Cold-Plate Rectification Module Layout for Server Power Cooling
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Solution Overview
Problem
Traditional air cooling technologies are inadequate for high-power-density servers, particularly in dissipating heat from transformer windings and magnetic cores in rectification modules, leading to increased winding loss and core loss, which complicates heat management in server power supplies.
Innovation Solution
A power supply device design that integrates a transformer unit, rectifier unit, and heat dissipation component, where the transformer unit includes windings and a magnetic core, and the rectifier unit includes a circuit board with rectifiers and output filter capacitors, all arranged to maximize heat dissipation through a cold plate system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If air cooling technology is used for high-power-density servers, then the cooling system is simple, but the heat dissipation performance is insufficient
Solution Approach 1:
The patent replaces air cooling (mechanical convection) with liquid cooling through cold plate technology. The cold plate directly contacts heat-generating components (transformer and rectifier) and uses liquid circulation to transfer heat, achieving superior heat dissipation performance for high-power-density servers while maintaining system compactness.
Solution Approach 2:
The patent introduces a cold plate as an intermediary heat dissipation component between the heat-generating components (transformer and rectifier) and the cooling system. The cold plate serves as a thermal conductor that efficiently transfers heat from multiple components simultaneously, resolving the contradiction between cooling effectiveness and system complexity.
2Loss of energy
If the transformer is designed for highest efficiency at half load with balanced winding loss and core loss, then the overall efficiency is optimized, but the winding heat dissipation becomes insufficient
Solution Approach 1:
The patent applies localized heat dissipation treatment specifically to the transformer windings through the cold plate design. The cold plate makes direct contact with the winding areas that generate excessive heat, providing targeted thermal management while preserving the overall efficiency-optimized design of the transformer with balanced winding and core losses at half load.
3Temperature
If a cold plate is designed to cool both transformer and rectifier simultaneously, then the heat dissipation coverage is maximized, but the structural complexity increases
Solution Approach 1:
The patent merges the heat dissipation functions for the transformer and rectifier into a single integrated cold plate structure. This unified cold plate simultaneously contacts both components, enabling one cooling system to handle heat from multiple sources, thereby maximizing heat dissipation coverage while avoiding the structural complexity of separate cooling systems.
Solution Approach 2:
The cold plate is designed as a multi-functional component that serves multiple heat-generating components (transformer and rectifier) simultaneously. This universal heat dissipation approach allows a single cooling structure to perform multiple thermal management functions, reducing overall system complexity while maintaining comprehensive heat dissipation coverage.
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
The design optimizes heat dissipation performance by ensuring that critical components are positioned to minimize AC losses and improve power density, extending the life of components like output filter capacitors and rectifiers while maintaining efficient cooling.
Implementation Method 1
the heat dissipation component covers a rectification module formed by the transformer unit and the rectifier unit
Implementation Method 2
Cold plate technology, as an efficient and green cooling method, is gradually becoming the best choice for data center construction
Data Source
AI summary
A power supply device is disclosed and includes a transformer unit, a rectifier unit and a heat dissipation component. The transformer unit includes a first winding, a second winding and a magnetic core. The rectifier unit includes a circuit board, a plurality of rectifiers and a plurality of output filter capacitors. The circuit board and the transformer unit are disposed adjacent to each other, and the second winding is electrically connected to the circuit board, wherein the circuit board has a first side and a second side opposite to each other, and the first side faces the transformer unit. The heat dissipation component covers a rectification module formed by the transformer unit and the rectifier unit.