Cooling device for cooling electronic components and use thereof

Abstract

In order to effectively cool electronic components (3), in particular power electronics in electric vehicles, the electronic components (3) are arranged on the outside of a first coolant chamber wall (2A) of the cooling device (1). The cooling device (1) has an inner coolant chamber (10) with a compartment array (14) formed by a first fin (13A) and a second fin (13B) transverse to the flow direction (5).

Description

Technical Field

[0001] This invention relates to cooling devices for cooling electronic components and their applications, such as in electric vehicles. It is also applicable to applications where high-power electronic components require liquid cooling, such as wind turbines or solar inverters. Background Technology

[0002] In electric vehicles, the available power for propulsion is regulated in modules containing power converters, switches, and regulators, which are subjected to heating and must be cooled to prevent damage. In particular, during acceleration, electric vehicles (EVs) require power exceeding 100 kW, such as up to 500 kW in popular EV models at the time of this application, and although only a small fraction of this power is converted into heat in the electronic power control system, the heat generated in the electronic system can reach several kilowatts, with a local power density greater than 500 W / cm². 2 This is quite considerable. To give an impression of this power, consider a power density greater than that produced by a kitchen cooking plate. This heat must be effectively removed from the electronics to prevent damage from overheating. Therefore, cooling the electronics is a critical issue in EVs.

[0003] This problem is discussed in detail in US11644253 and the corresponding US2021 / 037678 A1, which disclose cooling modules for power converters. For effective cooling, this disclosure proposes two opposing parallel thermally conductive walls for cooling electronics on the outer side of each wall. A flow field for the coolant is arranged within a volume between the two walls. Each wall has a plurality of parallel fins extending from the respective wall on its inner side to form the flow field. The two sets of fins are combined and arranged to be intertwined, such that a fin from one of the walls is located between two fins from the opposing wall. This fin is shorter than the distance between the walls, such that the flow field causes the coolant to flow between the two fins to one of the walls, then change direction at that wall and continue its flow into the space between an adjacent pair of fins to the opposing wall, where the coolant again changes direction to continue flowing through the coolant volume in a tortuous flow path. The cooling fins are corrugated and form flow channels to provide low pressure drop and high flow rate, which increases the throughput of coolant through the cooling module.

[0004] Although the considerations expressed in US 11644253 appear to be improvements over older prior art, they suffer from the disadvantage of a considerable high pressure drop if the number of fins is high, due to the fact that the coolant changes direction and flows in the opposite direction for each additional fin. Serpentine paths are disclosed in DE102017109890A1, EP1683404B1, US2012 / 0139096 A1, US2021 / 0130002 A1, and US2022 / 0170706 A1. Various alternatives are disclosed in CN105514064A, EP3772096A1, and WO2012 / 153414 A1.

[0005] DE112022002737T5 discloses a cooling unit in which corrugated ribs connect two opposing walls, wherein the corrugated ribs are perforated to allow coolant to flow through them.

[0006] US11293697 discloses a cooling device with a cold plate on which a semiconductor element is disposed. A coolant flow chamber is disposed between the cold plate and an opposing plate arranged parallel to the cold plate. Corrugated ribs extend from the cold plate to the opposing plate and are fastened to both plates. Adjacent corrugated ribs are corrugated in two opposite directions to create an oscillating channel for the flow of coolant, the average motion of which is largely parallel to the cold plate. Although this oscillating motion generates turbulence conducive to cooling, the mixing action is not optimal because only a very small force compresses the coolant against the cold plate, at which point the semiconductor must be cooled. Therefore, there is still potential for improvement to achieve more efficient cooling.

[0007] Despite the various forms of advantages disclosed for the aforementioned systems, there remains a sustained motivation to further improve the cooling modules, and there is still room for improvement and alternative configurations to efficiently cool high-power electronic devices such as inverters and converters in vehicles. Summary of the Invention

[0008] Therefore, the object of the present invention is to provide improvements in the art. In particular, the object is to provide a highly efficient cooling system for electronic devices, suitable for low-cost mass production, especially in relation to electric vehicles. Another object is to provide a cooling device for cooling electronic devices on a thermally conductive support plate, wherein the temperature distribution in the support plate is uniform. This object and further advantages are achieved by the cooling device for cooling electronic components, its use, and its method of operation, as described below.

[0009] In order to clarify the invention described herein in light of the aforementioned prior art, and especially in light of US11644253, it must be understood here, compared to the principles disclosed in US11644253, that the present invention is a remedy for the problem of effective cooling of electronic devices by taking a different approach. By examining the tortuous path of the coolant through the flow channel formed by the corrugated fins in US11644253, it should be understood that the smooth fins forming the flow channel involve reduced turbulence of the coolant, resulting in low pressure drop and high flow velocity, which is the objective of US11644253. However, the result of reduced turbulence is reduced mixing of the coolant within the channel, which in turn implies the risk that the coolant heats up near the cooling fins while remaining relatively cold in the center of the channel, thus underutilizing the coolant's capacity. In the present invention, the solution follows a different approach with increased turbulence and mixing.

[0010] In short, for cooling electronic components, such as power electronics in electric vehicles, these components are positioned on the outer side of the wall of a first coolant chamber in a cooling device. The cooling device has an inner coolant chamber with an array of fins forming chamber walls between multiple compartments, the compartments being transverse to or substantially transverse to the flow direction. For flow through the compartments, the coolant passes through the fins, which generates turbulence within the compartments to better mix the coolant and increase heat absorption.

[0011] Details are explained below.

[0012] The electronic component to be cooled is in thermal contact with the outer side of the thermally conductive first coolant chamber wall. For cooling purposes, the cooling device includes a coolant chamber defined by the inner side of the first coolant chamber wall and the inner side of an opposing second coolant chamber wall. The inner sides of the first and second coolant chamber walls face each other at a certain distance. Typically, for the sake of simplifying manufacturing, the first and second coolant chamber walls are planar and arranged parallel to each other at an interplanar distance. The coolant chamber is further defined by the first and second coolant chamber sidewalls.

[0013] The coolant (e.g., water, optionally containing ethylene glycol) flows through the coolant chamber in an average flow direction from coolant inlet to coolant outlet to cool the first coolant chamber wall, and optionally also to cool the second coolant chamber wall, particularly if the second coolant chamber wall also carries electronic devices on its outer side for cooling.

[0014] The coolant flow from the coolant inlet to the coolant outlet runs along the inner sides of the first coolant chamber wall and the second coolant chamber wall, as well as the first coolant chamber sidewall and the second coolant chamber sidewall, which generally restricts the coolant flow from one end to the opposite end through the coolant chamber.

[0015] The cooling device includes a first array of multiple side-by-side thermally conductive first fins. Each first fin is connected to the inner side of the first coolant chamber wall via a thermally conductive and sealed connection and has a first end extending a first distance from the inner side of the first coolant chamber wall toward the second coolant chamber wall into the coolant chamber. The coolant chamber also includes a second array of multiple side-by-side second fins. Each second fin is sealed to the inner side of the second coolant chamber wall and has a second end extending a second distance from the inner side of the second coolant chamber wall toward the first coolant chamber wall into the coolant chamber. The term "sealed" implies that it is liquid-tight and that no liquid passes through the connection at the respective coolant chamber wall.

[0016] Note that the connection between the fins and the corresponding coolant chamber wall conducts heat from the electronics through the coolant chamber wall and into the coolant. Typically, the coolant is a liquid.

[0017] Optionally, the device has only one coolant chamber wall on which electronic components are disposed, but electronic components may also be disposed on the outer side of a second coolant chamber wall opposite to the device. Since the first coolant chamber wall carries the electronic components, it is made of a thermally conductive material (e.g., metal), just like the first fins, and the first fins are thermally connected to the first coolant chamber wall to remove heat energy from the electronic components by passing through the first coolant chamber wall and through the fins into the coolant. Similar conditions apply if the second coolant chamber wall also carries electronic components that must be cooled. Otherwise, this is not necessary, and the second coolant chamber wall and the second fins do not necessarily need to be made of a thermally conductive material.

[0018] Although the coolant does not move linearly but has turbulence, there is an average flow direction for the coolant to pass through the coolant chamber from the coolant inlet to the coolant outlet to cool the walls of the first coolant chamber.

[0019] For example, the first fin array and the second fin array are paired to form a compartment wall array, each compartment wall separating two adjacent compartments among a plurality of compartments. Optionally, the compartment array is defined by the first coolant chamber wall and the second coolant chamber wall, the first coolant chamber sidewall and the second coolant chamber sidewall, and the first fin and the second fin.

[0020] The fins and the compartments are oriented perpendicular to or nearly perpendicular to the average flow direction. More specifically, each of the first and second fins, and correspondingly the compartments, extends from the sidewall of the first coolant chamber to the sidewall of the second coolant chamber, and is oriented relative to the average flow direction in the range of 70-110 degrees, for example, in the range of 80-100 degrees, or even in the range of 85-95 degrees. During the flow of coolant through the coolant chamber, the coolant must pass through all the first fins, second fins, and compartments.

[0021] The first distance the first fin extends from the first coolant chamber wall and the second distance the second fin extends from the second coolant chamber wall may optionally be the same, but need not be the same. However, the first distance, when measured vertically from the inside of the first coolant chamber wall, and the second distance, when measured vertically from the inside of the second coolant chamber wall, are at least 20%, for example, at least 30%, but less than 100%, of the coolant chamber wall spacing.

[0022] Compared to US 11293697 discussed in the introduction, in this patent, the fins extend from the cold plate to the opposite plate. It should be noted that the principle of the present invention is generally different because the corrugations are vertical in the present invention, unlike the disclosure in US 11293697. In the present invention, the corrugations oscillate along a plane parallel to the first coolant chamber wall, while in US 11293697, the corrugations oscillate along a plane perpendicular to the cold plate. This implies several points of difference. First, compared to US 11293697, the corrugated fins do not extend from the first coolant chamber wall to the opposite second coolant chamber wall. Therefore, the first and second fins extend less than 100% of the coolant chamber spacing into the coolant chamber.

[0023] Each of the heat-conducting first fins is connected to the inner side of the first coolant chamber wall only through a heat-conducting and sealed connection, and not to the inner side of the second coolant chamber wall, and extends toward the second coolant chamber wall but not into it. Similarly, each of the second fins is sealed to the inner side of the second coolant chamber wall, and not to the inner side of the first coolant chamber wall, and extends toward the first coolant chamber wall but not into it.

[0024] The sum of the first and second distances is 80-100% of the coolant chamber wall spacing. In other words, the fins may meet at the ends, for example, due to manufacturing tolerances, or there may be a small distance between the first and second fins, thus forming a gap. In any case, the gap will not exceed 20% of the spacing, for example, equal to or less than 10% of the spacing, and the gap will generally be smaller. This is useful for generating turbulence in the compartment formed by the first and second fins facing each other.

[0025] For example, the gap is approximately 0.05-3 mm. In particular, a gap of 0.1-1 mm has been found to be useful.

[0026] To ensure that the first and second fins actually meet each other in the contact area when the cooling device is assembled, while preventing overload in the contact area due to the sum of the fin lengths slightly exceeding the manufacturing tolerance of the wall spacing, the second fin is optionally made of an elastic material for compression. More specifically, for this purpose, the sum of the first and second distances is greater than 100% of the coolant chamber wall spacing in the pre-assembly state, and equals 100% of the coolant chamber wall spacing in the assembled state due to the compression of the elastic second fin.

[0027] The first fin, or the second fin, or both the first fin and the second fin, have an undulating shape. As the coolant passes through the laterally undulating compartment wall, the undulations cause turbulence within the coolant.

[0028] The first fin has a first undulating wavelength, and the second fin has a second undulating wavelength. Optionally, the first undulating wavelength is different from the second undulating wavelength.

[0029] For example, when the fins are not converging and have a small distance between them, as described above, the coolant will be squeezed through the narrow slit and affected in the further flow direction of the coolant behind the slit due to the lateral undulations of the fins. The coolant will be guided upward and downward by every other undulation. For example, the first curved portion of the undulation in the upstream direction causes the coolant to bend downward just after the first bend. The second curved portion of the undulation in the downstream direction causes the coolant to bend upward just before the second bend. As the coolant enters the compartment behind such undulating fins, this combination causes the coolant to move upward and downward, resulting in intense turbulence of the coolant, mixing the warmer and cooler portions of the coolant, and equalizing the temperature in the compartment. This, in turn, improves cooling efficiency.

[0030] In one embodiment, where each fin in the first fin extends into one fin of the second fin, coolant flows through a plurality of channels connecting the compartments from one compartment to a subsequent compartment.

[0031] Specifically, as an example, each combination of one fin of the first fin and one fin of the second fin forms multiple first and second flow channels through the respective compartment walls. This is achieved by combinations of first and second fins, wherein either the first fin or the second fin, or both the first fin and the second fin, have an undulating shape. For example, both have an undulating shape and are mirror images of each other, as will be illustrated in more detail below.

[0032] Alternatively, the first fin may be undulating and the second fin may be straight, or vice versa.

[0033] In one specific embodiment of such an embodiment, for each such combination consisting of one fin of the first fin and one fin of the second fin, each first flow channel is formed by a first portion of the first fin of the combination and a first portion of the corresponding second fin of the combination, and each second flow channel is formed by a second portion of the first fin of the combination and a second portion of the second fin of the combination, the second portion being different from the first portion. The first and second flow channels are arranged alternately along the compartment wall, wherein one of the first flow channels is located between two flow channels in the second flow channel, and one of the second flow channels is located between two flow channels in the first flow channel. Each first flow channel has a first coolant flow direction, and each second flow channel has a second coolant flow direction, which flows along the average flow direction from one compartment through the compartment wall into a subsequent compartment. The first flow direction is toward the first coolant chamber wall but not toward the second coolant chamber wall, and the second flow direction is toward the second coolant chamber wall but not toward the first coolant chamber wall.

[0034] Compared to US11644253, it is important to emphasize that in US11644253, the coolant flows unidirectionally along one side of the wall and then changes direction to flow in the opposite direction on the opposite side of the wall, which is typical in tortuous flows. This implies that the coolant enters the compartment in only one direction and moves in a nearly laminar manner along the undulating fins within the compartment. In this invention, the coolant flows from one compartment through the undulating fins to a subsequent compartment and is simultaneously deflected in two opposite directions by the undulating fins, which generates turbulence within the subsequent compartment.

[0035] In the cooling device described herein, since the average flow through the cooling chamber is largely transverse to the fin array, the flow passes largely transversely through all the undulating fins.

[0036] Each of the first and / or second fins has an alternating waveform undulating around a line parallel to the wall of the first coolant chamber, including a first set of bends on a first side of the line and a second set of bends on a second opposite side of the line. The first set of bends points upstream, and the second set of bends points downstream. For example, the line is perpendicular to the average flow direction. Alternatively, the line is inclined and deviates from the vertical direction by up to 10 degrees or even up to 20 degrees, the line being equivalent to an angle in the range of 70-110 degrees relative to the average coolant flow direction.

[0037] In some embodiments where the fins merge, the first bend and the second bend respectively constitute the first and second portions of the forming flow channel of the first fin, and the first and second portions of the forming flow channel of the first fin are combined with the corresponding second fin to form the first flow channel and the second flow channel.

[0038] In a more general embodiment, the first end of each of the first fins merges with the second end of at least one of the second fins, but not necessarily with only one of the second fins. Similarly, the second end of each of the second fins merges with the first end of at least one of the first fins, but not necessarily with only one of the first fins.

[0039] Alternatively, the first and second fins do not merge, but are spaced between them with a space not exceeding 10% of the coolant chamber wall spacing. Specifically, the first end of each of the first fins faces but does not contact the second end of at least one of the second fins, but not necessarily only one of the second fins. Similarly, each second end of each of the second fins faces the first end of at least one of the first fins, but not necessarily only one of the first fins.

[0040] In some embodiments that facilitate production, the second fin is identical to the first fin, but rotated 180 degrees about a line perpendicular to the wall of the first coolant chamber to provide a second fin that is mirrored relative to the first fin and relative to a plane perpendicular to the wall of the first coolant chamber. In such embodiments, the first coolant chamber wall having its first fin is similar to the second coolant chamber wall having its second fin, such that both the first and second fins are undulating.

[0041] Optionally, the compartment and the compartment wall are oriented perpendicular to the average flow direction. For the undulating fins and walls, and the compartments, the vertical direction of the fins, walls, and compartments refers to an average direction perpendicular to the average flow direction. Alternatively, these directions may deviate from the vertical direction by up to 10 degrees or even up to 20 degrees.

[0042] Optionally, the first fin is perpendicular to the first coolant chamber plate.

[0043] Alternatively, the second fin is perpendicular to the second coolant chamber plate.

[0044] Optionally, the first coolant chamber wall and the second coolant chamber wall are parallel.

[0045] Although the fins can be mounted to the inside of the corresponding coolant chamber wall, it may be advantageous if the first fin is integrated integrally with the first coolant chamber wall. For example, the first fin and the first coolant chamber wall are formed from a single piece of material. A single forged metal block is the preferred option in this regard. Metal forging under high pressure is a rapid production method, and because the first coolant chamber wall and the first fin are a single metal block, wherein the metal is thermally conductive, good thermal conductivity is provided from the coolant chamber wall through the fin to the coolant. As an alternative to metal forging, molding of metal or other thermally conductive materials (such as thermally conductive polymers) or sintering of thermally conductive ceramics are useful.

[0046] Optionally, the cooling device includes one or more cooling modules located within a housing, and typically also includes a manifold for distributing the coolant into and out of the modules. The cooling device has a coolant inlet and a coolant outlet, as well as a coolant flow path located within the internal volume of the device and passing through a coolant chamber for each module from the coolant inlet to the coolant outlet. Electronic components are disposed on each module wall for effective cooling, as the electronic components are in thermal contact with the heat-conducting wall for transferring heat energy from the electronic components through the module wall to the circulating coolant located within the coolant chamber of the module. Each module wall is formed similarly to the first coolant chamber wall described above, and its fins extend into the coolant chamber within the housing. Optionally, the housing forms a second coolant chamber wall for each module.

[0047] The term undulating waveform is used for structures that repeat and alternate in a straight or curved plane, such as structures with edges, like zigzag structures, or smooth undulating structures, such as sinusoidal structures.

[0048] Optionally, when measured along the average flow path, all the first fins have the same shape and are arranged equidistantly from each other with a first fin distance, and when measured along the average flow path, all the second fins have the same shape and are arranged equidistantly from each other with a second fin distance. The first fin distance and the second fin distance may optionally be the same, but they may also be different.

[0049] The coolant chamber encloses at least three, but typically more than three, first and second fins.

[0050] Typically, the compartment wall includes at least three first flow channels and at least three second flow channels.

[0051] It has been found that a first distance of 2-8 mm from the wall of the first coolant chamber for the first fin is a useful dimension. Similarly, it has been found that a second distance of 2-8 mm from the wall of the second coolant chamber for the second fin is useful.

[0052] Advantageously, compared to DE112022002737T5, the fins are non-perforated. In other words, the fins do not contain perforations through which the coolant will be able to flow, but rather the coolant is forced to flow around the fins for propulsion.

[0053] The cooling equipment is specifically designed for cooling power electronic devices, such as power modules, converters, and / or inverters, in electric vehicles (EVs) or wind turbines.

[0054] For automotive applications, the typical dimensions of a cooling module are 50-250mm × 50-250mm × 5-30mm.

[0055] For example, when used in personal electric vehicles, the cooling device measures approximately 200mm × 60mm × 15mm.

[0056] For renewable energy applications, such as power electronics in wind turbines handling several megawatts of power or off-road electric vehicles for mining, the cooling equipment would be approximately 200-800mm × 200-800mm × 20-80mm in size.

[0057] While the device is particularly useful for vehicles, it has more general characteristics and can also be advantageous for cooling electronic components in industrial machinery. Another advantageous application is for cooling electronic components in wind turbines. It is also suitable for other applications where high-power electronic components require liquid cooling, such as solar inverters. Attached Figure Description

[0058] The invention will be explained in more detail with reference to the accompanying drawings, in which...

[0059] Figure 1A The cooling device is shown in perspective. Figure 1B This is a perspective view of the first fin on the wall of the first coolant chamber; Figure 2A It is an overlapping image of the first and second fins; Figure 2B This is a perspective cross-sectional side view of the coolant chamber; Figure 2C yes Figure 2B Enlarged illustration of the cross section; Figure 3APerspective view of alternative embodiments Figure 3B yes Figure 3A The enlarged cross section; Figure 3C yes Figure 3A Enlarged illustration of the cross section; Figure 4A The flow of coolant through the coolant chamber is shown; Figure 4B yes Figure 4A The enlarged cross section; Figure 4C It is the side projection of the coolant flow through the coolant chamber; Figure 4B It is the end projection of the coolant flow through the coolant chamber; Figure 5A An embodiment with sinusoidal fins is shown in top view; Figure 5B It shows Figure 5A A perspective close-up view of a section; Figure 5C The parameters of the fins are shown; Figure 6 Two sets of fins rotating relative to each other are shown; Figure 7 Two sets of fins with different parameters are shown; Figure 8 It is a graph with different calculated flow values; Figure 9 This is an example of a finned structure; Figure 10A An array of coolant modules is shown in perspective. Figure 10B Shown in exploded view Figure 6 An array of A. Detailed Implementation

[0060] Figure 1A This is a perspective view of a cooling device 1 for cooling electronic components 3 on at least one of its outer surfaces (optionally both surfaces). The cooling device 1 has a sandwich structure consisting of a first coolant chamber wall 2A and a second coolant chamber wall 2B sandwiching a coolant chamber 10, which is further defined by side walls 4A and 4B.

[0061] Importantly, the first coolant chamber wall 2A used to cool the electronic device 3 is thermally conductive so that it absorbs heat from the electronic device 3 on its outer side and transfers the heat to the coolant flowing along the inner side of the first coolant chamber wall 2A in the coolant volume 10. If the electronic device 3 is disposed on the second coolant chamber wall 2B, this wall should also be thermally conductive.

[0062] Figure 1B An enlarged view of the first coolant chamber wall 2A, viewed from the side facing the coolant chamber 10, is shown, opposite to the side where the electronics 3 are mounted. A first flow structure 7A is disposed on the first coolant chamber wall 2A as part of a flow field guiding coolant flow through the coolant chamber 10. The first flow structure 7A comprises a plurality of identical undulating first fins 13A, with identical flow compartments 14 between the undulating first fins 13A. The first fins 13A are arranged parallel and equidistantly at a distance D as indicated by arrow 28. The undulations are periodic and have a constant wavelength L, as indicated by arrow 29. Arrow 5 indicates the average flow direction. It can be observed that the undulating first fins 13A and the corresponding first flow compartments 14 are arranged perpendicular to the flow direction 5. More specifically, the undulating first fins 13A and the resulting undulating compartments 14 have an average longitudinal direction along a line 19 perpendicular to the average flow path 5 of the coolant.

[0063] Figure 2A , Figure 2B and Figure 2C A first embodiment of the flow field in the coolant chamber 10 is shown. The first flow structure 7A on the inner side of the first coolant chamber wall 2A is as follows: Figure 1B As shown.

[0064] A second flow structure 7B is provided between the second coolant chamber wall 2B and the first flow structure 7A, comprising a plurality of straight, parallel second fins 13B. Similar to the equidistant undulating first fins 13A and the flow compartment 14 between the undulating first fins 13A, the straight and parallel second fins 13B are also equidistantly arranged at the same distance 28 and perpendicular to the flow direction 5 indicated by arrow 5.

[0065] like Figure 2A As shown in the optimal diagram, each undulating first fin 13A undulates symmetrically about the opposite sides of the corresponding straight, parallel second fin 13B. (See diagram below.) Figure 2B As shown in the best embodiment, each second fin in the second fin 13B is closely adjacent to, attached to, or integrated with the corresponding first fin 13A.

[0066] Therefore, each flow compartment 14 is defined by two adjacent undulating first fins 13A and the portion of the first coolant chamber wall 2A between these two adjacent undulating first fins 13A. Further definition is provided by two adjacent straight parallel second fins 13B and the portion of the second coolant chamber wall 2B between these two adjacent straight parallel second fins.

[0067] Figure 2B The perspective overview image shows undulating fins 13A extending toward the central region 6 of the coolant chamber 10.

[0068] The first fin 13A and optionally the second fin 13B are made of a thermally conductive material and are thermally connected to the corresponding coolant chamber walls 2A, 2B, which serve as cooling electronic devices.

[0069] For example, the first flow structure 7A is integrated with or attached to the first coolant chamber wall 2A, for example, by gluing, welding, or brazing. Similarly, the second flow structure 7B is integrated with or attached to the first coolant chamber wall 2A, for example, by gluing, welding, or brazing to the second coolant chamber wall 2B. Optionally, if the first flow structure 7A is attached to or integrated with the first coolant chamber wall 2A, and the second flow structure 7B is attached to or integrated with the second coolant chamber wall 2B, then the first flow structure 7A is closely adjacent to but not necessarily securely fastened to the second flow structure 7B. Such embodiments are useful if both the first coolant chamber wall 2A and the second coolant chamber wall 2B support electronic devices to be cooled.

[0070] If only the first coolant chamber wall carries the electronic device 3 to be cooled, a possible alternative is that the first flow structure 7A and the second flow structure 7B are attached to or integrated with each other, and are attached to or integrated with the first coolant chamber wall 2A, but not necessarily attached to the second coolant chamber wall 2B. Alternatively, in the latter case, the second flow structure 7B is closely adjacent to the second coolant chamber wall 2B, but not necessarily attached to the second coolant chamber wall 2B.

[0071] The term "attached to" refers to two structures provided separately and then joined together, for example, by gluing, welding, or brazing. The term "integrated with" refers to the corresponding structure being made from a single piece, for example, by grinding, casting, or sintering, optionally using a thermally conductive polymer or ceramic. Another possible production method that can be used to produce flow structures 7A, 7B integrated with the corresponding coolant chamber walls 2A, 2B is impact extrusion, also known as forging, in which a die with a template matrix deforms a metal block into the desired shape under high pressure.

[0072] In the embodiment shown in Figure 2, the first flow structure 7A is integrated with the first coolant chamber wall 2A because the undulating first fin 13A and the first coolant chamber wall 2A are made of a single piece of material, and the second flow structure 7B is integrated with the second coolant chamber wall 2B because the straight second fin 13B and the second coolant chamber wall 2B are made of a single piece of material.

[0073] refer to Figure 2A The undulating portion of the first fin 13A on the opposite side of the second fin 13B forms a first flow channel 15 and a second flow channel 16 connecting adjacent compartments 14. (As seen from the combination...) Figure 2C As will become apparent in the explanation, these channels 15, 16 provide flow in opposite directions from one compartment to its subsequent compartment 14, one direction in... Figure 2C The center is shown facing upwards, toward the first coolant chamber wall 2A, and in the opposite direction. Figure 2C The flow direction is shown downwards, toward the second coolant chamber wall 2B. This change in flow direction is important because it creates turbulence in the coolant, making the temperature of the coolant in compartment 14 largely constant throughout compartment 14, and thus optimized to maximize the absorption of heat energy from the first fin 13A and the second fin 13B.

[0074] The first fin 13A has a first end portion 23A located away from the inner side 25 of the first coolant chamber wall 2A, and extends a distance 24A from the inner side 25A of the first coolant chamber wall 2A into the coolant chamber 10. The second fin 13B has a second end portion 23B located away from the inner side of the second coolant chamber wall 2A, and extends a distance 24B from the inner side of the first coolant chamber wall 2A into the coolant chamber 10. The first end portion 23A and the second end portion 23B merge and connect to form a liquid-tight connection.

[0075] For example, distances 24A and 24B are equal. Alternatively, distances 24A and 24B may be different, but typically the difference does not exceed 20% of the width of the coolant chamber, which is the same as the distance 26 between the first coolant chamber wall 2A and the second coolant chamber wall 2B.

[0076] like Figure 2CAs shown, each first flow channel 15 is formed by a first portion 27A of a corresponding first fin 13A and a first portion 27B of a corresponding second fin (13B), the first portion being a part of the edge 23B of the second fin 13B. Correspondingly, each second flow channel 16 is formed by a second portion of a corresponding first fin 13A and a second portion of a corresponding second fin 13B. It can be seen from the figure that the second portions of the two flow channels 15 and 16 differ from the first portions because the positions of the flow channels 15 and 16 are different. In other words, only the combination of the first fin 13A and the second fin 13B produces the first flow channel 15 and the second flow channel 16.

[0077] Figure 2C yes Figure 2B A magnified section of the perspective cross-section image, with arrows 15A, 15B, 16A, 16B, and 17A illustrating the flow pattern. In the inlet compartment 11, the liquid coolant flows towards the first flow structure 7A and the second flow structure 7B. When the straight second fin 13B obstructs this straight flow of coolant, the coolant is forced into the first flow channel 15, as indicated by arrow 15A. The first flow channel 15 also... Figure 2A As shown in the diagram. Each first channel in the first flow channel 15 forces the coolant to change direction toward the first coolant chamber wall 2A, and this direction is... Figure 2C The coolant flows upwards so that it reaches the subsequent compartment 14. Once the coolant has passed through the first flow channel 15, it continues to flow towards the first coolant chamber wall 2A due to its velocity, as indicated by arrow 15B. After impacting the portion 22A of the first coolant chamber wall 2A that defines the compartment 14, the coolant flows back towards the second coolant chamber wall 2B, also as shown. Figure 2C As shown by arrow 15B in the diagram.

[0078] On the other hand, since the undulating first fins 13B also impede the straight flow of the coolant, the coolant from the inlet compartment 11 is forced into the second flow channel 16, as shown by arrow 16A. The second flow channel 16 also... Figure 2A As shown in the diagram. Each of the second channels in the second channel 16 forces the coolant to change direction toward the second coolant chamber wall 2B, which in turn... Figure 2C The coolant flows downwards so that it reaches the subsequent compartment 14. Once the coolant has passed through the second flow channel 16, it continues to flow towards the second coolant chamber wall 2B due to its velocity, as indicated by arrow 16B. After impacting the portion 22B of the second coolant chamber wall 2B that defines the compartment 14, the coolant flows back towards the first coolant chamber wall 2A, also as... Figure 2C As shown by arrow 16B in the diagram.

[0079] Before and after the coolant in compartment 14 flows back to the corresponding portions 22A, 22B of the coolant chamber walls 2A, 2B, it undergoes extensive mixing due to turbulence generated by the coolant flowing into compartment 14 in opposite directions through the first flow channel 15 and the second flow channel 16. After mixing, the coolant exits the compartment through the corresponding first flow channel 15 and second flow channel 16 to similarly enter subsequent compartments, as indicated by arrows 16B and 17A.

[0080] Figure 3A , Figure 3B and Figure 3C An alternative embodiment is shown in which the straight second fin 13B of FIG2 is replaced by an undulating second fin 13B. The overall effect is similar to that in FIG2. However, the first flow channel 15 and the second flow channel 16 have larger cross-sections, and therefore have reduced flow resistance and reduced pressure drop. Also in this embodiment, the first fin 13A has a first channel 15 and a second channel 16 on opposite sides of the second fin 13B. Due to the undulating shape of the second fin 13B, each undulating first fin 13A undulates symmetrically with respect to the opposite sides of the corresponding second fin 13B, and vice versa.

[0081] For the structure shown in Figure 3, in Figure 4A Overview images and Figure 4B The enlarged section shows the flow through the corresponding flow field. It illustrates the above discussion of bidirectional flow from one compartment 14 to the next, with arrow 5 indicating the average flow direction. Figure 4D A side projection similar to the alternating motion of the coolant is shown, with arrow 5 indicating the average flow direction. This flow field... Figure 4D What the front projection in the middle supports is that, as can be seen, the flow is not only similar to that according to Figure 4C The forward alternating motion also resembles a circular lateral motion, and its combination is similar to a spiral flow path.

[0082] As an alternative to the illustrated embodiment, the undulating fins 13A, 13B can have different shapes, such as a serrated structure with sharp edges, or a smooth undulating structure, such as a sinusoidal structure, for example... Figure 5A Top view and Figure 5B The image shows a magnified perspective view of the fins. The flow rate of the coolant through this structure depends on various parameters, some of which are... Figure 5C The diagram shows elements such as the wavelength L of the undulating fin, the amplitude A of the undulating fin, the distance D from one fin to an adjacent fin in the same direction as the measured amplitude A, and the wall thickness T of the fin, because the wall thickness T determines the accessible channel width W through which the coolant can flow. Figure 5B As shown, the channel width W of the undulating fin 13A is defined as the lateral distance between the straight portions of the walls of the fin 13A. It should be noted that... Figure 5C The amplitude A is shown as the peak-to-peak amplitude from the center of a first fin 13A to the center of an adjacent first fin 13A.

[0083] As an example, a useful wall thickness is in the range of 0.3-2 mm, and preferably in the range of 0.6-1.6 mm.

[0084] As shown in the accompanying drawings discussed above, the first fin 13A and the second fin 13B converge and contact each other along their ends 23A, 23B. To ensure that the first fin 13A and the second fin 13B actually converge at the contact area during assembly, while preventing overload in the contact area due to the sum of the lengths of the fins 13A and 13B slightly exceeding the manufacturing tolerance of the wall spacing 26, the second fin 13B is optionally made of a compressible elastic material. For this purpose, more specifically, the sum of the first distance 24A and the second distance 24B is greater than 100% of the coolant chamber wall spacing 26 in the state before assembly, and equal to 100% of the coolant chamber wall spacing 26 in the assembled state due to the compression of the elastic second fin 13B.

[0085] As an alternative to preventing overload of fins 13A and 13B during assembly, the end 23A of the first fin 13A and the end 23B of the second fin 13B can each face the gap between the end 23A of the first fin 13A and the end 23B of the second fin 13B, and the first fin 13A does not contact the second fin 13B. This gap between the first fin 13A and the second fin 13B is typically small, for example, in the range of 0.05-3 mm or more preferably in the range of 0.1-1 mm, because this gap should not allow the coolant to flow turbulently through the coolant chamber 10 without being forced against the coolant chamber walls 2A and 2B (especially the first coolant chamber wall 2A). In particular, this gap should not exceed 15% of the coolant chamber wall spacing 26, more preferably not exceeding 10%.

[0086] As described above, the first fin 13A, the second fin 13B, and the compartment 14 have an average longitudinal fin direction 19 and a corresponding compartment direction perpendicular to the flow path 5. However, as Figure 6As shown, the average fin direction 19 of the first fin 13a or the second fin 13B, or both the first and second fins, may deviate slightly from the precise vertical direction relative to the average flow direction 5, for example, by an angle of up to 10°. In alternative embodiments, the deviation from vertical is in the range of 0°-20°, 0°-30°, 10°-20°, 10°-30°, or 20°-30°. For example, the angle between the fin and the average flow path 5 is in the range of 70°-110°, more preferably in the range of 80°-100°, such as in the range of 85°-95°. As an example, the first fin 13A and the second fin 13B extend from the first coolant chamber sidewall 4A to the second coolant chamber sidewall 4B and are oriented in the range of 70°-110° relative to the average flow direction 5, optionally in the range of 80°-100°, such as in the range of 85°-95°. In all these embodiments, during the flow of coolant through coolant chamber 10, the coolant passes through all the first fins 13A and the second fins 13B. Figure 6 In the example, the first fin 13A and the second fin 13B have similar geometry.

[0087] However, the same geometry does not need to be in this case, such as Figure 2A As already shown in the diagram. Other options for geometry involve a first fin 13A and a second fin 13B with different wavelengths L, different amplitudes A, different spacing D, and / or different wall thicknesses T. Figure 7 An example is shown in the figure.

[0088] If these parameters are variable, experimental and / or flow model calculations, which are well-known in the technical field and commonly used to determine heat exchanger dimensions, can reveal their usefulness for a particular application and help identify the optimal combination of dimensions.

[0089] For example, in some automotive industries, it is desirable for the pressure of the cooling system to be within a predetermined level, such that the pressure drop dP across the cooling system does not exceed a predetermined value, optionally 100 mbar. On the other hand, thermal resistance should be minimized. This is a common challenge, and designers need some iterations.

[0090] For example, at a flow rate of 8 liters per minute through the coolant chamber, the pressure drop should not exceed 100 mbar.

[0091] Figure 8The figures show some results obtained by varying various parameters, including wavelength L, amplitude A, wall thickness T, fin spacing D, and channel width W. The numbering in the figures is not significant and is only used to distinguish multiple points. The horizontal axis represents pressure drop dP in mbar (1mb = 100 Pa), and the vertical axis represents thermal resistance Rth in K / W. The parameter variations range from 4–14 mm for wavelength L, 1–3 mm for amplitude A, and 1.5–3 mm for channel width W.

[0092] Figure 8 Point 1 in the calculation is for a pressure drop of 100 mbar, which was mentioned above as a desirable characteristic in the automotive industry. This is achieved through the design of the coolant chamber 10, in which the wavelength L1 = 12 mm of the first fin 13A is the same as the wavelength L2 = 12 mm of the second fin 13B, the peak-to-peak amplitude A1 = 4.50 mm of the first fin 13A is the same as the peak-to-peak amplitude A2 = 4.50 mm of the second fin 13B, and the flow channel width W1 = 1.6 mm of the first fin 13A is the same as the flow channel width W2 = 1.6 mm of the second fin 13B. This design follows the overall dimensions required for cooling equipment for electronic components in electric vehicles.

[0093] Figure 9 The calculation is shown Figure 8 The fin structure at point 1 in the diagram.

[0094] exist Figure 8 Further investigation revealed that many calculated designs exhibited significantly higher thermal resistances, some by as much as 15-20% at the same pressure drop of 100 mbar. While this may seem insignificant at first glance, it must be noted that a 20% increase in thermal resistance translates to a reduction in cooling efficiency by the same order. On the other hand, reducing the pressure drop dP can increase flow at a given pumping pressure, which may be beneficial; however, a lower pressure drop dP comes at the cost of higher thermal resistance, meaning that for a fixed pumping pressure, the flow through cooling chamber 10 is higher, see points 100, 90, 36, and 97, for example. Experiments, on the other hand, show that lower thermal resistance can be achieved if a higher pressure drop is acceptable, see, in particular... Figure 8 Points 35, 57, and 77 are included. Therefore, as mentioned above, this parameter must be balanced according to actual needs.

[0095] Figure 8The points in the diagram represent the results of the Design of Experiments (DoE), where relevant geometric parameters are varied to achieve optimal coverage of the design space. Modern simulation tools are then applied to obtain a “reduced-order model,” an analytical expression that predicts thermal resistance and pressure drop for any combination of input parameters. This method can be further applied to explore the so-called Pareto Frontier, which represents the optimal trade-off between thermal resistance and pressure drop (given by...). Figure 8 (Blue line indicator for optimal design of DoE connection).

[0096] Figure 10A Perspective and Figure 10B An exploded view shows a cooling device 100 having an array of cooling modules 101 mounted within a manifold housing 102. Each cooling module 101 is largely similar to the cooling device 1 of FIG. 1. It includes a first coolant chamber wall 2A, which is similar to the first coolant chamber wall 2A in FIG. 1, but does not include a different second coolant chamber wall 2B, which in this embodiment is replaced by a replacement portion of the manifold housing 102. Similar to the first coolant chamber wall 2A in FIG. 1, the first coolant chamber wall 2A includes a first flow structure 7A adjacent to the first coolant chamber wall 2A, for example, attached to or integrated with the first coolant chamber wall 2A. However, relative to the first flow structure 7A, a second flow structure 7B adjacent to the opposite side of the partition wall 5 is not attached to any second coolant chamber wall, because this second coolant chamber wall is not present in the module 101. The second flow structure 7B is disposed within the housing 102, for example, integrated with the housing 102. Gasket 105 seals between the first coolant chamber wall 2A and the housing 102. Coolant flows into the various coolant chambers from inlet 103 and flows along the flow field defined by flow structures 7A, 7B, and exits manifold 102 through coolant outlet 104.

Claims

1. A cooling device (1, 100) for cooling and thermally conducting electronic components (3) in thermal contact with the outer side of a first coolant chamber wall (2A); wherein The cooling device (1, 100) includes a coolant chamber (10) defined by the inner side (25A) of a first coolant chamber wall (2A) and the inner side of an opposing second coolant chamber wall (2B), as well as a first coolant chamber sidewall (4A) and a second coolant chamber sidewall (4B), wherein an average flow direction (5) is provided for the coolant to pass through the coolant chamber (10) from the coolant inlet to the coolant outlet along the inner side (25A) of the first coolant chamber wall (2A) and the second coolant chamber wall (2B), as well as the inner side (25B) of the first coolant chamber sidewall (4A) and the second coolant chamber sidewall (4B), to cool the first coolant chamber wall (2A), wherein the inner side of the first coolant chamber wall (2A) and the inner side of the second coolant chamber wall (2B) are separated by a coolant chamber wall spacing (26); The cooling device (1) includes a first array (7A) consisting of a plurality of side-by-side heat-conducting first fins (13A). Each of the plurality of side-by-side heat-conducting first fins (13A) is connected to the inner side (25A) of the first coolant chamber wall (2A) by a heat-conducting and sealing connection, and has a first end (23A). The first end extends a first distance (24A) from the inner side (25A) of the first coolant chamber wall (2A) toward the second coolant chamber wall (2B) into the coolant chamber. 10), and wherein the cooling device (1) includes a second array (7B) consisting of a plurality of side-by-side second fins (13B), each of the plurality of side-by-side second fins (13B) being hermetically connected to the inner side (25B) of the second coolant chamber wall (2B) and having a second end (23B) extending a second distance (24B) from the inner side (25B) of the second coolant chamber wall (2B) toward the first coolant chamber wall (2A) into the coolant chamber (10); Wherein, when measured in the vertical direction from the inner side (25A) of the first coolant chamber wall (2A), the first distance (24A) of each first fin in the first fin (13A) and the second distance (24B) of each second fin in the second fin (13B) when measured in the vertical direction from the inner side (25B) of the second coolant chamber wall (2B) are at least 20% of the coolant chamber wall spacing (26); Wherein, the first end (23A) of each first fin in the first fin (13A) merges with the second end (23B) of at least one second fin in the second fin (13B), and the second end (23B) of each second fin in the second fin (13B) merges with the first end (23A) of at least one first fin in the first fin (13A), or wherein, the first end (23A) of each first fin in the first fin (13A) faces the second end (23B) of at least one second fin in the second fin (13B), and the second end (23A) of each second fin in the second fin (13A) faces the first end (23B) of at least one first fin in the first fin (13B), and the gap between them does not exceed 15% of the coolant chamber wall spacing; Wherein, the first fin (13A) or the second fin (13B) has an undulating shape, or both the first fin and the second fin (13B) have an undulating shape; Each of the first fin (13A) and the second fin (13B) extends from the first coolant chamber sidewall (4A) to the second coolant chamber sidewall (4B) and is oriented in the range of 70-110 degrees relative to the average flow direction (5) so that the coolant passes through all the first fins (13A) and the second fin (13B) during the flow of the coolant through the coolant chamber (10).

2. The cooling device of claim 1, wherein, Both the first fin (13A) and the second fin (13B) have an undulating shape.

3. Cooling apparatus according to claim 2, wherein, The undulation shape of the first fin (13A) has a first undulation wavelength (L, 29), and the undulation shape of the second fin (13B) has a second undulation wavelength, wherein the first undulation wavelength (L, 29) is different from the second undulation wavelength.

4. The cooling device according to any of the preceding claims, wherein, The first fins (13A) are equidistant from each other (D, 28), or the second fins (13B) are equidistant from each other, or both the first fins and the second fins are equidistant from each other.

5. The cooling device according to claim 4, wherein, The first fin (13A) is equidistantly spaced between adjacent first fins (13A) by a first distance (D, 28), and the second fin (13B) is equidistantly spaced between adjacent second fins (13B) by a second distance, wherein the first distance (D, 28) is different from the second distance.

6. The cooling device according to any one of claims 2-5, wherein, The first fin (13A) has an undulating shape with a first undulating wavelength (L, 29) and is spaced apart by a first distance (D, 28) between adjacent first fins (13A), wherein the first undulating wavelength (L, 29) is greater than the first distance (D, 28); or wherein the second fin (13B) has an undulating shape with a second undulating wavelength and is spaced apart by a second distance between adjacent second fins (13B), wherein the second undulating wavelength is greater than the second distance; or both of the above.

7. The cooling device according to any one of the preceding claims, wherein, The first end (23A) of each of the first fins (13A) merges with the second end (23B) of at least one of the second fins (13B), and wherein the second end (23B) of each of the second fins (13B) merges with the first end (23A) of at least one of the first fins (13A).

8. The cooling device according to claim 7, wherein, The second fin (13B) is elastic to compression, and wherein the sum of the first distance (24A) and the second distance (24B) is greater than 100% of the coolant chamber wall spacing (26) in the state before assembly, and in the assembled state, due to the compression of the elastic second fin (13B) during assembly, it is equal to 100% of the coolant chamber wall spacing (26).

9. The cooling device according to any one of the preceding claims, wherein, The first coolant chamber wall (2A) and the second coolant chamber wall (2B) are parallel, wherein the first fin (13A) and the second fin (13B) extend vertically from the coolant chamber walls (2A, 2B), and wherein the first end (23A) and the second end (23B) face each other along a plane (30) perpendicular to the first coolant chamber wall (2A) and the second coolant chamber wall (2B).

10. The cooling device according to claim 9, wherein, The second fin (13B) is the same as the first fin (13A), but rotated 180 degrees about a line perpendicular to the first coolant chamber wall (2A) to provide the second fin (13B), which is mirrored relative to the first fin (13A) and relative to a plane perpendicular to the first coolant chamber wall (2A).

11. The cooling device according to any of the preceding claims, wherein, The first fin (13A) and the second fin (13B) in pairs form an array of compartment walls (20), each pair (13A, 13B) separating two adjacent compartments (14) of a plurality of compartments (14), wherein each compartment (10) is defined by the first coolant chamber wall (2A) and the second coolant chamber wall (2B), the first coolant chamber sidewall (4A) and the second coolant chamber sidewall (4B) and the two pairs (13A, 13B).

12. The cooling device according to claim 11, wherein, Each pair of combinations (13A, 13B) forms a plurality of first flow channels (15) and second flow channels (16) extending through the respective compartment wall (20), wherein each first flow channel (15) is formed by a first undulating portion (27A) of the first fin (13) and a first portion (27B) of the second fin (13B), and each second flow channel (16) is formed by a second undulating portion of the first fin (13A) and a second portion of the second fin (13B), the second portion being different from the first portions (27A, 27B); wherein the first flow channels (15) and the second flow channels (16) are arranged alternately along the compartment wall (20), wherein one of the first flow channels (15) is located in the second flow channel (16). Between the two second channels in 6), and one of the second channels (16) is located between the two first channels in the first channel (15), wherein each first channel (15) has a first coolant flow direction (15A), and each second channel (16) has a second coolant flow direction (16A), which flows along the average flow direction (5) from one compartment (11) through the compartment wall (20) into the subsequent compartment (14), wherein the first flow direction (15A) is toward the first coolant chamber wall (2A) but not toward the second coolant chamber wall (2B), and the second flow direction (16A) is toward the second coolant chamber wall (2A) but not toward the first coolant chamber wall (2A).

13. The cooling device according to claim 12, wherein, Each of the first fins (13) has an undulating shape around a line (19) parallel to the first coolant chamber wall (2A), and each of the first fins (13) includes a first set of bends (21A) on a first side of the line (19) and a second set of bends (21B) on a second opposite side of the line (19), wherein the first bend (21A) and the second bend (21B) are respectively the first portion (27A) and the second portion of the first fin (13A), and the first portion (27A) and the second portion, combined with the corresponding second fin (13B), respectively form the first flow channel (15) and the second flow channel (16); wherein the line (19) is perpendicular to the average flow direction (5), or is inclined and has an angle in the range of 70-110 degrees relative to the average flow direction (5).

14. The cooling device according to any of the preceding claims, wherein, Each of the first fins (13A) faces or merges with only one of the second fins (13B).

15. The cooling device according to any of the preceding claims, wherein, The first distance (24A) is the same for all the first fins (13A) and is constant along the first fins (13A), and the second distance (24B) is the same for all the second fins (13B) and is constant along the second fins (13B).

16. The cooling device according to any one of the preceding claims, wherein, The first fin (13A) and the first coolant chamber wall (2A) are a single forged metal block.

17. The cooling device according to any one of the preceding claims, wherein, The first fin (13A) and the second fin (13B) are non-perforated.

18. The use of the cooling device according to any one of the preceding claims in an electric vehicle for cooling an electronic component (3) for power regulation of an electric propulsion motor.

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