Industrial rectifier module with enhanced chemical resistance and dielectric immersion cooling

Abstract

The chemical resistance-enhanced dielectric liquid immersion cooling industrial rectifier module according to the present invention comprises an industrial rectifier module including a rectifier circuit that outputs a DC voltage with a three-phase AC voltage as input, wherein the rectifier circuit is housed in a sealed case in a state where it is completely immersed in a dielectric liquid; wherein the case is formed of an aluminum alloy and has a fluorine resin coating layer (PVDF or PTFE) formed on its outer surface, and the case is provided with a cooling water channel formed by physically separating a first space filled with the dielectric liquid and a second space through which cooling water flows, and a double sealing structure consisting of a first seal and a second seal made of fluororubber material is formed between the first space and the second space, and an isolation space is formed between the first seal and the second seal, wherein heat dissipation fins are formed on the outer surface of the case, and the case is supported by a mounting structure equipped with a vibration damper.

Description

Technology Field

[0001] The present invention relates to an industrial power supply device, and more particularly to an industrial rectifier module combining a dielectric immersion cooling structure and a chemical-resistant protection structure, applicable to AC-DC rectifiers used in corrosive chemical environments such as semiconductor processes, electroplating, and electrolysis facilities. Background Technology

[0003] Unlike general electronic equipment, industrial rectifiers used in semiconductor processes, electroplating, electrolysis, and chemical facilities operate in harsh environments where chemical, thermal, and mechanical stresses act simultaneously. In these industrial environments, hydrogen fluoride (HF), chlorine (Cl2), and ammonia (NH3) are present. 4) Strong acidic or oxidizing chemicals such as sulfuric acid (H2SO4) are always present in the form of gas, droplets, or mist, and these substances have the characteristic of rapidly degrading power elements and insulation structures when they penetrate into the equipment.

[0004] Furthermore, industrial rectifiers typically operate continuously for extended periods at near-rated loads, resulting in significant internal heat generation; simultaneously, they are exposed to continuous vibration and shock originating from pumps, agitators, compressors, and large-scale power equipment. In such complex environments, structural design is required that considers not only simple thermal management but also chemical erosion and mechanical fatigue.

[0005] Conventional industrial rectifiers primarily employ air-cooled or water-cooled cooling structures; however, air-cooled structures utilize direct external air intake for cooling, which allows corrosive gases and fine particles to enter the interior, causing insulation breakdown, contact degradation, and short circuits in electronic components. While water-cooled structures can improve cooling efficiency, they face limitations in ensuring long-term reliability due to the difficulty of completely isolating the system from the external environment.

[0006] Meanwhile, even when a sealed case is used, a so-called "breathing" phenomenon occurs in which external air is repeatedly drawn in due to pressure changes caused by the rise in internal temperature. During this process, corrosive gases and moisture penetrate into the interior through tiny gaps or sealing areas. Additionally, because air has low thermal conductivity, heat generated inside the sealed interior is not effectively transferred to the outside, leading to localized overheating (hot spots) that degrade the reliability of power devices.

[0007] Recently, immersion cooling technology, which involves submerging electronic components in dielectric liquid, has been proposed as a method to improve heat transfer performance; however, this technology is primarily based on relatively clean environments such as data centers and fails to adequately consider issues arising in industrial environments, such as case corrosion caused by external chemicals, seal degradation, contamination ingress through ports and fasteners, and structural damage caused by vibration. In particular, in immersion cooling structures, even if the interior is protected, chemical damage to the outer surface of the case or sealing areas can lead to the collapse of the entire system.

[0008] In addition, due to the presence of fluid inside the immersion structure, unique phenomena such as liquid sloshing, cavitation, and increased dynamic load occur during vibration, which can lead to fatigue failure of seals, degradation of solder joints in power devices, and cooling imbalance. Therefore, for industrial rectifiers, the application of simple immersion cooling alone is insufficient, and it is necessary to design a chemical protection structure, a mechanical stability structure, and a cooling structure in an integrated manner.

[0009] Ultimately, conventional technology fails to provide an integrated solution that simultaneously considers the chemical corrosion, high-temperature, and vibration environments faced by industrial rectifiers, and consequently, there are limitations in ensuring long-term reliability and safety. Prior art literature

[0011] Published Patent No. 10-2025-0024896 Cooling System for Immersion Cooling of Electronic Components Published Patent No. 10-2025-0043134 Battery Module Cooling Structure U.S. Registered Patent No. 4,739,204 U.S. Published Patent No. 2019 / 0260102 The problem to be solved

[0012] The main objective of this invention is to solve the problems of insulation breakdown, short circuits, and component degradation caused by the influx of external contaminants in rectifiers used in industrial environments where corrosive chemicals are present. In particular, it aims to fundamentally prevent the problem of corrosive gases penetrating into the interior due to breathing phenomena caused by pressure changes that occur even in sealed structures.

[0013] In addition, the objective is to provide a cooling structure that effectively removes heat generated during continuous high-load operation while simultaneously solving the problem of contamination ingress in air-cooled structures and the problem of heat accumulation in simple sealed structures.

[0014] In addition, the purpose is to prevent case corrosion, seal deterioration, and fluid mixing problems that may occur in an immersion cooling structure, and to ensure electrical safety by structurally separating the dielectric liquid and the cooling water.

[0015] Furthermore, the objective is to provide a reliability-enhancing structure that suppresses fluid oscillations and structural fatigue problems caused by vibrations in industrial sites, and can detect and respond to seal damage or chemical penetration at an early stage.

[0016] Ultimately, the objective of the present invention is to improve the long-term reliability and safety of industrial rectifiers by integrally securing chemical protection, thermal management, and structural stability.

[0017] The problems solved by the present invention are not limited to those mentioned above, and other problems not mentioned will be clearly understood by those skilled in the art from the description below. means of solving the problem

[0019] The present invention provides an industrial rectifier module comprising an AC-DC rectifier circuit that takes a three-phase AC voltage as input and outputs a variable DC voltage, which is immersed in a dielectric liquid, and a chemical-resistant sealed case that accommodates the rectifier circuit. The case includes a sealing structure for maintaining internal airtightness, and the sealing structure may be formed as a structure including a single seal or a plurality of seals. A heat dissipation structure is formed on the outer surface of the case, and the heat dissipation structure may be implemented in a form including heat dissipation fins.

[0020] The above case is formed of an aluminum alloy, and an acid-resistant coating layer of PVDF or PTFE is applied to the outer surface to ensure durability against corrosive chemicals. In addition, heat dissipation fins are formed on the outer surface of the case, and a cooling water channel physically separated from the dielectric space is embedded in the bottom of the case, forming a thermal management structure that combines natural convection cooling and water cooling.

[0021] In addition, a double sealing structure including a first seal and a second seal made of fluororubber (Viton) is applied between the dielectric space and the cooling water channel, and an isolation space is formed between the two seals, and a chemical detection sensor is placed in the space to detect leakage or contamination ingress at an early stage.

[0022] In addition, the module mounting bracket is configured to have an integrated vibration damper to reduce fluid oscillation and structural fatigue caused by vibrations occurring in industrial sites.

[0023] In addition, the control unit is configured to selectively switch between a natural convection cooling mode and a water cooling mode based on the temperature and load rate of the power element and data from the sensor, thereby ensuring both thermal stability and operational efficiency.

[0024] As such, the present invention is configured to ensure the durability and reliability required in industrial environments by integrally combining a dielectric immersion structure, a chemical-resistant case, a double sealing and sensing structure, a hybrid cooling structure, and a vibration-resistant structure.

[0025] The chemical resistance-enhanced dielectric liquid immersion cooling industrial rectifier module according to the present invention comprises an industrial rectifier module including a rectifier circuit that outputs a DC voltage with a three-phase AC voltage as input, wherein the rectifier circuit is housed in a sealed case in a state where it is completely immersed in a dielectric liquid; wherein the case is formed of an aluminum alloy and has a fluorine resin coating layer (PVDF or PTFE) formed on its outer surface, and the case is provided with a cooling water channel formed by physically separating a first space filled with the dielectric liquid and a second space through which cooling water flows, and a double sealing structure consisting of a first seal and a second seal made of fluororubber material is formed between the first space and the second space, and an isolation space is formed between the first seal and the second seal, wherein heat dissipation fins are formed on the outer surface of the case, and the case is supported by a mounting structure equipped with a vibration damper.

[0026] Preferably, the isolation space is characterized by having a sensor placed therein to detect leakage of chemicals or inflow of contamination.

[0027] Preferably, the cooling water channel is formed in the lower part of the case and is configured to allow heat transfer by natural convection and forced circulation cooling to occur simultaneously.

[0028] Preferably, the heat dissipation fins on the outer surface of the case are formed in a plurality of parallel arrangement structures to increase the heat exchange area with external air.

[0029] Preferably, the vibration damper is characterized by being formed as a composite structure combining an elastic body and a metal support to dampen vibration energy.

[0030] Preferably, the industrial rectifier module is characterized by being configured to selectively switch between a natural convection cooling state and a cooling water circulation state based on the temperature and load rate of the rectifier circuit.

[0031] Preferably, the dielectric liquid is characterized by being composed of a synthetic insulating oil that simultaneously satisfies insulating properties and thermal conductivity properties.

[0032] Preferably, the sealing structure of the case is characterized by being formed as an airtight structure to block the inflow of external air and suppress breathing phenomena caused by changes in internal pressure. Effects of the invention

[0034] According to the present invention, by applying a dielectric immersion structure and a chemical-resistant sealed case, the inflow of corrosive gases and chemical mist into the interior is fundamentally blocked, thereby preventing insulation breakdown and degradation of power devices and improving long-term reliability.

[0035] In addition, the hybrid cooling structure, which combines heat dissipation fins formed on the outer surface of the case with a lower cooling water channel, allows for the effective dissipation of internal heat to the outside, enabling stable thermal management even under high-load continuous operation conditions.

[0036] In addition, by applying a PVDF or PTFE coating layer and a fluororubber-based double sealing structure, problems such as case corrosion, seal deterioration, and fluid mixing can be prevented, and structural integrity can be maintained even in chemically harsh environments.

[0037] In addition, a chemical detection sensor placed in the isolation space between the double seals can detect leakage and contamination ingress at an early stage, providing a predictive maintenance function that enables response before a failure occurs.

[0038] Furthermore, by reducing fluid turbulence and structural fatigue caused by vibration in industrial sites through a mounting structure in which a vibration damper is integrated, the unique failure modes occurring in immersion cooling structures can be effectively suppressed.

[0039] Ultimately, the present invention has the effect of simultaneously improving the safety, reliability, and operational efficiency of industrial rectifiers by integrally securing chemical protection, thermal management, and mechanical stability.

[0040] The effects of the present invention are not limited to those mentioned above, and other unmentioned problems will be clearly understood by those skilled in the art from the description below. Brief explanation of the drawing

[0042] FIG. 1 is a schematic diagram of the exterior of a module according to an embodiment of the present invention. FIG. 2 is a cross-sectional view of a chemical-resistant case according to an embodiment of the present invention. FIG. 3 is a structural diagram of a vibration damper according to an embodiment of the present invention. FIG. 4 is a block diagram of a rectifier circuit according to an embodiment of the present invention. FIG. 5 is a platform common structure diagram according to an embodiment of the present invention. Specific details for implementing the invention

[0043] Further objects, features, and advantages of the present invention can be more clearly understood from the following detailed description and the accompanying drawings.

[0044] Before providing a detailed description of the present invention, it should be understood that the present invention is capable of various modifications and may have various embodiments, and that the examples described below and illustrated in the drawings are not intended to limit the present invention to specific embodiments, but rather include all modifications, equivalents, and substitutions that fall within the spirit and scope of the present invention.

[0045] When it is stated that one component is "connected" or "connected" to another component, it should be understood that while it may be directly connected or connected to that other component, there may also be other components in between. On the other hand, when it is stated that one component is "directly connected" or "directly connected" to another component, it should be understood that there are no other components in between.

[0046] The terms used in this specification are used merely to describe specific embodiments and are not intended to limit the invention. Singular expressions include plural expressions unless the context clearly indicates otherwise. In this specification, terms such as "comprising" or "having" are intended to indicate the existence of the features, numbers, steps, actions, components, parts, or combinations thereof described in the specification, and should be understood as not precluding the existence or addition of one or more other features, numbers, steps, actions, components, parts, or combinations thereof.

[0047] Furthermore, in the description referring to the attached drawings, identical components are assigned the same reference numeral regardless of drawing symbols, and redundant descriptions thereof are omitted. In describing the present invention, if it is determined that a detailed description of related prior art could unnecessarily obscure the essence of the present invention, such detailed description is omitted.

[0048] FIG. 1 is a perspective view showing the external configuration of a chemically resistant dielectric immersion cooling industrial rectifier module according to one embodiment of the present invention.

[0049] As illustrated in FIG. 1, the rectifier module according to the present invention comprises an input / output cable terminal block (110), a lower built-in cooling channel (120), a bracket-integrated vibration damper (130), a case outer surface heat dissipation fin structure (140), and a chemical-resistant sealed case (150).

[0050] The chemical-resistant sealed case (150) is configured to form a space filled with dielectric liquid inside to block the rectification circuit from the external corrosive environment, and to ensure chemical durability by applying an acid-resistant coating layer to an aluminum alloy-based structure.

[0051] The above-mentioned case outer surface heat dissipation fin structure (140) is formed integrally with the case outer wall to release internal heat to the outside by natural convection, and works together with the above-mentioned lower internal cooling channel (120) to form a hybrid cooling structure.

[0052] The above lower internal cooling channel (120) is formed in the lower part of the case and configured to allow cooling water to flow in and out, and performs heat exchange while physically separated from the internal dielectric liquid to simultaneously ensure electrical safety and cooling efficiency.

[0053] The above input / output cable terminal block (110) is configured to perform electrical connection with an external power source and load, and is designed to enable stable power transmission while maintaining a sealed structure.

[0054] In addition, the above-mentioned bracket integrated vibration damper (130) is provided at the bottom of the module to absorb and dampen vibrations transmitted from the equipment, and is configured to reduce fluid oscillations and mechanical fatigue of internal parts that may occur in the immersion structure.

[0055] Accordingly, the present invention has a structure that simultaneously implements external chemical environment blocking, efficient heat dissipation, and vibration suppression, and can secure long-term reliability and stability required in industrial environments.

[0057] FIG. 2 is a cross-sectional view showing the internal structure of the chemical-resistant sealed case of the present invention.

[0058] As shown in FIG. 2, a case (220) formed of aluminum alloy forms a dielectric liquid immersion space (230) filled with dielectric liquid inside, and a power conversion element is disposed within the space (230).

[0059] A heat dissipation fin (221) is formed on the outer surface of the above case (220) to release heat to the outside by natural convection, and an acid-resistant coating layer (PVDF or PTFE, not shown) is formed on the outer surface of the case to protect the case from corrosive chemicals such as HF, Cl2, NH2, H2SO4.

[0060] In addition, a first seal (240), an isolation space (250), and a second seal (260) are sequentially arranged between the above-mentioned dielectric liquid immersion space (230) and the cooling water channel (270) to form a double sealing structure.

[0061] The first seal (240) and the second seal (260) are made of fluorocarbon rubber (Viton, fluorocarbon rubber) and have excellent chemical resistance to corrosive gases and low gas permeability, so they can stably maintain airtightness for a long period of time.

[0062] A chemical detection sensor (not shown) is placed in the above isolation space (250) and configured to detect chemical substances entering due to damage to the first seal (240) or gas permeation at an early stage.

[0063] Accordingly, a multi-protection structure is formed in which primary blocking by the first seal (240), detection and inflow delay in the isolation space (250), and final blocking by the second seal (260) are performed in stages, and contamination of the dielectric liquid and mixing with the cooling water can be effectively prevented.

[0064] In particular, the above structure has the effect of preventing internal insulation breakdown and electrical accidents and improving system reliability by providing a predictive maintenance function capable of detecting and responding to the inflow of chemicals at an early stage.

[0065] Meanwhile, the cooling water channel (270) is formed in the lower part of the case and is physically separated from the dielectric liquid immersion space (230) to ensure electrical safety while enabling efficient heat exchange.

[0066] In addition, a mounting bracket (280) with an integrated vibration damper is provided at the bottom of the case to reduce the transmission of vibrations occurring in an industrial environment to the case and internal structure, and to suppress the agitation of the dielectric liquid and seal fatigue failure.

[0068] FIG. 3 is a schematic diagram showing a vibration damper integrated mounting structure according to one embodiment of the present invention.

[0069] As shown in FIG. 3, the mounting structure of the present invention comprises a vibration damper mounting bracket (310), a bracket reinforcing member (320), a rectifier fixing hole (330), a vibration damper bracket cover (340), and a vibration damper (350).

[0070] The above vibration damper mounting bracket (310) forms a basic structure for supporting and fixing the rectifier module to the equipment, and the bracket reinforcing member (320) is configured to improve the rigidity of the bracket to stably support the weight increase and dynamic load due to the liquid immersion structure.

[0071] The above rectifier fixing hole (330) is a fastening part for connecting the rectifier module and the bracket, and is positioned so that the load is evenly distributed.

[0072] In addition, the vibration damper (350) is configured to be interposed between the bracket and the equipment to absorb and dampen vibrations and shocks transmitted from the outside, and can be formed in a metal spring type or rubber cushion type structure.

[0073] The above vibration damper bracket cover (340) is configured to protect the vibration damper (350) from the external environment and at the same time maintain structural connection.

[0074] The above vibration damper (350) is designed to satisfy the sinusoidal vibration conditions required by the IEC 60068-2-6 standard and effectively reduces the transmission of continuous vibrations occurring in industrial sites to the case and internal power elements.

[0075] In particular, the present invention has the effect of suppressing fatigue failure of the sealing area and mechanical deterioration of the power element by integrating the vibration damper (350) into the bracket structure, taking into account specific problems such as liquid sloshing, microbubble formation, and increased dynamic load caused by the structure filled with dielectric liquid.

[0076] Accordingly, the present invention enables stable operation not only in chemical environments but also in mechanical vibration environments, thereby improving the long-term reliability of industrial rectifiers.

[0078] Figure 4 is a diagram showing the block configuration of the AC-DC rectifier circuit of the present invention.

[0079] As shown in FIG. 4, the rectifier circuit of the present invention is configured to include a three-phase AC input section (410), an EMI filter and input protection circuit (420), a three-phase full-bridge rectifier section (430), and an output voltage adjustment section.

[0080] The above 3-phase AC input section (410) receives AC power of 380V to 440V, and the above EMI filter and input protection circuit (420) remove external noise and protect the circuit.

[0081] The above three-phase full-bridge rectifier (430) is configured with a SiC diode or IGBT-based active rectifier to convert AC power into DC.

[0082] Subsequently, a variable DC voltage ranging from 12V to 750V is generated through the output voltage adjustment unit and supplied to industrial loads.

[0084] FIG. 5 is a conceptual diagram showing the common structure between the industrial rectifier module of the present invention and a conventional power conversion platform.

[0085] As illustrated in FIG. 5, the present invention comprises an AC-DC rectifier circuit (510), a Viton material sealing (520), a common use case (530), and a mounting bracket vibration damper (540).

[0086] The above AC-DC rectifier circuit (510) is configured to maintain verified power conversion performance and control stability by utilizing the circuit structure used in existing power conversion platforms.

[0087] The above common use case (530) is based on the case structure of an existing platform, but is configured to have an additional PVDF or PTFE-based coating layer applied to the outer surface to respond to a chemical-resistant environment.

[0088] In addition, the above Viton material sealing (520) is applied as a replacement for the existing general sealing structure and maintains airtightness even in a corrosive gas environment, thereby preventing contamination and leakage of the dielectric liquid.

[0089] In addition, the above-mentioned mounting bracket vibration damper (540) is a structure added to respond to increased mass and industrial equipment vibration in a liquid immersion structure, and is configured to reduce the transmission of external vibration to the case and internal circuit.

[0090] That is, the present invention is reconfigured into an industrial rectifier that responds to chemical and mechanical environments by utilizing the power conversion circuit (510) and case structure (530) of the existing platform in common, while additionally applying a Viton-based sealing structure (520) and a vibration-responsive mounting structure (540).

[0091] Accordingly, rather than a simple circuit change or conversion of use, it has a system structure in which the case, sealing, and mounting structures are integrally redesigned, and it has the effect of reducing development costs while simultaneously ensuring the reliability and durability required in industrial environments.

[0093] The embodiments described in this specification and the accompanying drawings are merely illustrative of a part of the technical concept included in the present invention. Accordingly, since the embodiments disclosed in this specification are intended to explain, not limit, the technical concept of the present invention, it is obvious that the scope of the technical concept of the present invention is not limited by these embodiments. All variations and specific embodiments that can be easily deduced by a person skilled in the art within the scope of the technical concept included in the specification and drawings of the present invention should be interpreted as being included within the scope of the rights of the present invention. Explanation of the symbols

[0095] 110: Input / Output Cable Terminal Block 120: Lower built-in cooling channel 130 : Bracket-integrated vibration damper 140 : External case heat dissipation fin structure 150 : Chemical-resistant sealed case 220: Aluminum alloy case 221 : Heat sink fin 230 : Genome liquid immersion space 240: 1st Seal 250 : Isolation space 260: Second Seal 270: Coolant Channel 280 : Mounting bracket 310 : Vibration damper mounting bracket 320 : Bracket reinforcement 330: Rectifier fixing hole 340 : Vibration Damper Bracket Cover 350 : Vibration damper 410 : 3-phase AC input section 420: EMI filter and input protection circuit 430: 3-phase full-bridge rectifier 510 : AC-DC rectifier circuit 520 : Viton material sealing 530 : General Use Cases 540 : Mounting bracket vibration damper

Claims

Claim 1 An industrial rectifier module comprising a rectifier circuit that outputs a DC voltage with a three-phase AC voltage as input, wherein the rectifier circuit is housed in a sealed case in a state where it is completely immersed in a dielectric liquid; wherein the case is formed of an aluminum alloy and has a fluorine resin coating layer (PVDF or PTFE) formed on its outer surface, and the case is provided with a cooling water channel formed by physically separating a first space filled with the dielectric liquid and a second space through which cooling water flows, wherein a double sealing structure consisting of a first seal and a second seal made of fluororubber is formed between the first space and the second space, and an isolation space is formed between the first seal and the second seal, wherein heat dissipation fins are formed on the outer surface of the case, and the case is supported by a mounting structure equipped with a vibration damper, wherein the heat dissipation fins on the outer surface of the case are formed in a plurality of parallel arrangement structures to increase the heat exchange area with external air. Claim 2 A chemical-resistant dielectric immersion cooling industrial rectifier module according to claim 1, characterized in that a sensor for detecting chemical leakage or contamination inflow is disposed in the isolation space. Claim 3 A chemical-resistant dielectric immersion cooling industrial rectifier module characterized in that, in paragraph 2, the cooling water channel is formed in the lower part of the case and configured to allow heat transfer by natural convection and forced circulation cooling to occur simultaneously. Claim 4 delete Claim 5 A chemically resistant dielectric immersion cooling industrial rectifier module according to claim 1, characterized in that the vibration damper is formed as a composite structure combining an elastic body and a metal support to dampen vibration energy. Claim 6 A chemical-resistant dielectric immersion cooling industrial rectifier module according to claim 1 or 5, characterized in that the industrial rectifier module is configured to selectively switch between a natural convection cooling state and a cooling water circulation state based on the temperature and load rate of the rectifier circuit. Claim 7 A chemically resistant dielectric immersion cooling industrial rectifier module according to claim 1, characterized in that the dielectric liquid is composed of a synthetic insulating oil that simultaneously satisfies insulation properties and thermal conductivity properties. Claim 8 A chemical-resistant dielectric immersion cooling industrial rectifier module according to claim 3 or 7, characterized in that the sealing structure of the case is formed as an airtight structure to block the inflow of external air and suppress breathing phenomena caused by changes in internal pressure.

Images