Pump-driven two-phase loop heat dissipation system for overcharge host

Abstract

The invention provides a pump-driven two-phase loop heat dissipation system for an overcharge host. A pump-driven two-phase loop comprises a liquid storage device, an electric ball valve, a filter, a mechanical pump, a heat regenerator, an evaporator and a condenser, and a condenser pipeline where the condenser is located and the liquid storage device form a circulation loop. A heating rod is arranged in the liquid storage device, and a built-in spiral coil pipe introduces a condenser outlet supercooled working medium. The evaporator is in targeted fit with the heating semiconductor element in the charging module. The fan is used for cooling the condenser. According to the pump-driven two-phase loop heat dissipation system for the overcharge host, the heat dissipation requirement for a heat source is met, the heat dissipation efficiency is improved, and meanwhile heat dissipation energy consumption is reduced.

Description

Technical Field

[0001] This invention belongs to the field of equipment heat dissipation, and specifically relates to a pump-driven two-phase circuit heat dissipation system suitable for supercharger hosts. Background Technology

[0002] Supercharging stations have become a key focus of national and local government efforts to build new energy vehicle charging stations.

[0003] However, the increased power of the charging module leads to a surge in heat. Excessive temperature will reduce the reliability of its components or even cause them to fail, affecting the reliable charging of the entire charging system and causing serious safety hazards.

[0004] Traditional air-cooling methods, due to the low thermal conductivity of air, require forced convection cooling to consume more power to increase airflow and enhance heat dissipation, which also generates significant noise. Furthermore, the unsealed design of the charging module makes it susceptible to environmental factors such as dust, salt spray, and smog. This increases the failure rate of internal electronic components, significantly shortening the module's lifespan and reliability, and drastically increasing deployment costs in dusty northern regions and coastal areas. Despite continuous efforts to improve the cooling efficiency of air-cooling systems, it must be acknowledged that these systems are increasingly struggling to handle the ever-increasing thermal loads of the charging modules.

[0005] Single-phase cooling utilizes the sensible heat of the working fluid for heat dissipation, but its temperature uniformity is poor when dealing with multiple heat sources. When the cooling fluid flows through the first half of the cold plate, it heats up. However, as it flows to the second half, the temperature difference between the high-temperature working fluid and the heat-generating element decreases, leading to a reduction in the cold plate's heat dissipation capacity and causing the temperature of the heat-generating element in the second half to be higher than in the first half. Furthermore, compared to pump-driven two-phase technology, single-phase liquid cooling dissipates less heat and has lower efficiency at the same mass flow rate. Therefore, single-phase liquid cooling requires a larger mass flow rate to achieve the same heat dissipation capacity as pump-driven two-phase systems. In addition, if an unsuitable cooling fluid is used, single-phase liquid cooling is prone to scaling, which, if not cleaned promptly, significantly reduces heat dissipation efficiency. As the heat dissipation requirements of superchargers increase, the difficulty of solving the heat dissipation problem for high heat flux density devices becomes increasingly challenging, and the heat dissipation capacity of single-phase cooling is gradually reaching its bottleneck.

[0006] Pump-driven two-phase targeted cooling technology can fully meet the multi-point heat source requirements of supercharger main units. This technology fully utilizes the characteristic that the heat absorption during vaporization is significantly greater than the heat absorption during liquid phase heating, significantly improving the heat dissipation efficiency of liquid cooling through phase change, achieving greater heat dissipation with a relatively small mass flow rate. This allows the use of smaller, more powerful pumps in the pump-driven two-phase system, further enhancing its integration and energy efficiency ratio. Furthermore, due to the extremely low pressure drop of the evaporator in the pump-driven two-phase system, the overall vaporization temperature of the evaporator section remains essentially constant during the working fluid's vaporization. This ensures good temperature uniformity even when dealing with multiple heat sources. Especially for foamed metal evaporators, the temperature change of the bottom plate is minimal. Since the pump-driven two-phase system eliminates the need for duct ventilation, it allows for the sealing of the main unit, improving its safety protection level, extending the lifespan of DC fast charging stations in harsh environments such as dusty areas and coastal regions, and reducing maintenance costs. Furthermore, the use of R1233zd(E) working fluid in this system eliminates the disadvantage of single-phase liquid cooling, which requires periodic descaling due to unavoidable impurities in the coolant. Summary of the Invention

[0007] This invention provides a pump-driven two-phase circuit heat dissipation system for a supercharger host. This system can dissipate heat from the main heat-generating components of the charging module, effectively solving the problem of poor temperature control for multiple heat sources. It also uses foamed copper metal to make an evaporator with four microchannels, utilizing the phase change of the working fluid within the microchannels to absorb heat, significantly improving heat dissipation power and reducing the noise of the charging host fan.

[0008] To achieve the above objectives, the technical solution of the present invention is as follows:

[0009] A pump-driven two-phase circuit cooling system for an overcharger host includes a liquid receiver 1-6, an electric ball valve 1-3, a filter 1-7, a mechanical pump 1-1, a regenerator 1-2, an evaporator 1-4, and a condenser 1-5. The condenser 1-5 piping and the liquid receiver 1-6 form a circulation loop. A heating rod 3-1 is installed inside the liquid receiver 1-6, and a built-in spiral coil 3-2 introduces the subcooled working fluid from the outlet of the condenser 1-5. The evaporator 1-4 is specifically designed to align with the heat-generating semiconductor components inside the charging module. A fan is used to dissipate heat from the condenser 1-5.

[0010] Preferably, a heating rod 3-1 is installed inside the liquid receiver 1-6 to heat the internal working fluid, keep the temperature at the set point, maintain the system pressure, and stabilize the saturation temperature of the working fluid; a built-in spiral coil 3-2 is installed to introduce the subcooled working fluid from the outlet of the condenser 1-5. When the temperature of the liquid receiver 1-6 is too high, the electric ball valve 1-3 is opened to cool the liquid receiver 1-5 using the subcooled working fluid from the outlet of the condenser 1-5.

[0011] Preferably, the circuit is equipped with a regenerator 1-5, which uses the two-phase working fluid at the outlet of the evaporator 1-4 to preheat the liquid working fluid flowing out of the mechanical pump 1-1, so that the working fluid entering the evaporator 1-4 is close to the saturation temperature.

[0012] Preferably, the evaporator 1-4 pipes are connected in parallel in ten ways, and four evaporators 1-4 are connected in series in each parallel pipe.

[0013] Preferably, the evaporator 1-4 is targeted and bonded to the heat-generating semiconductor element inside the charging module, and a highly thermally conductive material is used to connect the evaporator 1-4 and the heat-generating semiconductor element.

[0014] Preferably, the working fluid undergoes phase change and absorbs heat within the microchannels 1-14 of the evaporator, resulting in a large latent heat of phase change.

[0015] Preferably, the microchannels of the evaporator 1-4 are provided with a gas phase guiding structure 2-1, and each gas phase guiding structure 2-1 is 108mm long, 0.35mm wide, and 0.35mm high.

[0016] Preferably, the microchannels of evaporators 1-4 are made of copper foam, and the pressure drop of evaporators 1-4 satisfies the formula:

[0017]

[0018]

[0019] Where: μ f denoted as Darcy velocity, i.e., seepage velocity; v is the fluid velocity in the evaporator; ∈ is the porosity of the porous copper foam; Δp is the pressure drop of the working fluid before and after passing through the porous copper foam evaporator; L is the length of the porous medium along the flow direction; μ is the dynamic viscosity of the working fluid; K is the permeability of the porous copper foam; ρ is the density of the working fluid; C is the inertia coefficient, characterizing the blockage of the fluid by the complex internal structure of the porous medium.

[0020] Preferably, the liquid reservoir 1-6, mechanical pump 1-1, and regenerator 1-2 are located at the bottom of the supercharger, and the condenser 1-5 and fan are in close contact with the outer surface of the supercharger.

[0021] Compared with the prior art, the present invention has the following advantages.

[0022] 1) This invention provides a pump-driven two-phase circuit heat dissipation system for a supercharger host. Based on the pump-driven two-phase principle, a mechanical pump 1-1 drives a two-phase fluid, utilizes phase change to absorb heat, reduces the amount of working fluid, and lowers the pump power. The system uses a regenerator 1-2 to preheat the working fluid, eliminating the need for active components such as preheaters and reducing additional power consumption. While meeting the heat source heat dissipation requirements, it also reduces heat dissipation energy consumption.

[0023] 2) The evaporator 1-4 of this invention uses foamed copper material, and the evaporator 1-4 is targeted and attached to the heating component to solve the problem of heat dissipation from multiple heat sources in complex spaces; based on the pump-driven two-phase principle, the mechanical pump 1-1 drives the two-phase fluid, and the heat exchange capacity is improved by utilizing the phase change of the working fluid to absorb heat.

[0024] The present invention reduces the heat dissipation environment and effectively lowers the heat dissipation temperature difference by using only the contact thermal resistance generated by the heat-conducting material and the overall heat transfer thermal resistance of the evaporator 1-4 between the heating semiconductor element of the charging module and the external cold source. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the pump-driven two-phase circuit heat dissipation system for a supercharger according to the present invention.

[0026] Figure 2 This is a schematic diagram of the gas phase guiding structure in the evaporator of the present invention.

[0027] Figure 3 This is a schematic diagram of the internal structure of the liquid reservoir in this invention.

[0028] The numbers in the diagram are: 1-1-Mechanical pump; 1-2-Regenerator; 1-3-Electric ball valve; 1-4-Evaporator; 1-15-Condenser; 1-6-Receiving tank; 1-7-Filter. Detailed Implementation

[0029] The specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0030] In the description of this invention, the terms "inner," "outer," "upper," "lower," "front," "rear," "left," and "right," etc., which indicate orientation or positional relationship, are based on the position or orientation relationship shown in the accompanying drawings. They do not indicate or imply a specific installation and operation orientation that the described device or element must have, and therefore should not be construed as a limitation of this invention.

[0031] It should be noted that in the description of this invention, the terms "set," "install," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. Furthermore, the terms "a," "two," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features.

[0032] like Figure 1As shown, the present invention—a pump-driven two-phase circuit cooling system for a supercharger—comprises a mechanical pump 1-1, a regenerator 1-12, an electric ball valve 1-3, an evaporator 1-4, a condenser 1-5, a liquid receiver 1-6, and a filter 1-7. The mechanical pump 1-1, regenerator 1-2, condenser 1-5, liquid receiver 1-6, and filter 1-17 are installed at the bottom of the supercharger.

[0033] As an optional implementation, the inlet of mechanical pump 1-1 is connected to the outlet of filter 1-7, and the outlet of mechanical pump 1-1 is connected to the cold source inlet of regenerator 1-2. Mechanical pump 1-1 is installed at the bottom of the supercharger.

[0034] As an optional implementation, the cold source inlet of the regenerator 1-2 is connected to the outlet of the mechanical pump 1-1, and the cold source outlet of the regenerator 1-2 is connected to the inlet of the electric ball valve 1-3 at the inlet of each parallel circuit; the heat source inlet of the regenerator 1-2 is connected to the outlet of the electric ball valve 1-3 at the outlet of each parallel circuit, and the heat source outlet of the regenerator 1-2 is connected to the inlet of the condenser 1-5. The regenerator 1-2 is installed at the bottom of the supercharger.

[0035] As an optional implementation, the inlet of condenser 1-5 is connected to the heat source outlet of regenerator 1-2, the outlet of regenerator 1-2 is connected to liquid receiver 1-6, and condenser 1-5 is installed on the outside of the supercharger.

[0036] As an optional implementation, the liquid reservoir 1-6 is connected to the outlet of the condenser 1-5 and the inlet of the filter 1-7, and the liquid reservoir 1-6 is installed at the bottom of the supercharger.

[0037] As an optional implementation, the inlet of filter 1-7 is connected to reservoir 1-6, and the outlet of filter 1-7 is connected to the inlet of mechanical pump 1-1. The filter is installed on the loop pipe between reservoir 1-6 and mechanical pump 1-1.

[0038] As an optional implementation, evaporators 1-4 are installed in series in groups of four within a charging module. The supercharger has ten charging modules connected in parallel, resulting in ten units consisting of four evaporators 1-4 connected in series. The evaporator's inlet is connected to the outlet of the electric ball valve 1-3 at the inlet of each parallel circuit, and its outlet is connected to the inlet of the electric ball valve 1-3 at the outlet of each parallel circuit. The evaporators 1-4 are installed inside the charging module at the top of the supercharger.

[0039] The liquid working fluid R1233zd enters the regenerator 1-12 under the drive of mechanical pump 1-11. Simultaneously, the two-phase working fluid R1233zd after flowing through each branch evaporator 1-4 flows into the heat source inlet of the regenerator 1-2. After entering the shell, the two-phase working fluid R1233zd is laterally flushed by the tube bundle under the guidance of the baffles, which greatly improves the convective heat transfer coefficient of the shell side.

[0040] After being heated by the regenerator 1-2, the R1233zd working fluid has reached approximately its phase change temperature. The electric ball valve 1-3 at the inlet of the parallel pipeline is only opened when the supercharger module is running to reduce the flow of working fluid to the charging module, which has no heat dissipation requirements, thus lowering energy consumption. After entering the evaporator through the electric ball valve 1-3, the working fluid is heated and vaporized by the evaporator 1-4, undergoing a phase change and absorbing a large amount of heat to reduce the temperature of the cold plate, achieving temperature control. The evaporator 1-4 cover plate features an innovative design with gas-phase microchannels 2-1. When gaseous working fluid is generated, it rises into these microchannels 2-1, separating it from the liquid working fluid and allowing it to flow separately. This effectively prevents the accumulation of gaseous working fluid, which can cause the flow channels to dry out and reduce heat transfer capacity. It also improves flow velocity uniformity by 40%, increasing the overall heat exchange capacity of the evaporator.

[0041] The two-phase working fluid R1233zd re-enters the regenerator 1-2 and transfers its heat to the subcooled liquid working fluid through heat exchange. This reduces the subcooling of the liquid working fluid and the dryness of the two-phase working fluid, which can reduce the power consumption of the condenser 1-5 and save energy.

[0042] After the two-phase working fluid R1233zd enters the condenser 1-5, it is condensed into a liquid working fluid through forced air convection heat exchange.

[0043] Any remaining R1233zd gaseous working fluid in the condensed liquid working fluid is intercepted as it flows through filters 1-7. This prevents it from entering mechanical pumps 1-11, inducing cavitation, and damaging the pump body.

[0044] The liquid receiver 1-6 serves to store, supply, stabilize pressure, and separate the R1233zd working fluid in the system. For the R1233zd gaseous working fluid, saturation temperature and pressure are linearly related, and the system pressure can be controlled by adjusting the temperature of the saturated working fluid. In this invention, the liquid receiver 1-6 uses an internal spiral coil 3-2 structure to introduce subcooled working fluid from the outlet of the condenser 1-5 for heat exchange and cooling, reducing refrigeration power consumption. If the dryness increases due to an increase in heat source power, thus raising the temperature of the gaseous working fluid inside the liquid receiver 1-6, the heating rod 3-1 is closed, and the opening of the spiral coil valve is increased until it returns to the set value; if the temperature is too low due to a decrease in heat source power, the spiral coil valve is closed, and the power of the heating rod 3-1 is increased until it returns to the set value to regulate the temperature of the liquid receiver 1-6.

[0045] In summary, the innovative aspects of this product are as follows:

[0046] 1) This technology applies the pump-driven two-phase system from the aerospace thermal control field to civilian applications. Based on the principle of pump-driven two-phase operation, a mechanical pump drives a two-phase fluid, utilizing the heat absorption of the working fluid through phase change, thus greatly improving heat exchange capacity. This solves the existing problems of poor thermal control capability, high heat dissipation energy consumption, and slow system response speed in supercharger host heat dissipation technology.

[0047] 2) The innovative design of the supercharging pile thermal control system results in low heat dissipation energy consumption. Based on the pump-driven two-phase principle, mechanical pump 1-1 drives the two-phase fluid, utilizing phase change heat absorption to reduce the amount of working fluid and lower pump power. The system uses a regenerator 1-2 to preheat the working fluid, eliminating the need for active components such as preheaters and reducing additional power consumption. Although the present invention has been disclosed above with preferred embodiments, the present invention is not limited thereto. Any person skilled in the art can make various modifications and alterations without departing from the spirit and scope of the present invention; therefore, the scope of protection of the present invention should be determined by the scope defined in the claims.

Claims

1. A pump-driven two-phase circuit cooling system for an overcharger, wherein the pump-driven two-phase circuit includes a liquid receiver 1-6, an electric ball valve 1-3, a filter 1-7, a mechanical pump 1-1, a regenerator 1-2, an evaporator 1-4, and a condenser 1-5, wherein the condenser piping containing the condenser forms a circulation loop with the liquid receiver. A heating rod 3-1 is installed inside the liquid receiver, and a built-in spiral coil 3-2 introduces the subcooled working fluid from the condenser outlet. A fan is used for condenser cooling.

2. The pump-driven two-phase circuit heat dissipation system as described in claim 1, characterized in that, A heating rod 3-1 is installed inside the liquid receiver 1-6 to heat the internal working fluid, keep the temperature at the set point, maintain the system pressure, and stabilize the saturation temperature of the working fluid; a built-in spiral coil 3-2 introduces the subcooled working fluid from the outlet of the condenser 1-5. When the temperature of the liquid receiver 1-6 is too high, the electric ball valve 1-3 is opened to cool it using the subcooled working fluid from the outlet of the condenser 1-5.

3. The pump-driven two-phase circuit heat dissipation system as described in claim 1, characterized in that, The regenerator 1-2 is fed with a two-phase working fluid from the outlet of the evaporator 1-4 to preheat the liquid working fluid pumped from 1-1 by the mechanical pump, so that the working fluid entering the evaporator 1-4 is close to the saturation temperature.

4. The pump-driven two-phase circuit heat dissipation system as described in claim 1, characterized in that, The evaporator 1-4 pipes are connected in parallel in ten ways, and four evaporators 1-4 are connected in series in each parallel pipe.

5. The evaporator 1-4 as described in claim 4, characterized in that, Evaporator 1-4 is targeted and bonded to the heat-generating semiconductor element inside the charging module, and a high thermal conductivity material is used to connect evaporator 1-4 and the heat-generating semiconductor element.

6. The evaporators 1-4 as described in claim 4, characterized in that, The evaporator 1-4 microchannels have gas phase guiding structures. Each gas phase guiding structure 2-1 is 108mm long, 0.35mm wide, and 0.35mm high.

7. The evaporators 1-4 as described in claim 4, characterized in that, The evaporator's 1-4 microchannels are made of foamed copper material.

8. The pump-driven two-phase circuit heat dissipation system as described in claim 1, characterized in that, The liquid storage tank 1-6, mechanical pump 1-1, and regenerator 1-2 are located at the bottom of the supercharger, and the condenser 1-5 and fan are in close contact with the outer surface of the supercharger.

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