  (i.e., the seal may be a mechanical seal). The grooves  145  may be made using an o-ring or other gasket material to facilitate the tight seal between the thickness  107  and the molding  120 . The exemplary molding  120  shown in  FIGS. 4-5  has a substantially rectangular section and a substantially elliptical section. Slots  160  extend through the molding for electrical connections  110  to fit through. The slots  160  may be substantially the shape of the cross-section of the electrical connections and may fit “snugly” so as to create a fluid or mechanical seal between the molding  120  and the electrical connections  110 . 
       FIG. 4A  illustrates some of the internal components in the first exemplary device for cooling a power electronics module  125 , according to some aspects of the present disclosure. In some embodiments, the molding  120  may contact both sides of the power electronics module  125 . In some embodiments, the molding  120  may encompass the power electronics module  125  (i.e., contact all sides of the power electronics module  125 ) as shown in  FIG. 4A . A rear view of the molding  120  is shown in  FIG. 4B . The molding  120  has grooves  145  for creating a seal with the thickness  107  of the housing  105  and slots  160  for electrical connections  110  to extend through the molding  120 . 
       FIG. 5  illustrates some of the internal components in the first exemplary device  100  for cooling a power electronics module  125 , according to some aspects of the present disclosure. In some embodiments, the electrical connections  110  may include a substantially planar electrical connection  110   a  (i.e., a busbar) and/or a substantially cylindrical electrical connection  110   b . The substantially cylindrical electrical connections  110   b  may be bolted, welded, screwed, soldered, sintered, or glued to the power electronics module  125  and may provide an electrical connection to the motor of the vehicle. The substantially cylindrical electrical connections  110   b  may have at least one groove (not shown) which may interlock with the thickness  107  to form a fluid and/or mechanical seal. In some embodiments, an o-ring or gasket may be present in the groove to facilitate the seal. The substantially planar electrical connections  110   b  may be direct current (DC) or alternating current (AC) connections. 
     In some embodiments, the electrical connections  110  may connect the power electronics module  125  to other parts of the vehicle which require power, such as the air conditioning system, navigation system, radio/sound system, or a display system and to the vehicle&#39;s battery and/or capacitor. The electrical connections  110  may be made with a substantially conductive material, so as to transfer electricity (i.e., energy) to other parts of the vehicle. The electrical connections  110   a  and  110   b  may contact at least a portion of the power electronics module  125 . That is, the electrical connections  110  may be in thermal and/or electrical communication with the power electronics module  125 . 
       FIG. 6A  illustrates an isometric view of the manifold  130  in a first exemplary device  100  for cooling a power electronics module  125  using a fluid and  FIG. 6B  illustrates a cross section view of the manifold  130  in the first exemplary device  100  cut along line A, according to some aspects of the present disclosure. The manifold  130  includes two parts (upper  130   a  and lower  130   b ) that may be interlocked, soldered, sintered, welded, glued, screwed, or otherwise connected. In some embodiments, the two parts  130   a  and  130   b  may be a single component, which may be made using additive manufacturing, 3D printing, or molding. Each manifold  130   a  and  130   b  have a plurality of jets  150  and channels  155 , which may direct the fluid to impinge on (i.e., contact at a relatively high velocity) the power electronics module  125 . The exemplary manifold  130  shown in  FIGS. 5-6  contains 36 jets, although a manifold  130  may contain more or less jets. The exemplary manifold  130   a  shown in  FIG. 6B  contains three channels  155 , although a manifold  130  may contain more or less channels  155 . In some embodiments, the channels  155  may be relatively parallel to each other (as shown in  FIG. 6B ). In other embodiments, the channels  155  may not be parallel to each other, and may even intersect. The channels  155  may be indentations in the manifold  130  creating paths for the fluid to flow. The manifold  130  contains a tube  135  which may be connected to the first port  115   a  (i.e., the inlet). The tube  135  may direct the fluid from the first port  115   a  to impinge on one or both sides of the power electronics module  125  through the upper manifold  130   a  and/or lower manifold  130   b . After impinging on the power electronics module  125  the fluid may exit the housing  105  through the second port  115   b.    
       FIG. 7A  illustrates an exploded view of the first exemplary device  100  for cooling a power electronics module  125  using a fluid and  FIG. 7B  illustrates a port in the first exemplary device  100  for cooling a power electronics module  125  using a fluid, according to some aspects of the present disclosure. The first exemplary device  100  includes a housing  105  which may create a mechanical and/or fluid seal with electrical connections  110   a  and  110   b  and/or a first port  115   a  and/or a second port  115   b . The mechanical and/or fluid seal may be created using grooves  145  on the ports  115   a  and/or  115   b  or on the housing  105  (i.e., on the thickness  107 ) (not shown). The grooves  145  may interlock with the thickness  107  to create a gasket or tight seal. The first port  115   a  may extend through a first opening  140   a  in the housing  105  which may extend through the thickness  107 . The first opening  140   a  may connect to the tube  135  of the manifold  130  as shown in  FIG. 6A . The first port  115   a  may also have at least one o-ring groove to allow for creating a seal with the thickness  107  and/or the tube  135 . The second port  115   b  may extend through a second opening  140   b  in the housing  105  which may extend through the thickness  107 . 
     In some embodiments, the housing  105  may be made of a plastic, a ceramic, a metal, and/or a fiberglass material. The housing  105  may be made of a substantially solid material capable of containing (i.e., encompassing or enclosing) the power electronics module  125 . In some embodiments, the housing  105  may be made of several components connected (e.g., soldered, sintered, welded, glued, nailed, screwed, or interlocked) together. In other embodiments, the housing  105  may be a single component. 
     In some embodiments, the manifold  130  may be made of a substantially dielectric or insulative material, such as plastic, ceramic, fiberglass, composite, epoxy, or a mixture thereof. In some embodiments, the manifold  130  may be made of a substantially conductive material, such as a metal (e.g., copper, aluminum). In some embodiments, the manifold  130  may be made of individually made components which may be assembled, press fit, and/or joined together using solder, braze, epoxy, and/or a thermal interface material. 
     In some embodiments, the molding  120  may be made of a substantially dielectric or insulative material, such as plastic, ceramic, fiberglass, composite, epoxy, rubber, or a mixture thereof. In some embodiments, the molding  120  may be capable of encompassing electrical connections  110  and forming a seal between the housing  105  and the electrical connections  110 . That is, the molding  120  may be positioned between the housing  105  and the electrical connections  110  such that any fluid contained in the housing would not leak through the opening the electrical connections  110  extend through. 
     In some embodiments of the first exemplary device  100 , the fluid may contact the power electronics module  125  directly and the fluid may be dielectric fluid. Exemplary dielectric fluids may be a solution containing at least one synthetic hydrocarbon such as a mineral oil, hexane, heptane, silicone oil, water, benzene, an ester, transformer oil, a perfluoroalkane, an alkane, and/or transmission fluid. In some embodiments, the fluid may be a dielectric fluid already in use in the power electronics  125  system, such as a transmission fluid or a battery coolant. In some embodiments, the fluid may be a refrigerant. The first exemplary device  200  may allow for the power electronics module  125  to be cooled from a single side (i.e., by having the fluid contact a single side of the power electronics module  125  directly) or from both sides (i.e., by having the fluid contact both sides of the power electronics module  125  directly). 
       FIG. 8  illustrates a second exemplary device  200  for cooling a power electronics module  125  using a fluid, according to some aspects of the present disclosure. Similar to the first exemplary device  100 , the second exemplary device  200  includes a housing  105  connected to a first port  115   a  and a second port  115   b . The housing  105  may contain (i.e., enclose or encompass) the power electronics module  125  (not shown in  FIG. 8 ). In some embodiments, baffles (i.e., extensions) may be present in the housing  105  to guide the fluid to contact the electrical connections  110  for cooling. Electrical connections  110  may extend out of the housing  105 . Within the housing  105  the electrical connections  110  may contact the power electronics module  125 . In some embodiments, a plurality of fins  165  (not shown in  FIG. 8 ) may extend from the electrical connections  110  to allow for additional heat dissipation. The electrical connections  110  may contact the fluid directly, to allow for heat removal from the electrical connections  110  to the fluid. The second exemplary device  200  may be substantially modular. That is, the second exemplary device  200  may be used to cool more than one power electronics module  125  by adding additional housings  105  and/or manifolds  130 . 
       FIG. 9  illustrates a cross sectional view of the second exemplary device  200  for cooling a power electronics module  125  using a fluid, according to some aspects of the present disclosure. The device  200  shown in  FIG. 9  was cut along line B in  FIG. 8 . The device  200  includes a housing  105  which contacts the power electronics module  125 . Electrical connections  110  may extend through the housing  105  and may contact the power electronics module  125 . A manifold  130  is contained within the housing  105 . The manifold  130  may have at least one jet  150  and channel  155 . A plate  170  may be connected to the power electronics module  125 . The manifold  130  may be oriented so that the jets  150  would direct onto the surface of the plate  170 . In some embodiments, a plurality of fins  165  may extend from the plate  170 . The fluid may enter the housing  105  via the first port  115   a  and the tube  135 , then flow to the manifold  130  which may direct the fluid through the channels  155  to the jets  150 . After exiting the jets  150  the fluid may impinge on the plate  170  and may flow through the fins  165 . 
       FIG. 10  illustrates a plurality of fins  165  in the second exemplary device  200  for cooling a power electronics module  125  using a fluid, according to some aspects of the present disclosure. In some embodiments, the individual fins  165  may have a substantially elliptical cross section. The fins  165  may be substantially perpendicular to the plate  170 . The fins  165  may be spaced such that the fluid may flow through the fins  165 . The fins  165  shown in  FIG. 10  could also be used in some embodiments of the first exemplary device  100 . In such an embodiment of the first exemplary device  100 , the fins  165  may extend from the electrical connections  110 . 
       FIG. 11  illustrates a manifold  130  in the second exemplary device  200  for cooling a power electronics module  125  using a fluid, according to some aspects of the present disclosure. The manifold  130  may include at least one channel  155 . In some embodiments, as shown in  FIG. 11 , the channel  155  may have a substantially triangular or conical shape, wherein the opening of the channel  155  is larger than the terminal end of the channel  155 . The manifold  130  may include at least one jet  150 . The jet  150  may be substantially circular or elliptical in shape (as shown in  FIG. 11 ) or may be substantially rectangular or polygonal. The manifold  130  may be used to direct the fluid to contact or impinge the power electronics module  125 . In some embodiments, the manifold  130  may direct the fluid in such a way that the velocity of the fluid may increase. 
     In some embodiments of the second exemplary device  200 , the fluid may contact the plate  170  directly and not contact the power electronics module  125  directly. In such embodiments, the fluid may be substantially conductive. Examples of a conductive fluid may be a solution including water and ethylene glycol or propylene glycol. Note that the second exemplary device  200  may allow for the power electronics module  125  to be cooled from either one side or both sides (i.e., through a single plate  170  or through at least two plates  170  located on either side of the power electronics module  125 ). 
       FIG. 12  illustrates an external view of a third exemplary device  300  for cooling a power electronics module  125  using a fluid, according to some aspects of the present disclosure. The third exemplary device  300  includes a housing (shown as a front housing  105 A, a second housing  105 B, a third housing  105 C, and a rear housing  105 D) containing the power electronics module  125  (not shown in  FIG. 12 ). The front housing  105 A has a first port  115   a  and a second port  115   b . Either port  115   a  or  115   b  may act as a fluid inlet and either port  115   a  or  115   b  may act as a fluid outlet. Electrical connections (i.e., busbars)  110  extend from the device  300 . In some embodiments the electrical connections  110  may be connected to the plate  170  (not shown in  FIG. 12 ) or may contact at least a portion of the power electronics module  125 . Note that the third exemplary device  300  may be modular and may be used to cool more than one power electronics module  125  in some embodiments. Regardless of the number of power electronics modules  125 , the front housing  105 A and the rear housing  105 D would be present on either side the power electronics module(s)  125 . If more than one power electronics module  125  is present, additional housings (such as second housing  105 B and third housing  105 C) may be used. 
       FIG. 13  illustrates a cut-away view of the third exemplary device  300 , according to some aspects of the present disclosure.  FIG. 13  shows the device  300  with the front housing  105 A removed, so the internal components may be shown. The molding  120  has two large channels  155 . A manifold  130  is connected to the molding  120  and has several channels  155 . Within the housing  105 B is a plate  170  which is connected (i.e., in electrical connection with) to a power electronics module  125  (not shown in  FIG. 13 ). A plurality of fins  165  extend from the plate  170  and can be seen through the jets  150  in the manifold  130 . In some embodiments, a fluid (not shown) may enter the housing  105  through one of the ports  115 . From there the fluid may enter the channels  155  in the manifold  130 . The fluid may impinge on the plate  170  by flowing through the jets  150  and the plurality of fins  165 . The fluid may exit the manifold  130  through the channels  155 , then to one of the ports  115 . 
       FIG. 14  illustrates a manifold  130  within the third exemplary device  300 , according to some aspects of the present disclosure. The manifold  130  may have several channels  155 . In some embodiments, the channels  155  may have openings towards the sides of the manifold  130 . These openings may alternate sides of the manifold  130 . The exemplary manifold  130  shown in  FIG. 15  contains five channels  155 , but any number of channels  155  may be used in a manifold  130 . The channels  155  may have a plurality of jets  150 . A jet  150  may be an opening extending through the manifold  130  to allow fluid to flow through the manifold and imping on the plate  170  or the power electronics module  125  (not shown in  FIG. 14 ). 
       FIG. 15  illustrates a cross-sectional view of the internal components of the third exemplary device  300  for cooling a power electronics module  125  using a fluid, according to some aspects of the present disclosure. As shown in  FIG. 15 , the third exemplary device  300  includes the housing  105  with at least one port  115  and a molding  120 . Within the molding  120  is the manifold  130 , with several channels  155 . A channel  155  may contains at least one jet  150 , through which a plurality of fins  165  may be seen. The plate  170  is on the opposite side of the plurality of fins  165  from the manifold  130 . The power electronics module  125  is connected to the opposite side of the plate  170  from the plurality of fins  165 . 
       FIG. 16  illustrates the fins  165  within the third exemplary device  300  for cooling a power electronics module  125  using a fluid, according to some embodiments of the present disclosure. The fins  165  shown in  FIG. 16  may be used in a first exemplary device  100  or a second exemplary device  200  as extending from the electrical connections  110  and/or the plate  170 . As used herein, fins  165  refers to an array of individual fins, substantially grouped together. As shown in the example of  FIG. 16 , the fins  165  may be said to be “folded” or “tented.” In some embodiments, the fins  165  may comprise a sheet of material which is folded “accordion style” to create multiple folds, which may be substantially symmetrical, allowing a fluid to flow on either or both sides of the fins  165 . In some embodiments, the fins  165  include a first side and a second side, angled together with various cut out openings allowing cooling fluid to enter the fins  165  and/or contact the fins  165  on both sides. The cut outs may allow the fluid to enter the fins  165  and contact the plate  170 , then the cut outs may allow the fluid to exit the fins  165 . In some embodiments, the fins  165  may have a profile or cross-section which is substantially triangular, square, rounded, or a series of profiles/shapes. The cooling fluid (not shown) can flow between the fins  165  and through the cut-out openings under and/or over the “folds” of the fins  165 . In some embodiments, the fins  165  may be “pins” or “spines” and may be substantially cylindrical extensions of the plates  170 . The fins  165  are heat transfer surface enhancements for the plates  170 . The fins  165  may be assembled, press-fit, and/or joined to the plates  170  using solder, braze, epoxy, and/or a thermal interface material. The fins  165  enhance (i.e., increase the speed and efficacy of) the conductive and convective heat transfer from the power electronics module  125  to the fluid (not shown). In some embodiments, the fins  165  may be made of a substantially conductive material such as copper and/or aluminum. 
       FIG. 17  illustrates a method  400  for cooling a power electronics module  125  using a fluid, according to some aspects of the present disclosure. The method  400  may include positioning  405 , directing  410 , and impinging  415 . The method  400  may be performed using any of the exemplary devices  100 ,  200 , or  300  described herein, or using other embodiments of the present disclosure. 
     The first step of the method  400  is positioning  405  the power electronics module  125  within a housing  105 . In some embodiments, the positioning  405  may include extending an electrical connection  110  through the thickness  107  of the housing  105  to contact at least a portion of the power electronics module  125 . In some embodiments, the positioning  405  may include extending an electrical connection  110  through a molding  120 . In some embodiments, the positioning  405  may include extending a molding  120  through the thickness  107  of the housing  105  to contact at least a portion of the power electronics module  125 . The molding  120  and the thickness  107  may be interlocked using grooves  145  to create a gasket or mechanical seal. 
     The next step of the method  400  is directing  410  a fluid to enter a manifold  130  and/or contact the power electronics module  125 . The directing  410  may comprise using the manifold  130  to direct (or guide) the fluid path to contact the power electronics module  125 . In some embodiments, the directing  410  may result in the fluid contacting both a first side and a second side of the power electronics module  125 . In some embodiments, the directing  410  may include allowing the fluid to enter the housing  105  through a first port  115   a , contacting the power electronics module  125  with the fluid, and allowing the fluid to exit the housing  105  through a second port  115   b . In some embodiments, the manifold  130  may direct  410  the fluid in such a way as to substantially increase the velocity of the fluid. 
     The next step of the method  400  is impinging  415  the fluid on the power electronics module  125 . In some embodiments, the fluid may be impinged  415  directly on the power electronics module  125  (i.e., the fluid may contact the power electronics module  125  directly). In some embodiments, the fluid may be impinged  415  on a plate  170  connected to the power electronics module  125 . The plate  170  may be in thermal communication with the power electronics module  125  such that impinging  415  the plate  170  results in a cooling effect on the power electronics module  125 . In some embodiments, a plurality of fins  165  may extend from the plate  170  and the impinging  415  may result in the fluid contacting the plurality of fins  165 . 
     The present disclosure describes devices capable of cooling power electronics modules  125 , such as insulated-gate bipolar transistors modules (IGBT modules), diodes, metal-oxide semiconductor field effect transistors modules (MOSFET modules). and/or other electrical components. The fluid (not shown) utilized herein may be based on the design of the device utilized, and whether the cooling fluid will contact the power electronics module  125  directly or may contact non-electrically active components. In some embodiments, such as for power electronics modules for vehicles or automobiles, when the fluid will contact the power electronics module  125  directly (such as for the first exemplary device  100  shown in  FIGS. 1-7 ), the fluid may be a dielectric fluid. In this way, a new fluid may not need to be introduced to the vehicle system to cool the power electronics module  125 . Examples of dielectric fluids include synthetic hydrocarbons such as transformer fluid, mineral oil, and/or perfluoroalkanes. In some embodiments, when the fluid will not contact the power electronics module  125  directly (but will contact the plate  170 ) such as in exemplary devices  200  and  300 , the fluid may be a conductive fluid, such as water ethylene glycol or propylene glycol. 
       FIG. 18  illustrates the improved thermal performance (as shown by lower thermal resistance) of the first exemplary device  100  for cooling a power electronics module  125  using a fluid compared with existing automotive solutions, according to some aspects of the present disclosure. The graph shown in  FIG. 18  was generated using modeling data and was validated using small scale experiments. The stars denote the performance of each device at a fluid flow rate of approximately 10 L/min. The graph shown in  FIG. 18  illustrates how the first exemplary device  100  has significantly lower thermal resistance than existing automotive solutions. For example, the first exemplary device  100  has approximately an 81% lower thermal resistance than a cooling device for a 2015 BMW i3 EV (a thermal resistance of approximately 9 mm 2  K/W for the device  100  compared to a thermal resistance of approximately 49 mm 2  K/W for the 2015 BMW i3 EV). 
       FIG. 19  illustrates the improved thermal performance (as shown by lower thermal resistance) of the second exemplary device  200  for cooling a power electronics module  125  using a fluid compared with existing automotive solutions, according to some aspects of the present disclosure. The graph shown in  FIG. 19  was generated using modeling data and was validated using small scale experiments. The stars denote the performance of each device at a fluid flow rate of approximately 10 L/min. The graph shown in  FIG. 19  illustrates how the second exemplary device  200  has significantly lower thermal resistance than existing automotive solutions. For example, the second exemplary device  200  has approximately a 70% lower thermal resistance than a cooling device for a 2015 BMW i3 EV. 
     EXAMPLES 
     Example 1. A system for cooling a power electronics module using a fluid, the system comprising a housing comprising a thickness and configured to contain the power electronics module; a molding configured to extend through the thickness and contact at least a portion of the power electronics module; an electrical connection configured to extend through the molding and contact at least a portion of the power electronics module; and a manifold positioned within the housing; wherein: the power electronics module comprises a first side and a second side, the manifold is configured to direct the fluid to contact the first side and the second side, and the fluid is configured to contact the power electronics module and the electrical connection inside the housing. 
     Example 2. The system of Example 1, further comprising: a first port configured to extend through the thickness; and a second port configured to extend through the thickness; wherein: the fluid is configured to enter the housing through the first port, and the fluid is configured to exit the housing through the second port. 
     Example 3. The system of claim  2 , wherein the first port is configured to form a seal with the thickness. 
     Example 4. The system of claim  3 , wherein the seal comprises at least one o-ring or groove. 
     Example 5. The system of any of claims  2 - 4 , wherein the second port is configured to form a seal with the thickness. 
     Example 6. The system of any of claims  2 - 5 , wherein the seal comprises at least one o-ring or groove. 
     Example 7. The system of any of Examples 1-6, wherein the fluid comprises a dielectric fluid. 
     Example 8. The system of Example 7, wherein the dielectric fluid comprises a synthetic hydrocarbon. 
     Example 9. The system of Examples 7 or 8, wherein the dielectric fluid comprises at least one of a mineral oil, hexane, heptane, silicone oil, water, benzene, an ester, transformer oil, a perfluoroalkane, or an alkane. 
     Example 10. The system of any of Examples 7-9, wherein the dielectric fluid comprises an automotive fluid or transmission fluid. 
     Example 11. The system of any of Examples 110, wherein the housing comprises at least one of plastic, ceramic, or fiberglass. 
     Example 12. The system of any of Examples 1-11, wherein: the molding is configured to create a seal with the thickness, and the seal comprises interlocking grooves of the molding and the thickness. 
     Example 13. The system of Example 12, wherein: the seal comprises a gasket or an o-ring. 
     Example 14. The system of any of Examples 1-13, wherein the molding is configured to contact the first side and the second side of the power electronics module. 
     Example 15. The system of any of Examples 14, wherein: the electrical connection comprises a planar surface which extends through the molding. 
     Example 16. The system of Example 15, wherein the electrical connection comprises at least one fin. 
     Example 17. The system of Example 16, wherein the at least one fin comprises an elliptical cross-section. 
     Example 18. The system of Example 16, wherein the at least one fin comprises a folded structure. 
     Example 19. The system of Example 18, wherein the folded structure comprises at least one cut out. 
     Example 20. The system of any of Examples 1-19, wherein: the molding comprises at least one slot, and the electrical connection extends through the slot. 
     Example 21. The system of Example 20, wherein: the electrical connection comprises a cylindrical extension which extends through the thickness. 
     Example 22. The system of Example 21, wherein the electrical connection comprises at least one fin. 
     Example 23. The system of Example 22, wherein the at least one fin comprises an elliptical cross-section. 
     Example 24. The system of Example 22, wherein the at least one fin comprises a folded structure. 
     Example 25. The system of Example 24, wherein the folded structure comprises at least one cut out. 
     Example 26. The system of any of Examples 1-25, wherein: the cylindrical extension is configured to create a seal with the thickness, and the seal comprises interlocking grooves of the cylindrical extension and the thickness. 
     Example 27. The system of any of Examples 1-26, wherein: the manifold comprises a first channel and a second channel, the first channel is configured to direct the fluid to the first side of the power electronics module, and the second channel is configured to direct the fluid to the second side of the power electronics module. 
     Example 28. The system of any of Examples 1-27, wherein the electrical connection comprises at least one busbar. 
     Example 29. The system of Example 28, wherein the busbar comprises at least one of copper, aluminum, silver, or gold. 
     Example 30. A system for cooling a power electronics module using a fluid, the system comprising: a housing configured to contact the power electronics module; an electrical connection configured to extend through the housing and configured to contact the power electronics module; a manifold contained within the housing having at least one jet; and a plate connected to the power electronics module and oriented substantially parallel to the manifold; wherein: the fluid is configured to enter the manifold, exit the jet, and impinge on the plate. 
     Example 31. The system of Example 30, further comprising: a plurality of fins extending from the plate; wherein: the fluid is configured to contact the plurality of fins after exiting the slot. 
     Example 32. The system of Example 31, wherein the plurality of fins comprise at least one fin having an elliptical cross-section. 
     Example 33. The system of Example 31, wherein: the plurality of fins comprise at least one folded fin, the folded fin comprises a first side and a second side joined at an angle, and the first side and the second side contact the plate. 
     Example 34. The system of Example 31, wherein: at least one folded fin comprises a slot, and the slot comprises a cutout in the first side and the second side at the angle. 
     Example 35. The system of any of Examples 31-34, wherein the plurality of fins comprise at least one of copper, aluminum, silver, or gold. 
     Example 36. The system of any of Examples 31-35 wherein the fluid is configured to contact the fins. 
     Example 37. The system of any of Examples 30-36, further comprising: a first port connected to the housing; and a second port connected to the housing; wherein: the fluid is configured to enter the housing through the first port, and the fluid is configured to exit the housing through the second port. 
     Example 38. The system of any of Examples 30-37, wherein the fluid comprises water ethylene glycol or water propylene glycol. 
     Example 39. The system of any of Examples 30-38, wherein the housing comprises at least one of plastic, ceramic, or fiberglass. 
     Example 40. The system of any of Examples 30-39, wherein the plate comprises at least one of copper, aluminum, silver, or gold. 
     Example 41. The system of any of Examples 30-40 wherein the manifold comprises at least one channel. 
     Example 42. The system of Example 41, wherein the channel comprises an opening and a terminal end, and the opening is wider than the terminal end. 
     Example 43. A method for cooling a power electronics module using a fluid, the method comprising: positioning the power electronics module within a housing; and directing the fluid to contact the power electronics module; wherein: the power electronics module comprises a first side and a second side, and the directing comprises using a manifold to direct the fluid to contact the first side and the second side of the power electronics module. 
     Example 44. The method of Example 43, wherein: the housing comprises a thickness, and the positioning comprises extending a molding through the thickness to contact at least a portion of the power electronics module. 
     Example 45. The method of Examples 43 or 44, wherein: the molding and the thickness create a seal, and the seal comprises interlocking groves of the molding and the thickness. 
     Example 46. The method of any of Examples 43-45, wherein: the positioning comprises extending an electrical connection through the molding to contact at least a portion of the power electronics module. 
     Example 47. The method of any of Examples 43-46, wherein: the positioning comprises extending an electrical connection through the thickness to contact at least a portion of the power electronics module. 
     Example 48. The method of any of Examples 43-47, wherein: the directing comprises: allowing the fluid to enter the housing through a first port, contacting the power electronics module with the fluid, and allowing the fluid to exit the housing through a second port. 
     Example 49. The method of any of Examples 43-48, wherein the fluid comprises a dielectric fluid. 
     Example 50. The method of Example 49-, wherein the dielectric fluid comprises at least one of mineral oil, hexane, heptane, silicone oil, water, benzene, an ester, transformer oil, a perfluoroalkane, or an alkane. 
     Example 51. The method of any of Examples 43-50, further comprising impinging the fluid on a plate connected to the power electronics module. 
     Example 52. The method of any of Examples 43-51, wherein: a plurality of fins extend from the plate, and the impinging comprises contacting the plurality of fins with the fluid. 
     Example 53. The method of Example 52, wherein the plurality of fins comprise at least one fin having an elliptical cross-section. 
     Example 54. The method of Example 52, wherein: the plurality of fins comprise at least one folded fin, the folded fin comprises a first side and a second side joined at an angle, and the first side and the second side contact the plate. 
     Example 55. The method of Example 52, wherein: at least one folded fin comprises a slot, and the slot comprises a cutout in the first side and the second side at the angle. 
     Example 56. The method of Example 55, wherein the fluid is configured to flow through the slot. 
     Example 57. The method of any of Examples 52-56, wherein the plurality of fins comprise at least one of copper, aluminum, silver, or gold. 
     Example 58. The method of any of Examples 43-57, wherein the fluid comprises water ethylene glycol or water propylene glycol. 
     Example 59. The method of any of Examples 43-58, wherein the housing comprises at least one of plastic, ceramic, or fiberglass. 
     Example 60. The method of any of Examples 43-59 wherein the plate comprises at least one of copper, aluminum, silver, or gold. 
     The foregoing discussion and examples have been presented for purposes of illustration and description. The foregoing is not intended to limit the aspects, embodiments, or configurations to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the aspects, embodiments, or configurations are grouped together in one or more embodiments, configurations, or aspects for the purpose of streamlining the disclosure. The features of the aspects, embodiments, or configurations may be combined in alternate aspects, embodiments, or configurations other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention that the aspects, embodiments, or configurations require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment, configuration, or aspect. While certain aspects of conventional technology have been discussed to facilitate disclosure of some embodiments of the present invention, the Applicants in no way disclaim these technical aspects, and it is contemplated that the claimed invention may encompass one or more of the conventional technical aspects discussed herein. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate aspect, embodiment, or configuration.