Immersion Cooling Conversion Using Single-Phase High-Boiling Fluids
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Solution Overview
Problem
There is a need to convert two-phase and hybrid immersion cooling systems to one-phase systems due to the high cost of expensive non-flammable, thermally conductive, dielectric, low boiling point fluorochemicals used in these systems, but no convenient method has been devised for such conversions.
Innovation Solution
The conversion involves modifying the two-phase or hybrid system by introducing a high boiling point composition as a substitute operating fluid and altering the system structure, such as positioning barriers, removing condensers, and installing heat exchangers to allow the cooled fluid to flow into the reservoir from a direction other than above, thereby facilitating the transition to a one-phase system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two-phase or hybrid immersion cooling systems are used, then cooling efficiency is improved through phase change heat transfer, but the cost of the system increases due to expensive non-flammable fluorochemicals
Solution Approach 1:
The patent changes the physical parameters of the operating fluid by using high boiling point compositions (boiling point above 100°C) instead of low boiling point fluorochemicals. This parameter change allows the system to maintain effective heat transfer while using cheaper, non-flammable alternatives such as perfluorocarbons with boiling points above 100°C or other dielectric fluids, thereby reducing cost while preserving cooling efficiency
Solution Approach 2:
The patent replaces expensive, specialized low boiling point fluorochemicals with cheaper high boiling point compositions that can be more readily obtained and handled. The high boiling point fluids serve as a cost-effective substitute that maintains the essential cooling function without requiring the expensive specialized chemicals used in two-phase systems
2Power
If condensers and vapor management components are added to two-phase systems, then heat rejection capability is improved, but the device complexity increases
Solution Approach 1:
The patent extracts and removes the condenser components from the system by transitioning to a single-phase cooling approach. High boiling point compositions remain in the liquid phase throughout the cooling process, eliminating the need for vapor condensation equipment. The heat rejection is achieved directly through liquid-to-liquid heat exchange, simplifying the overall system structure while maintaining heat rejection capability
Solution Approach 2:
The patent segments the cooling system into distinct functional zones: a reservoir for the high boiling point composition, a cooling chamber where heat is absorbed from electronics, and a heat exchanger for heat rejection. This segmentation allows each component to be optimized independently and simplifies the overall system architecture by eliminating the need for integrated condensation and vapor management subsystems
3Quantity of substance
If high boiling point compositions are used as operating fluid, then the volume of fluid required is reduced, but the heat transfer mechanism changes from phase change to convection
Solution Approach 1:
The patent employs hydraulic principles by utilizing the natural convection currents generated by temperature-induced density differences in the high boiling point composition. The heated fluid rises and the cooler fluid sinks, creating continuous circulation patterns that enhance heat transfer without requiring phase change. This hydraulic convection mechanism effectively replaces the phase change heat transfer while reducing the total volume of fluid needed in the system
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 approach allows for a cost-effective conversion of two-phase or hybrid systems to one-phase systems, reducing the volume of operating fluid required and enhancing cooling efficiency by using a high boiling point composition, which can be pumped into the reservoir at the bottom, utilizing convective forces or pumps to circulate the cooled fluid.
Implementation Method 1
The operating fluid extracts heat from the heat generating components, and transfers it to a coolant via a heat exchanger... In natural convection the operating fluid utilizes gravity currents for circulation
Implementation Method 2
In forced convection, a pump is used to circulate the operating fluid within from the reservoir, through the heat exchanger, and back to the reservoir
Implementation Method 3
The operating fluid extracts heat from the heat generating components, and transfers it to a coolant via a heat exchanger, which the rejects the transferred heat at a facility level through a coolant flowing through the heat exchanger
Implementation Method 4
In forced convection, a pump is used to circulate the operating fluid within from the reservoir, through the heat exchanger, and back to the reservoir
Data Source
AI summary
A two-phase or hybrid immersive cooling system is converted to a one-phase immersive cooling system, by (1) modifying a structure of the two-phase immersive cooling system such that a cooled portion of a substitute operating fluid flows into the operating fluid reservoir from a direction other than from above the reservoir, and (2) using a high boiling point composition as the substitute operating fluid. In some embodiments the tube condensers of the two-phase or hybrid immersive cooling system are retained, and in other embodiments at least portions of the regions previously occupied by tube condensers are used for heat exchangers, and optionally fluid pumps. In still other embodiments at least portions of the regions previously occupied by tube condensers are used for hot fluid holding tanks.