Cooling system with controlled biphase mixing of refrigerant

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Solution Overview

Problem

Current cooling systems, such as those using inverter compressors, face challenges in achieving cost efficiency, power efficiency, and reduced noise while providing precise temperature regulation for semiconductor components under test, especially when operating over large temperature ranges and dealing with heat generation by the devices being tested.

Innovation Solution

A bi-phase refrigerant based cooling system with dedicated flow paths for liquid and gas phases and a mixing chamber to dynamically control the ratio of gas to liquid refrigerant entering the evaporator, allowing for precise temperature regulation and rapid changes without additional moving parts or complex mechanical elements, enabling operation at a steady compressor speed and reducing compressor ON/OFF cycles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If inverter compressors are used to achieve variable speed operation and precise temperature regulation, then temperature control accuracy is improved, but manufacturing cost and mechanical complexity increase

Engineering Contradiction:

Improvetemperature control accuracyVSAvoidmechanical complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical variable speed control system (inverter compressor) with a fluid-based control system. A mixing chamber combines liquid refrigerant from the condenser with gaseous refrigerant from the accumulator, allowing precise temperature regulation by controlling the mixing ratio rather than compressor speed. This substitution eliminates the need for complex mechanical inversion mechanisms while achieving the same temperature control objective.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The mixing chamber acts as an intermediary device between the condenser and evaporator. It receives both liquid and gaseous refrigerant streams and mixes them in controlled proportions before delivering to the evaporator. This intermediary mechanism enables precise temperature control through ratio adjustment without requiring the compressor itself to vary its speed or operate cyclically.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If compressor is turned ON/OFF cyclically to regulate temperature, then system cost is reduced, but temperature regulation precision deteriorates

Engineering Contradiction:

Improvesystem costVSAvoidtemperature regulation precision

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The patent maintains continuous operation of the compressor without ON/OFF cycling. The mixing chamber continuously blends liquid and gaseous refrigerant streams in varying proportions, providing continuous temperature adjustment capability. This eliminates the discontinuous temperature regulation inherent in cyclic compressor operation while keeping the simple, low-cost compressor design.

Inventive Principle:

Principle #20Continuity of useful action

3Speed

If inverter compressor operates at full capacity initially to reach desired temperature quickly, then cooling speed is improved, but power consumption increases

Engineering Contradiction:

Improvecooling speedVSAvoidpower consumption

Core Design Contradiction:

SpeedVSUse of energy by moving object

Solution Approach 1:

The patent implements dynamic temperature control through the mixing chamber, which can rapidly adjust the ratio of liquid to gaseous refrigerant. This allows the system to provide maximum cooling capacity when needed by increasing liquid refrigerant proportion, then quickly transition to maintenance mode by reducing liquid proportion. The dynamic mixing ratio adjustment enables rapid response without requiring the compressor to cycle or operate at full capacity continuously.

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution achieves high accuracy temperature regulation (up to 0.1° C - 1° C) with rapid temperature changes over large ranges, improving power efficiency and reducing noise, while maintaining cost efficiency and operational simplicity.

Implementation Method 1

A mixing chamber is provided in which the liquid and gas refrigerant may be mixed at the desired ratio

Methodology Applied

Scientific EffectPhase mixing: Two-Phase Flow

Implementation Method 2

circulating a refrigerant... through an evaporator so that, during circulation, said refrigerant is maintained at high pressure between a compressor and a metering device

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 3

bi-phase refrigerant... maintained at high pressure between a compressor and a metering device of the subsystem and at low pressure while flowing through the evaporator

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS11112147B2Cooling system with controlled biphase mixing of refrigerant

Publication Date: 2021.09.07 M D MECHANICAL DEVICES

AI summary

A method for cooling with a refrigerant based cooling system includes circulating a refrigerant in a main flow path of a refrigeration cycle including an accumulator, compressor, condenser and an evaporator, diverting a portion of flow to a bypass flow path from a location along the main flow path that is downstream the compressor and upstream the condenser and combining flow through the bypass flow path with flow through the main flow path downstream the condenser and upstream from the evaporator. The rate of flow through the bypass flow path may be dynamically controlled.