Flexible Sleeve Cooling Circuit for Heat-Stressed Electronic Cavities
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Solution Overview
Problem
Current cooling solutions for high-heat electronic devices, such as gyrotrons, face challenges in achieving effective heat transfer while maintaining mechanical stability, as they are limited by thermal stress and radial expansion, and often result in non-uniform cooling and mechanical stresses due to the use of mini-canals and braze materials.
Innovation Solution
A cooling system with a heat-transport fluid circuit featuring grooves on the external surface of the internal cavity and a flexible sleeve forming mini-canals with varying thicknesses, allowing for closer proximity of the fluid to the heated surface and reducing thermal resistance, while maintaining mechanical stability through a dynamic geometry that adapts to thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the wall thickness is reduced to improve heat transfer, then the heat exchange efficiency is improved, but the mechanical stability is adversely affected due to thermal expansion
Solution Approach 1:
The cooling circuit is segmented into multiple mini-canals distributed across the wall thickness, allowing heat transfer optimization without compromising structural integrity. The segmentation enables independent thermal management zones while maintaining overall mechanical stability.
Solution Approach 2:
The mini-canals are nested within the wall structure, with the cooling circuit embedded inside the wall thickness. This nesting allows the cooling fluid to be positioned close to the heated surface for efficient heat transfer while the outer wall structure maintains mechanical stability.
2Device complexity
If mini-canals are implemented in a single block of material, then the structure is simplified, but the distance between mini-canals and heated wall increases causing thermal resistance
Solution Approach 1:
The mini-canals are arranged in a three-dimensional configuration within the wall structure, allowing them to approach the heated surface from multiple directions and positions. This dimensional arrangement minimizes the distance between cooling fluid and heated wall while maintaining structural integrity.
3Ease of manufacture
If rectilinear mini-canals are used, then the manufacturing is simplified, but the cooling uniformity is reduced due to inability to follow cavity curvature
Solution Approach 1:
The mini-canals are designed with curved paths that follow the contour of the cavity wall, enabling uniform heat transfer across the entire heated surface. The curved configuration allows the cooling fluid to maintain optimal distance from the heated wall throughout, improving cooling uniformity while remaining manufacturable.
4Strength
If braze material is used to join cooling elements, then the mechanical strength is improved, but the thermal stress and mechanical stresses are increased
Solution Approach 1:
The cooling circuit is integrated directly into the wall structure through nesting, eliminating the need for separate joining operations. The mini-canals are formed as part of the monolithic structure, removing braze joints and their associated thermal and mechanical stresses.
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 solution enhances heat transfer efficiency, reduces thermal stress, and improves mechanical robustness by minimizing the distance between the heat-transport fluid and the heated surface, achieving a flatter temperature profile and lower mechanical stresses, while ensuring vacuumtightness and stability.
Implementation Method 1
The heat heats the fluid and is removed by the flowing of this fluid through the cooling circuit
Implementation Method 2
the presence of a thick wall between the heated surface and the stream of heat-transport fluid limits the exchange of heat
Data Source
AI summary
An electronic system includes an external jacket; a wall of an internal cavity that is to be cooled; at least one fixed connection fixing the external wall of the internal cavity that is to be cooled to the external jacket; a heat-transport fluid cooling circuit comprising grooves on the external surface of the wall of the internal cavity and a sleeve comprising a flexible portion positioned flush with the external surface of the external wall of the internal cavity, thereby forming mini-canals with said grooves; a radial extension of the wall of the internal cavity creating connecting points intended to hold the sleeve in place; and a space between the external jacket and the sleeve at the flexible portion of the sleeve.