Electrical Module Cooling with Self-Driven Closed-Loop Channels
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Solution Overview
Problem
Existing cooling methods for electrical modules, such as air cooling and liquid cooling, are inadequate for high power densities due to complexity, increased interfaces, energy consumption, and maintenance requirements, while pulsating heat pipes require precise geometric structures.
Innovation Solution
An electrical module with an annularly closed elongated media channel divided into alternating hot and cold segments, utilizing thermally induced fluid transport driven by temperature differences and flow-guiding elements to facilitate effective heat dissipation without complex geometric precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid cooling with external pump and piping is used, then heat dissipation capability is improved, but device complexity and number of interfaces increase
Solution Approach 1:
The cooling channels are integrated directly into the substrate structure, merging the cooling function with the electrical module substrate. This eliminates the need for separate cooling plates, external pumps, and complex piping systems, thereby reducing device complexity while maintaining effective heat dissipation capability
Solution Approach 2:
The substrate serves dual functions: as the electrical module mounting base and as the cooling channel carrier. This multi-functionality reduces the number of separate components and interfaces, simplifying the overall device structure while preserving cooling effectiveness
2Temperature
If liquid cooling with external pump is used, then heat dissipation capability is improved, but energy consumption increases
Solution Approach 1:
The cooling system utilizes the temperature difference between hot and cold segments to automatically drive fluid circulation through thermal expansion and contraction, eliminating the need for external pumps. This self-service mechanism reduces energy consumption while maintaining heat dissipation capability
Solution Approach 2:
The fluid circulation is driven by thermal expansion in hot segments and contraction in cold segments, creating a natural convection current. This thermally-driven flow mechanism eliminates the need for energy-consuming external pumps while preserving effective heat dissipation
3Temperature
If pulsating heat pipe with self-pulsing operation is used, then heat dissipation capability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The cooling channel is divided into alternating hot and cold segments that periodically exchange roles, creating self-pulsating flow without requiring narrow channel structures. This segmentation approach enables effective heat dissipation while avoiding the stringent geometric precision requirements of conventional pulsating heat pipes
Solution Approach 2:
The system employs dynamic, time-varying temperature distributions along the channel, where hot and cold segments periodically switch positions. This dynamic operation enables self-pulsating fluid flow and enhances heat dissipation without requiring the fixed, precision-critical geometry of conventional pulsating heat pipes
4Device complexity
If air cooling with fan is used, then device complexity is reduced, but heat dissipation capability becomes insufficient for high power densities
Solution Approach 1:
The system uses liquid coolant flowing through integrated channels instead of air cooling, providing superior heat dissipation capability for high power densities. The liquid cooling approach, combined with integrated channel design, maintains relatively simple device structure while dramatically improving thermal management performance
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
Achieves efficient heat dissipation with reduced complexity and external interfaces, using a single-phase fluid system that self-regulates fluid flow for effective heat transfer and distribution.
Implementation Method 1
a local heat input induces a thermally induced longitudinal transport of the fluid working medium
Implementation Method 2
The hot segments are each arranged in the region of the at least one electrical component and are thermally coupled to it in such a way that they enable the electrical component to be cooled
Implementation Method 3
with which a preferred direction can be imposed on a thermally driven transport of the fluid working medium
Data Source
Figure 1
Figure 2a~2c
Figure 3~4
AI summary
An electrical module (30) with at least one electrical component (35) and a cooling device (1) for cooling the electrical component (35) is specified, wherein the cooling device (1) has an annularly closed elongated media channel (3) for circulating a fluid working medium (M) in a closed circuit, wherein the annularly closed media channel (3) is bounded by a channel wall (5) which is divided at least in a partial region (40) in its local longitudinal direction (x) into a plurality of alternating hot segments (W) and cold segments (K), wherein the hot segments (W) are each arranged in the region of the at least one electrical component (35) and are thermally coupled to it in such a way that they enable the electrical component (35) to be cooled by means of a local heat input (Qin) into the fluid working medium (M) via the respective hot segment (W) of the channel wall (5).- wherein a transition zone (T) is formed between each of the adjacent hot segments (W) and cold segments (K), - and wherein at least one flow-guiding element (7) is arranged in at least a subset of these transition zones (T), with which a preferred direction (r) can be imposed on a thermally driven transport of the fluid working medium (M) by the local heat input (Qin). Furthermore, a corresponding cooling device (1) and a corresponding operating method are specified.