Modular Liquid Cooling Block for Isolated Switching Assemblies
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Solution Overview
Problem
Modern power flow control systems in distributed power generation and distribution grids face challenges with high thermal loads due to the use of air cooling, which is inefficient for high current devices, and there is a need for liquid cooling configurations adapted for these systems.
Innovation Solution
A liquid cooling system for power flow control systems, comprising a modular liquid cooling block with a pump and switching assemblies, where the liquid coolant is circulated through each switching assembly, and the assemblies are electrically isolated from the enclosure to prevent ionization at high electric fields, allowing for series and parallel topologies and efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If air cooling is used for heat dissipation in power flow control systems, then the system structure is simple, but the cooling efficiency is insufficient for high current devices
Solution Approach 1:
The patent applies liquid cooling (hydraulic principle) by circulating coolant through channels in the baseplate to remove heat from high-power semiconductor devices. The liquid cooling block with integrated pump and coolant circulation system replaces inadequate air cooling, enabling efficient heat dissipation for high current devices while maintaining manageable system complexity through modular design.
2Loss of energy
If liquid cooling is implemented without voltage isolation, then heat dissipation efficiency increases, but ionization occurs at high electric fields
Solution Approach 1:
The patent introduces an electrical isolation barrier as an intermediary between the liquid cooling system and the high-voltage switching assemblies. This isolation layer allows thermal coupling for efficient heat dissipation while preventing direct electrical contact that would cause ionization of the liquid coolant at high electric fields exceeding 1500V DC potential.
Solution Approach 2:
The switching assemblies are divided into electrically isolated modules, each with its own baseplate for thermal coupling to the liquid cooling system. This segmentation enables series and parallel topologies while maintaining voltage isolation, allowing efficient heat removal without causing coolant ionization.
3Reliability
If switching assemblies are electrically isolated from the enclosure, then ionization is prevented, but the device complexity increases
Solution Approach 1:
The patent merges the electrical isolation function with the thermal management system by integrating isolation barriers into the liquid cooling block structure. The baseplate serves dual purposes: thermal conduction for heat dissipation and structural support for isolation. This integration reduces overall device complexity while maintaining reliability through a unified design approach.
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 liquid cooling system effectively manages high thermal loads, enabling the power flow control systems to operate reliably with extended lifetimes and high efficiency, injecting reactive power into transmission lines while maintaining voltage isolation and operational stability across varying temperatures.
Implementation Method 1
Each switching assembly has a baseplate arranged to thermally couple to the liquid coolant
Implementation Method 2
The pump is for circulating liquid coolant
Data Source
AI summary
A liquid cooling power flow control system and related method are described. The system has switching assemblies for power flow control, in an enclosure. A pump circulates liquid coolant through a liquid cooling block to each switching assembly. The switching assemblies are electrically isolated from the enclosure.