Cooling system for a heat generating electric component

Abstract

The invention relates to a cooling system (1) for a heat generating electric component (2), comprising a tank (10) including a top opening (12) and an interior configured for accommodating the heat generating electric component (2) and a fluid (F); and a heat exchanger (30) including a fluid channel structure (32) and an air channel structure (38) configured for heat exchange with the fluid channel structure (32); wherein the heat exchanger (30) is configured as a cover for the top opening (12) and the fluid channel structure (32) is in fluid communication with the interior through the top opening (12).

Description

[0001] H D 42349; P240092 1 / 23

[0002] Cooling system for a heat generating electric component

[0003] Technical Field

[0004] The invention relates to a cooling system for a heat generating electric component, the cooling system comprising a tank configured for accommodating the heat generating electric component and a fluid, and comprising a heat exchanger.

[0005] Background Art

[0006] Known designs of cooling systems for heat generating electric components rely on circulating a fluid within a tank, with the fluid to be air cooled. The tank may have fins or radiators to provide convective cooling. However, known designs comprise a large footprint or size. This is a significant challenge, particularly when space constraints are a concern.

[0007] JP H02 144904 A describes a radiator for air-cooling a heating element, where a container is filled with a cooling medium to cool the heating element.

[0008] EP 0396949 A2 describes a gas-insulated transformer housed in a metallic housing closed by a cover with cooling ribs.

[0009] Summary of invention

[0010] It is an object of the invention to provide solutions with respect to cooling systems for heat generating electric components that provide increased efficiency and a reduced size. Particularly it is an object to avoid or reduce disadvantages of known solutions.

[0011] The object of the invention is solved by the features of the independent claims. Preferred implementations are detailed in the dependent claims, the description and the figures. H D 42349; P240092 2 / 23

[0012] The object is particularly solved by a cooling system for a heat generating electric component, such as a power transformer, the cooling system comprising a tank including a top opening and an interior configured for accommodating the heat generating electric component and a fluid; and a heat exchanger including a fluid channel structure and an air channel structure configured for heat exchange with the fluid channel structure; wherein the heat exchanger is configured as a cover for the top opening and the fluid channel structure is in fluid communication with the interior through the top opening.

[0013] Particularly, the heat exchanger provides at least one bottom surface that is configured for delimiting the interior of the tank. Particularly, the heat exchanger includes a three dimensional lattice cell structure and has an air inlet and an air outlet. It can be provided that an air flow can be directed efficiently through the heat exchanger to enhance a cooling effect, wherein the heat transfer is strongly improved based on the three dimensional lattice cell structure. Prior art does not disclose or render obvious such a feature combination. For example, JP H02 144904 A leaves no space for a lattice cell structure or inlet and outlet and EP 0 396 949 A2 merely directs towards a cover with cooling fins, leaving no space for a lattice cell structure or inlet and outlet, and even guides away from a fluid communication through the top opening.

[0014] In other words, particularly, the object is solved by a cooling arrangement for a transformer including a tank to accommodate the transformer and a particularly liquid coolant, wherein the tank is closed at the top by means of a heat exchanger configured for heat exchange between an ambient fluid, such as air, and the coolant.

[0015] The invention advantageously realizes to have a heat exchanger integrated as or in a cover for a tank. Thereby the footprint of the cooling system can be reduced.

[0016] Typically, the density of the fluid falls with rising temperature. Thus, the hottest section of the fluid can be accessed in the vicinity of the heat exchanger at the top opening. Thereby, heat can be carried away from the interior at the hottest point and thereby a likeliness for electrical failure can be reduced and cooling efficiency can be improved. H D 42349; P240092 3 / 23

[0017] The invention may realize to reduce the number of components of the cooling system and thereby may make assembly easier and reduce the amount of material.

[0018] The cooling system typically relates to a system that is configured for cooling. The cooling system may include means necessary in order to cool the heat generating electric component. The cooling system may be arranged integrated with the heat generating electric component. The cooling system may provide accommodation for the heat generating electric component.

[0019] The cooling system has a tank. The tank includes a top opening and an interior. The interior can be accessed through the top opening. The interior can accommodate the heat generating electric component and a fluid, particularly so that the heat generating electric component is immersed in and / or surrounded by the fluid. The tank typically comprises at least one wall on its sides and a bottom. The at least one wall and the bottom can define the shape of the interior at least sectionally. The at least one wall can define the shape of the top opening at least sectionally. The at least one wall may comprise and / or form a top surface, especially a flange, which top surface may be substantially flat. The top opening is particularly on an opposite site of the tank relative to the bottom. The top opening is typically configured for inserting or removing the heat generating electric component, e.g. in part, entirely, or as a whole. For example, the top opening may have a width and length or diameter of at least 10 cm or at least 20 cm.

[0020] The cooling system may comprise the fluid. The fluid may be a gas or a liquid. The fluid may comprise a coolant and / or an oil. Particularly, the fluid is substantially dielectric and / or electrically non-conductive in order to ensure function of the heat generating electric component despite getting directly in touch with parts of the electric component carrying electricity.

[0021] The heat exchanger includes the fluid channel structure and the air channel structure. The air channel structure is configured for heat exchange with the fluid channel structure. The heat exchanger is particularly configured so that a heat exchange through solid material, e.g. a wall, by way of heat conduction between H D 42349; P240092 4 / 23 said channel structures is possible. For example, the channel structure with the higher temperature, which is typically the fluid channel structure containing the fluid, will provide that a heat transfer to the other channel structure can be realized. The channel structures are particularly configured fluid tight relative to one another. Typically, the air channel structure can guide an ambient fluid, particularly air, so that said ambient fluid can carry away heat from the fluid channel structure by way of forced convection.

[0022] The heat exchanger is configured as a cover and / or lid for the top opening. For example, the heat exchanger can at least substantially cover and / or close the top opening. The heat exchanger may be a lid to the top opening. For example, the heat exchanger provides at least one bottom surface that is configured for delimiting or delimits the interior of the tank and / or directly faces the heat generating electric component.

[0023] The fluid channel structure is in fluid communication with the interior, particularly at least through the top opening. For example, the fluid may enter the fluid channel structure and / or leave the interior through the top opening. The fluid channel structure may be configured to return fluid after the heat exchange to the interior, e.g. through the top opening and / or through a port of the tank coupled to the interior, e.g. at a bottom section of the tank and / or arranged at a distance to the top opening. To be in fluid communication particularly relates to enabling a fluid transfer.

[0024] The heat generating electric component may be a high voltage static electric induction system, especially including a power transformer and / or a shunt reactor. A high voltage may be at least 30 kV or at least 100 kV. Although the heat generating electric component is mainly described as a power transformer, the electric arrangement is not limited to a power transformer.

[0025] The heat exchanger may provide and / or include at least one passage, e.g. for an electrical connection of the heat generating electric component especially through the heat exchanger. The at least one passage may extend through the heat exchanger. The at least one passage particularly extends between a top surface and a bottom surface of the heat exchanger. The bottom surface may face and / or H D 42349; P240092 5 / 23 may be configured to face the interior. The bottom surface may abut with a / the top surface of the tank. The at least one passage may be substantially round in shape and / or may comprise a substantially cylindrical wall. The at least one passage may be surrounded by the fluid channel structure and / or the air channel structure. The at least one passage may provide direct access to the interior from an outside, especially in order to electrically connect the heat generating electric component. The cooling system may comprise two, three or more passages of the at least one passage, e.g. configured similarly or differently. The passages may be arranged at a distance to one another, particularly in a specific distance and / or in a row. The cooling system may comprise different types of the at least one passage, e.g. different in size and / or diameter.

[0026] The at least one passage may include and / or may be surrounded by a gasket section, especially at the top surface and / or for accommodation of a gasket. The gasket section may have a round shape and / or include the gasket. The gasket section may include a groove for the gasket. The gasket may be ring gasket and / or an 0-ring. The gasket section should assure that the fluid cannot leak despite electrical connections via the at least one passage.

[0027] The heat exchanger may have a / the bottom surface. The bottom surface may be at least substantially and / or sectionally flat. The bottom surface may partially exhibit the fluid channel structure, particularly wherein other parts of the fluid channel structure may be arranged inside the heat exchanger. The bottom surface may abut with a / the top surface of the tank. The top surface of the tank may be substantially flat, e.g. in the form of a flange. The heat exchanger may be attached to the tank, particularly to the top surface, e.g. bolted to the tank.

[0028] Particularly, the top surface of the tank may surround and / or form the top opening. It may be provided that the heat exchanger is shaped substantially flat, e.g. with one of three dimensions being at least two times, four times, or one order of magnitude smaller than the other two of the three dimensions. The heat exchanger may have a substantially rectangular shape, e.g. exhibiting two long sides and two short sides, particularly with the long and short sides being substantially perpendicular to one another. The heat exchanger may have a shape substantially and / or sectionally H D 42349; P240092 6 / 23 corresponding to the shape of the tank and / or the top surface, particularly in a top view onto the tank. For example, the heat exchanger may have rounded and / or straight sides.

[0029] The top surface and the bottom surface of the heat exchanger may be arranged at least substantially in parallel to one another. The bottom surface and / or the top surface of the heat exchanger may be arranged at least substantially in parallel to the top surface and / or the bottom of the tank.

[0030] A / the bottom surface of the heat exchanger may include a gasket section, particularly for accommodation of a gasket in order to seal against the tank. The gasket section may include a groove. The groove may have a narrowed entrance and particularly with a trapezoidal and / or tapered shape in a cross section of the gasket section. The gasket section may correspond in shape to the top surface of the tank, especially for a gasket to seal against the top surface of the tank, e.g. in a circumferential manner. This design facilitates vertical mounting for sealing between the tank and the heat exchanger.

[0031] The heat exchanger may include a three dimensional lattice cell structure, e.g. in order to define the air channel structure and the fluid channel structure in shape.

[0032] The three dimensional lattice cell structure can enable heat transfer between the air channel structure and the fluid channel structure in an efficient manner. The three dimensional lattice cell structure can increase the surface areas exposed for heat transfer and can promote a compact design of the heat exchanger relative to known heat exchangers. Heat transfer efficiency and cooling efficiency of the electric component can be improved using the dimensional lattice cell structure. Due to the high heat transfer efficiency of the lattice cell structure, the amount of fluid necessary may be reduced.

[0033] The three dimensional lattice cell structure may comprise a periodic pattern in each of three different directions. Each periodic pattern may comprise at least two, three, or more periods. The directions may be at least substantially perpendicular to one another. The three dimensional lattice cell structure typically comprises a plurality H D 42349; P240092 7 / 23 of cells. The cells may be arranged at least substantially orthogonally in two or three directions.

[0034] The three dimensional lattice cell structure may define an interior lattice cell structure volume as the fluid channel structure. The interior lattice cell structure volume may be continuous or discontinuous. Thus, the interior lattice cell structure volume may form a continuous labyrinth network for the fluid, or may form several parallel labyrinth networks for the fluid. Particularly, the interior lattice cell structure volume may be in fluid communication with the interior of the tank through the top opening.

[0035] The three dimensional lattice cell structure may define an exterior lattice cell structure volume as the air channel structure. The exterior lattice cell structure volume may be continuous or discontinuous. Thus, the exterior lattice cell structure volume may form a continuous labyrinth network for the ambient fluid, like air, or may form several parallel labyrinth networks for the ambient fluid. Particularly, the exterior lattice cell structure volume may be in fluid communication with the ambient fluid.

[0036] The three dimensional lattice cell structure may have a substantially minimal surface, especially a triply periodic minimal surface, TPMS for short. The three dimensional lattice cell structure may comprise a Schwarz P surface. The three dimensional lattice cell structure may comprise or may be a surface that is similar to a TPMS, but that does not fulfil the requirement to be named TPMS.

[0037] A TPMS typically is a smooth (typically at least C2or at least twice continuously differentiable) surface in three-dimensional Euclidean space that (i) is invariant under translations by three linearly independent lattice vectors, thereby admitting a bounded fundamental (unit) cell, and (ii) has mean curvature identically zero everywhere or at least substantially everywhere. When embedded, e.g. i.e. without self-intersections, a TPMS partitions space into two disjoint, bicontinuous regions. A TPMS can also encompass rotations, reflections, translations, and uniform scalings; symmetry-equivalent choices of primitive cells and supercells; and TPMS- derived structures obtained by offsetting the surface along its normal by a finite H D 42349; P240092 8 / 23 distance on one or both sides and trimming to a specified bounding volume. Nonlimiting examples include the gyroid (G), Schwarz P, Schwarz D (diamond), Neovius, and l-WP surfaces. Numerically generated approximations that share the same lattice periodicity and satisfy a minimal-surface criterion within a specified tolerance, e.g. a bound on the maximum absolute mean curvature, are likewise included.

[0038] The three dimensional lattice cell structure may comprise non-flat and / or flowpromoting ends. The ends may for example include a cone and / or a hemisphere. One end, particularly each end, may close a respective cell of the three dimensional lattice cell structure.

[0039] Particularly, the heat exchanger may comprise at least one wall, e.g. forming the fluid channel structure, the air channel structure and / or the lattice cell structure. The at least one wall may form the three dimensional lattice cell structure, especially the TPMS. The at least one wall may be formed by, particularly comprise or consist of, a metal material.

[0040] The metal material may include iron, carbon, aluminum, copper, silver, or a combination thereof, particularly an alloy with one, two or more thereof. For example, the metal material may include iron and carbon as a steel alloy.

[0041] The at least one wall or at least one surface of the heat exchanger forming the fluid channel structure and / or the air channel structure may at least sectionally exhibit a mean surface roughness Ra of at least 1 pm, 2 pm, or 3 pm. As such, the heat transfer can be enhanced. Such a surface can be achieved, for example, by additively manufactured metal materials, for example using a 3D printing or additive manufacturing process, particularly powder-based, e.g. powder bed fusion or laser powder bed fusion. An advantage of this proposal is that the design is considerably simplified, which can reduce the risk of leakage from welding. This also brings more free space for control cabinets, accessories and the like.

[0042] The heat exchanger may have an air inlet, e.g. provided with a blower, and may have an air outlet, particularly on an opposite side of the air inlet. The heat H D 42349; P240092 9 / 23 exchanger may have two or more air inlets and / or air outlets. For example, the air inlet may be arranged on one side of the heat exchanger and the air outlet may be arranged on another side of the heat exchanger. The blower may be configured as an electric blower. The blower may be a radial blower or radial fan.

[0043] The heat exchanger, particularly the fluid channel structure, may have or exhibit a first port (e.g. as a fluid inlet to the heat exchanger) and a second port (e.g. as a fluid outlet and / or fluid inlet to the heat exchanger). The first port may be at least sectionally elongated. The first port may be arranged to sectionally extend across a / the bottom surface of the heat exchanger facing the interior, e.g. in order to draw fluid from different regions for a homogeneous temperature distribution. The second port may be arranged away from the interior and / or away from the top opening. For example, the second port may be on the bottom surface of the heat exchanger and / or facing downwards, particularly distant to the top opening. The second port may face towards a similar or a different direction compared to the first port. The first port and the second may at least substantially be arranged in a common plane.

[0044] The first port may comprise sections which are shaped curved and / or periodically repeating, e.g. considered across the bottom surface of the heat exchanger. The first port may be shaped corresponding to the lattice cell structure. For example, the first port can have a sinusoidal or wave-like shape. Thereby, the first port can cover an enlarged surface area of the top opening in order to avoid or reduce blind spots.

[0045] The second port may be coupled, especially via a conduit arranged exterior to the interior, to a bottom section of the tank. The conduit may be provided by a pipe or by two or more pipes. The conduit may run substantially vertically relative to a ground. The conduit may be integrated in the tank, e.g. in a wall of the tank. For example, there may be two or more second ports arranged on opposite sides of the tank which second ports may be coupled to the bottom section of the tank. As such, an even distribution of cooled fluid that is guided back to the interior can be achieved.

[0046] The heat exchanger, especially a part thereof, may project beyond a / the top surface of the tank, e.g. considered horizontally relative to a ground. The heat exchanger H D 42349; P240092 10 / 23 may overlap the tank in one or more section. Thus, the second port of the heat exchanger may be arranged away from the top opening, e.g. by means of the overlapping or projecting-beyond part of the heat exchanger.

[0047] The tank may have at least one rounded and / or recessed side extending along a height of the tank for the conduit to extend from a part of the heat exchanger projecting beyond a / the top surface of the tank at said side and to extend along the height at said side. Said side may exhibit that the heat exchanger projects beyond the top opening. The height of the tank may be at least 20 cm or at least 40 cm. For example, the tank may have a curved or convex side where the conduit can be arranged without substantially increasing the footprint. In a top view, the conduit may be arranged completely below the heat exchanger. This supports a compact design.

[0048] The cooling system may comprise a pump device, e.g. an electric pump. The pump device may be configured for pumping the fluid through the fluid channel structure and particularly coupled to the second port and / or to the conduit. For example, the pump device may be coupled to the heat exchanger, especially to the second port. The pump device may be configured to apply suction to the respective second port in order to draw the fluid and pump the fluid, e.g. via the conduit and / or into the interior, e.g. into the bottom section of the tank. The cooling system may have more than one pump device, e.g. two or more. The pump device can increase fluid movement in order to enhance the heat exchange. The pump device may enable the possibility to enhance the control of the temperature of the fluid.

[0049] For example, the pump device and / or the blower may be configured to start, stop and / or run with a certain speed depending on a temperature of the fluid.

[0050] Alternatively or additionally, the cooling system may be configured to circulate the fluid and / or the air only by means of natural convection, i.e. without any mechanical assistance for circulating the fluid or air.

[0051] Further, a use of a / the cooling system suggested, particularly wherein a tank of the cooling system is configured to be arranged at least indirectly on a ground with a HD 42349; P240092 11 / 23 top opening of the tank arranged to face away from the ground. The use may include that the tank is filled with a particularly dielectric fluid, e.g. oil. The use may include that the tank accommodates a heat generating electric component, especially a power transformer. The power transformer may be electrically coupled through a heat exchanger of the cooling system.

[0052] Further, a method to produce a / the cooling system for a heat generating electric component is suggested. The method may comprise providing a tank with a top opening an interior configured for accommodating the heat generating electric component and a particularly dielectric fluid. The method may comprise providing a heat exchanger including a fluid channel structure and an air channel structure configured for heat exchange with the fluid channel structure. The heat exchanger may be configured as a cover for the top opening. The fluid channel structure is particularly configured to be or is in fluid communication with the interior through the top opening.

[0053] The heat exchanger may be at least sectionally produced by an additive manufacturing process, e.g. laser powder bed fusion. Particularly, the heat exchanger includes the lattice cell structure, especially with the triply periodic minimal surface, TPMS for short.

[0054] 3D printing or additive manufacturing technology often requires significant support structures during the printing process to achieve overhanging or complex geometries with precise dimensions. These support structures are essential to prevent deformation or collapse of the part during printing, ensuring the desired shape, size, and dimensional accuracy. However, once the part is printed, all these support structures need to be manually removed, which is a time-consuming and labor-intensive post-processing step. Removing the supports can be challenging, especially for intricate designs or hard-to-reach areas and may require specialized tools or techniques to avoid damaging the final part. The extensive post-processing required to remove the support structures not only increases the overall manufacturing time but also adds to the cost of the printed part. The additional labor, materials, and potential waste generated during the support removal process contribute to higher production costs, making the single-piece printing approach less H D 42349; P240092 12 / 23 economical. The proposed design seeks to avoid such drawbacks. The present idea aims to leverage the benefits of the heat exchanger using a lattice cell structure, especially a TPMS, for cooling while achieving a more compact volume. This approach can significantly improve printing time and post-processing efforts. The invention realizes to print smaller modular components and then joining them together, eliminating the size constraint imposed by printer build volumes. Consequently, the invention makes it possible to scale the size of the cooling system. This modular approach not only improves manufacturing efficiency but also expands the potential applications to transformers of various sizes.

[0055] The term ‘or’ may be replaced by ‘and / or’ throughout the present disclosure. As such, where ‘or’ is used, it is not necessarily meant that merely alternatives are named.

[0056] Brief description of drawings

[0057] These and other aspects of the invention will be apparent from and elucidated with reference to the implementations described hereinafter.

[0058] In the drawings:

[0059] Fig. 1 A-B shows cooling systems with a tank and a heat exchanger configured as a cover for the tank in a perspective view;

[0060] Fig. 2A-B shows a heat exchanger (A) and a detail thereof (B) in a perspective view;

[0061] Fig. 3 shows the heat exchanger of Fig. 1 in a perspective view;

[0062] Fig. 4A-B shows a section of a heat exchanger in a perspective view (A) and a schematic detail thereof (B);

[0063] Fig. 5 shows a section of the heat exchanger of Fig. 4 in a perspective view; and

[0064] Fig. 6 shows the heat exchanger of Fig. 4 in a perspective view. H D 42349; P240092 13 / 23

[0065] Description of implementations

[0066] The description contains procedural or methodical aspects upon describing structural features of the invention; the structural features can be understood well in that way. It is emphasized to the reader that such structural features can be lifted from the described context without hesitation or the question of an intermediate generalization to form aspects of the invention. It is also emphasized to the reader that any the structural features described in the following can be understood as individual aspects of the invention to distinguish from known solutions, despite being possibly lifted from the context. The Figs, show schematic views, particularly not to scale.

[0067] Fig. 1A-B shows cooling systems 1 which are meant for heat generating electric components 2. The cooling system 1 in Fig. 1 A has pump devices 3 while the cooling system 1 of Fig. 1 B does not. Aside from this, the cooling systems 1 are substantially similar; thus, it is referred to a single cooling system 1 in the following.

[0068] The cooling system 1 includes a heat exchanger 30 as shown in Fig. 2A-B and Fig. 3 in detail. Another example of a heat exchanger 30 is shown in Fig. 4 and Fig. 5, which heat exchanger 30 is - aside from a design of ports and channel structures - substantially similar to that of Fig. 2A-B and Fig. 3.

[0069] Similar reference and names of features indicate that respective description can be considered to be valid across the embodiments or implementations.

[0070] The cooling system 1 comprises a tank 10 including a top opening 12 and an interior configured for accommodating the heat generating electric component 2 and a fluid F. The fluid F is dielectric oil in which the electric component 2 is immersed. The tank 10 has a substantially flat top surface 12 in direct contact to a bottom surface 52 of the heat exchanger 30. H D 42349; P240092 14 / 23

[0071] The top surface 14 of the tank 10 surrounds and forms the top opening 12. The top surface 14 has a substantially circumferential form. Particularly, the top surface 14 is formed on a flange of the tank 10. The heat exchanger 30 is bolted to the flange.

[0072] Alternatively, the heat exchanger 30 can be welded to the top surface and / or the flange.

[0073] The heat exchanger 30 includes a fluid channel structure 32 and an air channel structure 38, which air channel structure 38 is configured for heat exchange with the fluid channel structure 32. Ambient fluid, especially air, can be guided through the air channel structure 38 in order to realize said heat exchange.

[0074] The heat exchanger 30 is configured as a cover for the top opening 12 and the fluid channel structure 32 is in fluid communication with the interior through the top opening 12. Thereby, the fluid F can be cooled down in the heat exchanger 30 by means of air flowing through the air channel structure 38.

[0075] The cooling system 1 is closed in a substantially fluid tight manner so that the fluid F cannot leak and / or is not exposed to the ambient fluid or air.

[0076] The heat exchanger 30 provides in total six passages 40. For example, the passages 40 are to accommodate bushings.

[0077] The number and size of passages 40 may vary depending upon the configuration of the heat generating electric component 2. The number of passages 40 may be six or more, e.g. eight, ten or twelve. A further passage 40 can be adopted to install other accessories like a pressure relief valve, a vent, or a gauge.

[0078] The passages 40 may be used for an electrical connection of the heat generating electric component 2 through the heat exchanger 30. The six passages 40 extend between a top surface 42 and the bottom surface 52 of the heat exchanger 30, with the bottom surface 52 facing the interior and the fluid F contained therein. Three of the six passages 40 are arranged in a row. H D 42349; P240092 15 / 23

[0079] Each of the passages 40 includes a passage surface 48 that is a substantially cylindrical surface extending between the top surface 42 and the bottom surface 52 of the heat exchanger 30. Each passage 40 is surrounded by a gasket section 44, particularly at least at the top surface 42 of the heat exchanger 30, for accommodation of a gasket 46, cf. Fig. 2B where ring gaskets 46 are indicated with dotted lines. Each gasket section 44 includes a groove for the gasket 46.

[0080] With respect to Fig. 3, Fig. 4 and Fig. 5, the bottom surface 52 of the heat exchanger 30 is substantially flat, partially exhibits the fluid channel structure 32 and is configured to abut with the top surface 14 of the tank 10. The heat exchanger 30 is shaped substantially flat, wherein the bottom 52 and the top 42 surfaces are arranged substantially in parallel to one another.

[0081] With particular respect to Fig. 4 and Fig. 5, the bottom surface 52 of the heat exchanger 30 includes a gasket section 54 for accommodation of a gasket 56 in order to seal against the tank 10, particularly against the top surface 14 thereof. The gasket section 54 of the bottom surface 52 of the heat exchanger 30 includes a groove with a narrowed entrance and particularly with a substantially trapezoidal shape in a cross section of the gasket section 54 (cf. Fig. 4B). The groove makes it possible that the gasket 56 can be inserted and kept via a form fit so that an assembly of the heat exchanger 30 to the top surface 14 of the tank 10 prevents a displacement or loss of the gasket in a vertical direction.

[0082] The heat exchanger 30 includes a three dimensional lattice cell structure with a triply periodic minimal surface. Thereby, the heat exchanger 30 has a minimized flow resistance and turbulence, resulting in low pressure drop and reduced energy requirements for fluid F and air circulation. Particularly due to the lattice cell structure, the heat exchanger 30 exhibits high mechanical strength and stiffness, making it suitable for applications that require structural support while providing efficient cooling.

[0083] Particularly, the three dimensional lattice structure, especially including the triply periodic minimal surface, can greatly increase a heat exchange surface per unit of volume, e.g. relative to other known heat exchangers. H D 42349; P240092 16 / 23

[0084] The heat exchanger 30 is integrated in the cooling system 1 as a cover. This enables direct cooling initiation at a hottest zone of the fluid F. This targeted approach improves cooling efficiency by addressing the area with peak temperatures first, mitigating excessive heat build-up at the top and promoting uniform temperature distribution throughout the fluid F.

[0085] Walls 33 of the heat exchanger 30 that form the fluid channel structure 32 and the air channel structure 38 are formed by a metal material, e.g. by means of additive manufacturing.

[0086] The heat exchanger 30 has two air inlets 34 each provided with a blower 35, e.g. an electric radial fan, and at least one air outlet 36 on an opposite side of the air inlets 34.

[0087] For example, with respect to Fig. 6, a single air outlet 36 may be provided, e.g. which extends along the respective side of the heat exchanger 30.

[0088] The arrangement of the blower 35 on the heat exchanger 30 can vary. The blower 35 can be mounted on a short side of the heat exchanger 30 (as shown) or on the long side (not shown), this can depend on the design configuration and selection of the type of blower 35. Conduits 66 connected to the bottom of the tank 10 can vary in size and quantity.

[0089] With respect to Fig. 3 and Fig. 4, the heat exchanger 30 has first ports 60 which are elongated and arranged to sectionally extend across a / the bottom surface 52 of the heat exchanger 30 facing the interior. The heat exchanger 30 has four second ports 64 arranged away from the interior and away from the top opening 12 (not shown in detail). The second ports 64 are substantially located at comers or parts of the heat exchanger 30, which corners / parts may project beyond the top surface 14 of the tank 10.

[0090] The first ports 60 comprise sections which are shaped curved and periodically repeating, e.g. in a periodic pattern or sinusoidal. In can be seen that the first ports H D 42349; P240092 17 / 23

[0091] 60 extend across the bottom surface 52 corresponding to the top opening and / or corresponding to a region surrounded by the gasket section 54.

[0092] In Fig. 3, the first ports 60 run - particularly periodically and / or in a curved shape

[0093] - along a length of the heat exchanger 30, the length being larger than a width.

[0094] In Fig. 4, the first ports 60 run - particularly periodically and / or in a curved shape

[0095] - along the width of the heat exchanger, the width being smaller than the length.

[0096] With reference to Fig. 1A-B, the second ports 64 are coupled via conduits 66 arranged exterior to the interior to a bottom section 16 of the tank 10. Each of the conduits 66 is provided by a pipe. The tank 10 having rounded and / or recessed sides 18 that extend along a height 20 of the tank 10 allows that the conduits 66 can extend from the part of the heat exchanger 30 projecting beyond the top surface 16 at said side 18 along the height 20 of the tank 10.

[0097] With respect to the pump devices 3 shown in Fig. 1A, these are configured as electric pumps that can draw the fluid F from the second ports 64 and push or pump said fluid F into the respective conduit 66. Thereby, the cold fluid F from the heat exchanger 30 is pushed back into the interior at a bottom section 16 of the tank, while hot fluid F is drawn through the top opening 12 into the heat exchanger 30 through the first ports 60.

[0098] Arrows in Fig. 1 A-B indicate the flow of the fluid F. In Fig. 1 A, it is indicated that fluid F is pushed downwards in the respective conduits 66 coupled to the pump devices 3, while in conduits 66 not directly coupled to the pump devices 3 the fluid F may move upwards (as indicated) or downwards, depending on resistance in the cooling system 1 . Thus, the fluid F may enter the heat exchanger 30 above the electric component and through the top opening, and optionally via the second ports 64 and / or one or more conduits 66 not provided with a pump device 3.

[0099] In Fig. 1 B, it is indicated by arrows that fluid F is moving upwards in the interior and downwards in the conduits 66. The fluid F may enter the heat exchanger 30 above the electric component and through the top opening 12. Particularly, the cooling H D 42349; P240092 18 / 23 system of Fig. 1 B allows natural convection of fluid F, e.g. the fluid F rising inside the tank 10 from being heated in the vicinity of the electric component in the interior, wherein its density reduces, cooling down in the heat exchanger 30 and being drawn back via the second ports 64 into a bottom section 16 of the tank 10.

[0100] At a bottom of the tank 10, the direction of the fluid F may substantially turn.

[0101] Shown and described is a use of a cooling system 1 , wherein the tank 10 of the cooling system 1 is configured to be arranged at least indirectly on a ground G with the top opening 12 arranged to face away from the ground G.

[0102] The shown cooling systems 1 can be made by a method to produce a cooling system 1 for a heat generating electric component 2. The method may comprise providing the tank 10 and the heat exchanger 30, the heat exchanger 30 configured as a cover for the top opening 12 of the tank 10. The method may comprise providing the fluid F and optionally the heat generating electric component 2. The heat exchanger 30 can be at least sectionally produced by an additive manufacturing process, e.g. laser powder bed fusion. The heat exchanger 30 can be placed atop the tank 10 in order to cover the top opening 12. The heat exchanger 30 may be fastened and / or welded to the tank 10. Fluid F and the heat generating electric component 2 may be inserted into the interior of the tank 10. The heat generating electric component 2 may be electrically connected via passages 40 in the heat exchanger 30.

[0103] H D 42349; P240092 19 / 23

[0104] Reference signs list

[0105] 1 cooling system

[0106] 2 electric component

[0107] 3 pump device

[0108] 10 tank

[0109] 12 top opening

[0110] 14 top surface

[0111] 16 bottom section

[0112] 18 side

[0113] 20 height

[0114] 30 heat exchanger

[0115] 32 fluid channel structure

[0116] 33 wall

[0117] 34 air inlet

[0118] 35 blower

[0119] 36 air outlet

[0120] 38 air channel structure

[0121] 40 passage

[0122] 42 top surface

[0123] 44 gasket section

[0124] 46 gasket

[0125] 48 passage surface

[0126] 52 bottom surface

[0127] 54 gasket section

[0128] 56 gasket

[0129] 60 first port

[0130] 64 second port

[0131] 66 conduit

[0132] F fluid

Claims

H D 42349; P240092 20 / 23Claims1. Cooling system (1 ) for a heat generating electric component (2), comprising a tank (10) including a top opening (12) and an interior configured for accommodating the heat generating electric component (2) and a fluid (F); and a heat exchanger (30) including a fluid channel structure (32) and an air channel structure (38) configured for heat exchange with the fluid channel structure (32); wherein the heat exchanger (30) is configured as a cover for the top opening (12), provides at least one bottom surface (52) that is configured for delimiting the interior of the tank, and the fluid channel structure (32) is in fluid communication with the interior through the top opening (12), and wherein the heat exchanger (30) includes a three dimensional lattice cell structure and has an air inlet (32) and an air outlet (36).

2. Cooling system according to the preceding claim, wherein the heat exchanger (30) provides at least one passage (40) for an electrical connection of the heat generating electric component (2) through the heat exchanger (30), and the at least one passage (40) extends between a top surface (42) and a bottom surface (52) of the heat exchanger (30), with the bottom surface (52) facing the interior.

3. Cooling system according to the preceding claim, wherein the at least one passage (40) is surrounded by a gasket section (44) at the top surface (42) of the heat exchanger (30) for accommodation of a gasket (46).

4. Cooling system according to the any one of the preceding claims, wherein the heat exchanger has a / the bottom surface (52) which is substantially flat, partially exhibits the fluid channel structure (32) and abuts with a substantially flat top surface (14) of the tank (10), which top surface (14) surrounds and / or forms the top opening (12), and particularly the heat exchanger (30) is shaped substantially flat.HD 42349; P240092 21 / 235. Cooling system according to the any one of the preceding claims, wherein a / the bottom surface (52) of the heat exchanger (30) includes a gasket section (54) for accommodation of a gasket (56) in order to seal against the tank (10), and the gasket section (54) of the bottom surface (52) of the heat exchanger (30) includes a groove with a narrowed entrance and particularly with a tapered and / or trapezoidal shape in a cross section of the gasket section (54).

6. Cooling system according to the any one of the preceding claims, wherein the three dimensional lattice cell structure has a triply periodic minimal surface.

7. Cooling system according to any one of the preceding claims, wherein the air outlet (36) is on an opposite side of the air inlet (34).

8. Cooling system according to the any one of the preceding claims, wherein the heat exchanger (30) has the air inlet (34) provided with a blower (35).

9. Cooling system according to the any one of the preceding claims, wherein the heat exchanger (30) has a first port (60) which is elongated and arranged to sectionally extend across a / the bottom surface (52) of the heat exchanger (30) facing the interior and has a second port (66) arranged away from the interior and / or away from the top opening (12).

10. Cooling system according to the preceding claim, wherein the first port (60) comprises sections which are shaped curved and / or periodically repeating.11 . Cooling system according to the preceding claim, wherein the second port (64) is coupled via a conduit (66) arranged exterior to the interior to a bottom section (16) of the tank (10), particularly the conduit (66) provided by a pipe.

12. Cooling system according to the any one of the preceding claims, whereinHD 42349; P240092 22 / 23 the tank (10) has at least one rounded and / or recessed side (18) extending along a height (20) of the tank (10) for the conduit (66) to extend from a part of the heat exchanger (30) projecting beyond a / the top surface (14) of the tank (10) at said side (18) and to extend along the height (20) at said side (18).

13. Cooling system according to the any one of the preceding claims, comprising a pump device (3) configured for pumping the fluid (F) through the fluid channel structure (32) and particularly coupled to the second port (64) and / or to the conduit (66).

14. Use of a cooling system (1 ) according to one of the preceding claims, wherein the tank (10) is configured to be arranged at least indirectly on a ground (G) with the top opening (12) arranged to face away from the ground (G).

15. Method to produce a cooling system for a heat generating electric component, comprising providing a tank (10) with a top opening (12) an interior configured for accommodating the heat generating electric component (2) and a fluid (F); providing a heat exchanger (30) including a fluid channel structure (32) and an air channel structure (38) configured for heat exchange with the fluid channel structure (32); wherein the heat exchanger (30) is configured as a cover for the top opening (12); the fluid channel structure (32) is in fluid communication with the interior through the top opening (12); and the heat exchanger (30) is at least sectionally produced by an additive manufacturing process, e.g. laser powder bed fusion.

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