I am a member of University of British Columbia's Electric Car Club. We recently drove our electric beetle 6400km from Vancouver to Halifax across Canada in 14 days.
After we climbed over the rockies and drove hours and hours at highway speed without over heating. A few local EV enthusiast here in Vancouver asked us to sell them the same water-cooling system we had in our vehicle for the Curtis 1238 motor controller.
The reliability of semi-conductor is exponentially correlated with it's operating temperature. Which means the cooler you can run your controller, the more reliable it will be.
This water-block was designed by a master student in mechanical engineering with the goal of maximizing efficiency and minimizing pressure drop.
The Waterblock is cut from a solid block of aluminum on a CNC, so economics of scale is a big factor when it comes to manufacturing a small amount of these. The more we can make this, the less it will cost per unit. If anyone is interested in joining in on a group buy, please e-mail me at email@example.com
I've attached a couple images of the waterblock we installed in our vehicle, one is bare aluminum, one is finished in anodized black.
for more info on our trip across Canada, see link: