Pass-Through Busbar Sealing Structure for Immersion Cooling
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Solution Overview
Problem
Conventional busbar modules in immersion liquid cooling systems fail to provide a reliable seal between the busbar and the cooling container wall, leading to potential leakage of cooling liquid due to gaps and bubbles formed by insulating materials.
Innovation Solution
A pass-through busbar module with stacked busbars and gaps filled with a sealant, such as epoxy resin, to create a sealed barrier between the busbars and the cooling container wall, ensuring a secure seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional busbar or busbar assembly is used to supply electric power through the cooling container wall, then electric power can be supplied from outside to immersed apparatus, but the busbar itself cannot provide sealing function leading to potential cooling liquid leakage
Solution Approach 1:
The patent combines the busbar structure with sealing function by integrating a sealant layer directly onto the busbar surface. The sealant is applied to the outer surface of the busbar that contacts the cooling liquid, creating a composite structure that simultaneously provides electrical conduction and sealing protection against cooling liquid leakage.
Solution Approach 2:
The invention uses composite material structure where a sealant material is applied onto the metallic busbar. This creates a composite assembly combining the electrical conductivity of metal busbar with the sealing properties of the sealant material, achieving both power transmission and leak prevention functions.
2Reliability
If insulating materials are used between stacked busbars, then electrical insulation is provided, but gaps and bubbles are formed compromising the seal
Solution Approach 1:
The patent employs a sealant layer as a flexible sealing film that is applied over the busbar assembly. This thin film sealant can conform to the busbar structure and fill any gaps or voids that may exist between stacked busbars or at the wall interface, providing continuous sealing without requiring perfect manufacturing precision.
Solution Approach 2:
The invention changes the physical state and properties of the sealant material to achieve effective sealing. The sealant is applied in a state that allows it to flow and fill gaps, then cured or set to provide rigid sealing protection, transforming the material parameters to suit different stages of the sealing process.
Data Source
AI summary
A pass-through busbar module is configured to pass through a wall of a cooling container of an immersion cooling system in a first direction so as to be mounted onto the wall, and to supply electric power from the outside to an electronic apparatus immersed in a cooling liquid within the cooling container. The pass-through busbar module comprises at least two busbars, which are stacked and partially spaced apart in a thickness direction such that there is a gap between adjacent busbars. The pass-through busbar module further comprises a sealant, which is at least filled in the gap to provide a seal between the busbars.