Dielectric Spray Nozzle Layout for Uniform Cooling on Sloped Modules

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Solution Overview

Problem

Existing thermal control devices for electrical and electronic components, such as batteries in vehicles, suffer from non-uniform cooling due to the sloping installation of components, leading to local overheating and poor thermal homogeneity.

Innovation Solution

A thermal control device with a dielectric fluid circuit and spray nozzles configured to project a generally fan-shaped or flat jet of dielectric fluid, ensuring uniform wetting of components regardless of their slope or installation position.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional spray nozzles are used for cooling components, then cooling is achieved, but non-uniform cooling occurs due to sloping installation leading to local overheating

Engineering Contradiction:

Improvethermal homogeneityVSAvoiduniformity of cooling

Core Design Contradiction:

TemperatureVSEase of operation

Solution Approach 1:

The patent changes the spray pattern parameter from conventional circular/conical spray to a flattened fan-shaped spray pattern. This parameter modification allows the spray to maintain uniform distribution across sloping surfaces, resolving the contradiction between achieving cooling and maintaining thermal homogeneity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The spray nozzle is designed to project a dynamic fan-shaped spray pattern that can adapt to sloping surfaces. The flattened spray geometry dynamically adjusts the distribution of cooling fluid across the component surface, ensuring uniform coverage regardless of installation angle.

Inventive Principle:

Principle #15Dynamics

2Temperature

If the number of nozzles is increased to improve uniformity, then thermal homogeneity improves, but device complexity and space requirements increase

Engineering Contradiction:

Improvethermal homogeneityVSAvoidnumber of nozzles

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

Instead of increasing the number of nozzles, the patent modifies the spray pattern parameter of existing nozzles to a fan-shaped configuration. This single parameter change enables one nozzle to perform the work of multiple nozzles, maintaining thermal homogeneity while reducing device complexity.

Inventive Principle:

Principle #35Parameter changes

3Temperature

If cold plate with cooling fluid circulation is used, then cooling is achieved, but thermal resistance increases due to material thickness

Engineering Contradiction:

Improvecooling effectivenessVSAvoidthermal resistance

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent uses dielectric fluid spray (aerosol form) directly onto the component surfaces instead of using a cold plate with internal fluid circulation. This hydraulic approach eliminates the thermal resistance introduced by cold plate material thickness, as the cooling fluid makes direct contact with the component surfaces.

Inventive Principle:

Principle #29Pneumatics and hydraulics

4Temperature

If dielectric fluid is sprayed onto sloping components, then cooling is achieved, but non-uniform wetting occurs leading to local overheating

Engineering Contradiction:

Improvecooling coverageVSAvoiduniformity of wetting

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The patent changes the spray pattern geometry parameter from conventional circular/conical to a flattened fan-shaped pattern. This parameter modification ensures that the spray distributes uniformly across sloping component surfaces, achieving precise and homogeneous wetting coverage.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The fan-shaped spray pattern introduces an asymmetric geometry that is specifically suited for cooling sloping surfaces. The flattened asymmetric pattern directs cooling fluid coverage in a way that compensates for the slope, ensuring uniform wetting where conventional symmetric spray patterns would fail.

Inventive Principle:

Principle #4Asymmetry

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 solution achieves more homogeneous thermal control, preventing local overheating and ensuring consistent cooling performance across the components, even when installed sloping.

Implementation Method 1

A heat exchange may then take place between the components and the dielectric fluid which comes into direct contact with a surface of the components

Methodology Applied

Scientific EffectHeat exchange: Convection

Implementation Method 2

the spray nozzles (11) are configured to project, via at least one projection orifice, a generally fan-shaped or generally flat jet of dielectric fluid

Methodology Applied

Scientific EffectDielectric fluid spray: Fluid Spray

Data Source

PatentUS20250159842A1Thermal control device, in particular for a motor vehicle, and associated thermal control unit

Publication Date: 2025.05.15 VALEO SYST THERMIQUES SAS

AI summary

A thermal control device for at least one module for a motor vehicle includes a dielectric fluid circuit and a number of nozzles for spraying dielectric fluid and configured to be arranged to wet at least one surface of the at least one module with dielectric fluid. The spray nozzles are configured to project, via at least one projection orifice, a fan shaped jet of dielectric fluid. The spray nozzles each include a projection channel configured to direct the dielectric fluid and at least one dielectric fluid deflector onto which the projection channel opens, to orient the dielectric fluid to create a fan shaped jet.