Liquid Metal Cold Plate Interface for Drain-Free Power Module Cooling
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Solution Overview
Problem
Existing electrical cooling systems require draining of heat transfer fluid for installation and maintenance of power modules, which is inconvenient and can be challenging, especially in integrated systems like aircraft where dismantling is difficult.
Innovation Solution
An electrical system with a heat sink and cold plate design where liquid metal is interposed between the heat sink's thermal dissipation projections and the cold plate's cavities, allowing easy separation and maintaining effective heat exchange without the need for fluid purging, using liquid metal with high thermal conductivity and suitable temperature range for aircraft environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical clamping or sintering is used to attach the heat sink to the cold plate, then the power module can be securely mounted, but the heat transfer fluid must be drained for installation and maintenance
Solution Approach 1:
Liquid metal is introduced as an intermediary substance between the heat sink and cold plate. This liquid metal filler allows the heat sink to be securely attached to the cold plate while enabling easy separation without fluid draining, as the liquid metal remains in the sealed cavity and continues to provide thermal contact after assembly
Solution Approach 2:
The liquid metal is contained within the sealed cavity of the cold plate, creating a nested structure where the heat sink with projections fits into the cavity filled with liquid metal. This nesting allows secure thermal contact while maintaining the ability to separate components without losing the heat transfer medium
2Temperature
If the heat sink projections extend into the cooling channel, then heat exchange performance is improved, but the power module cannot be easily separated from the heat transfer fluid box
Solution Approach 1:
The liquid metal acts as a mediator that fills the gaps between the heat sink projections and the cold plate cavity walls. This allows the projections to extend into the cooling channel for improved heat exchange while the liquid metal maintains thermal contact without mechanically interlocking the components, enabling easy separation
Solution Approach 2:
The cooling system is segmented into a sealed cold plate cavity containing the liquid metal and a separate power module. The heat sink projections extend into the cavity but are not permanently fixed, allowing the power module to be separated from the heat transfer fluid box while maintaining heat exchange functionality
3Ease of manufacture
If traditional heat sink attachment methods are used, then assembly is straightforward, but maintenance requires draining the heat transfer fluid
Solution Approach 1:
The liquid metal intermediary enables both easy assembly and maintenance. During assembly, the liquid metal is placed in the sealed cavity and the power module is mounted straightforwardly. During maintenance, the power module can be removed and reinstalled without draining the liquid metal, as it remains contained within the sealed cold plate cavity
Solution Approach 2:
The liquid metal is pre-filled into the sealed cold plate cavity before the power module is attached. This preliminary action ensures that the heat transfer medium is already in position and will remain there during assembly and maintenance operations, eliminating the need for draining during repairs
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 design enables easy assembly and maintenance of power modules with enhanced heat exchange performance, ensuring efficient cooling without fluid purging, suitable for aircraft environments where integration complexity is high.
Implementation Method 1
the liquid metal is interposed between the heat sink and the cold plate, at least between the projections and the cavities... the liquid metal improves heat exchange... the liquid metal has a thermal conductivity greater than 50 W/m·K
Implementation Method 2
Because it is liquid, it spreads naturally in the gap between the heat sink and the cold plate, despite its irregular shape due to the interlocking projections in the cavities
Data Source
AI summary
An electrical system includes an electrical power module with a heat sink provided with heat-dissipating projections. The system further includes a cold plate of a heat-transfer fluid box. The cold plate has cavities which are complementary to the projections so as to receive said projections. Liquid metal is inserted between the heat sink and the cold plate, at least between the projections and the cavities.