Liquid Cooler Output Duct Segmentation for Uniform Flow
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Solution Overview
Problem
Liquid-cooled power electronics coolers face inefficiencies in heat transfer due to uneven liquid circulation, particularly at low flow rates, leading to potential overheating and damage of components when air bubbles form in upper ducts, reducing cooling effectiveness.
Innovation Solution
A tubular additional part is installed in the output duct to direct the liquid flow through two routes, with approximately 50% of the flow passing via apertures near the bottom and the remainder via apertures near the top, ensuring uniform distribution across all transverse ducts, enhancing liquid circulation and venting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid cooling is used with transverse ducts to improve cooling effectiveness, then heat transfer capability is improved, but uneven liquid circulation occurs at low flow rates causing air bubbles to form in upper ducts
Solution Approach 1:
The output duct is segmented into two separate outlets: a upper outlet and a lower outlet. This segmentation allows the liquid flow to be divided into two paths, with liquid exiting through both upper and lower regions of the cooler, thereby preventing air bubble accumulation in upper ducts and ensuring uniform liquid circulation throughout all transverse ducts even at low flow rates
Solution Approach 2:
The invention introduces a vertical dimension to the liquid flow distribution by creating both upper and lower outlets in the output duct. Instead of single-directional flow, the system utilizes vertical separation of flow paths, allowing liquid to be distributed to upper and lower transverse ducts simultaneously, which resolves the air bubble entrapment problem in upper ducts
2Quantity of substance
If the amount of liquid supplied is reduced to save resources, then liquid consumption is decreased, but liquid circulation becomes uneven causing air to remain in upper ducts
Solution Approach 1:
By segmenting the output duct into upper and lower outlets, the system efficiently distributes the reduced liquid quantity to multiple paths. This ensures that even at low flow rates, liquid reaches both upper and lower transverse ducts, preventing air bubble formation and maintaining reliable cooling performance while consuming less liquid
3Device complexity
If a simple duct arrangement is used to reduce device complexity, then manufacturing is simplified, but liquid flow distribution becomes uneven at low flow rates
Solution Approach 1:
The output duct is segmented into two outlets (upper and lower), which is a simple structural modification that achieves uniform liquid distribution. This segmentation approach maintains manufacturing simplicity while dramatically improving liquid flow uniformity and preventing air bubble entrapment in upper ducts
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 arrangement achieves more uniform liquid flow and improved cooling efficiency at both full and low flow rates, preventing overheating and enhancing the reliability of the cooling system by ensuring all ducts are filled with liquid, even at reduced flow rates.
Implementation Method 1
the dissipation power actually transfers into the liquid
Implementation Method 2
a number of transverse ducts (side ducts) in the transverse direction arranged between the longitudinal ducts for circulating the liquid
Data Source
AI summary
Arrangement for circulating liquid in a liquid cooler (11) intended particularly for power electronics appliances, inside which cooler at least two longitudinal main ducts (22, 23) are arranged and transverse ducts (21) arranged between them and connecting them, and in which cooler at least one of the longitudinal ducts is an input duct (22), into which liquid from coming from outside is led via an input joint (12) and one is an output duct (23), from where the liquid is led out via the output joint (13), inside which output duct a tubular additional part (41) having an open end at least on the side of the output joint is installed, and which additional part is arranged detached from the output duct such that a gap remains between the outer surface of the additional part and the inner surface of the output duct for enabling a liquid flow in the output duct outside the additional part, and in which arrangement a first aperture or first apertures (P, N, P2) are arranged in the part of the additional part on the output joint side and/or in the output joint and/or between them for enabling a first path of passage for a part of the nominal total flow to the output joint, and a second aperture or second apertures (T, P1) are arranged in the part of the additional part that is farther from the output joint or between the additional part and the output duct for enabling a second path of passage for the remaining part of the total flow into the additional part and via it onwards to the output joint.