Biphase Refrigerant Mixing for Precise Evaporator Temperature Control
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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 requiring rapid temperature changes.
Innovation Solution
A bi-phase refrigerant-based cooling system with dedicated flow paths for liquid and gas phases and a mixing chamber that dynamically controls the ratio of gas to liquid refrigerant entering the evaporator, allowing for precise temperature regulation without additional moving parts or complex mechanical elements, and enabling operation at a constant compressor speed without ON/OFF cycling.
Engineering Contradictions & Design Principles
Engineering 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
Solution Approach 1:
The patent replaces the mechanical speed control system (inverter compressor with variable speed mechanism) with a fluid-based control system. A mixing chamber combines hot gas refrigerant from the compressor with cold liquid refrigerant from the condenser, allowing precise temperature control through flow ratio adjustment rather than mechanical speed variation. This substitution eliminates the need for complex inverter mechanics while achieving the same temperature regulation function.
Solution Approach 2:
The mixing chamber acts as an intermediary device between the compressor and evaporator. It receives hot gas from the compressor and cold liquid from the condenser, mixing them in controlled proportions before delivering to the evaporator. This intermediary mechanism enables precise temperature control without requiring the compressor itself to vary its speed, thereby reducing mechanical complexity.
2Ease of manufacture
If compressor is operated at constant speed with ON/OFF cycling to regulate temperature, then manufacturing cost is reduced, but power efficiency decreases and noise increases
Solution Approach 1:
The system maintains continuous operation of the compressor at constant speed, eliminating the ON/OFF cycling of conventional systems. The mixing chamber continuously blends hot gas and cold liquid refrigerant in varying proportions to match cooling demands, ensuring uninterrupted useful action while maintaining constant compressor operation for improved power efficiency and reduced noise.
Solution Approach 2:
Instead of changing the compressor's operating parameters (speed on/off), the system changes the thermal parameters of the refrigerant by mixing hot and cold phases in different ratios. This parameter change in the refrigerant mixture allows temperature regulation while keeping the compressor operating continuously at constant speed, improving power efficiency.
3Speed
If inverter compressor operates at full capacity initially to reach desired temperature quickly, then cooling speed is improved, but power consumption increases
Solution Approach 1:
The system dynamically adjusts the mixing ratio of hot gas and cold liquid refrigerant in the mixing chamber based on real-time cooling demands. During rapid cooling phases, the mixture contains more cold liquid for faster cooling; during maintenance phases, the ratio shifts to reduce cooling intensity. This dynamic adjustment enables rapid temperature changes when needed while minimizing power consumption during steady-state operation.
Solution Approach 2:
The system utilizes phase transitions of the refrigerant by mixing hot gas (vapor phase) with cold liquid (liquid phase) in the mixing chamber. By controlling the proportion of each phase, the system can rapidly introduce cold liquid for fast cooling or predominantly use hot gas for low-power maintenance, achieving variable cooling intensity without variable compressor speed.
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 mechanical simplicity.
Implementation Method 1
The mixing chamber receives hot gas from the compressor and cold liquid from the condenser and mixes them in desired proportions
Implementation Method 2
The evaporator receives the mixed refrigerant and allows it to evaporate, thereby cooling the component under test
Implementation Method 3
the refrigerant is maintained at high pressure between a compressor and a metering device of the subsystem and at low pressure while flowing through the evaporator
Implementation Method 4
a condenser, downstream from which the mixing chamber is positioned to receive cold liquid from the condenser
Data Source
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.