Jet Impingement Foam Cooling for High-Heat-Flux Electronics
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Solution Overview
Problem
The increasing heat flux and temperature in electronic components due to miniaturization and higher processing speeds lead to performance degradation, reliability issues, and potential failure, necessitating advanced cooling systems that maintain temperature uniformity and prevent hotspots.
Innovation Solution
Development of high efficiency thermal management devices incorporating jet impingement technology, high conductive metal foam, rib structured surfaces, and a conductive heat spreader plate, with geometrical parameters optimized for effective cooling, including partially or fully foam-filled channels and rib configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional cooling methods (fans, heat sinks, cold plates) are used, then the device structure is simple, but the cooling efficiency is insufficient for high heat flux values
Solution Approach 1:
The cooling device is segmented into multiple functional zones: jet impingement regions with multiple nozzles, porous media filling the channel, and rib-roughened surfaces. This segmentation allows each component to perform its specific cooling function optimally, achieving high cooling efficiency for high heat flux applications while maintaining a manageable structural complexity through modular design
Solution Approach 2:
Porous media is introduced to fill the channel space, providing extensive surface area for heat transfer between the coolant and the heated surface. This porous structure significantly enhances cooling efficiency by increasing the contact area between the cooling fluid and the high heat flux surface, while the material itself is engineered to balance porosity with structural integrity
Solution Approach 3:
The cooling device employs composite structures combining jet impingement nozzles, porous media, and rib-roughened surfaces within a unified channel design. This composite approach integrates multiple heat transfer mechanisms (impingement cooling, porous media convection, and surface roughness enhancement) to achieve superior cooling performance for high heat flux electronic components
2Productivity
If jet impingement is used to increase cooling efficiency, then heat transfer rate improves, but pressure drop increases
Solution Approach 1:
Jet impingement is applied locally at specific regions where high heat flux occurs, rather than uniformly across the entire surface. The porous media is strategically positioned in channels where it can maximize heat transfer while minimizing flow resistance. This localized application of intense cooling measures achieves high heat transfer rates at the critical hot spots without subjecting the entire system to high pressure drops
Solution Approach 2:
The porous media acts as a flow distributor and heat transfer enhancer that reduces the pressure drop associated with jet impingement. By providing a distributed network of flow paths, the porous structure allows the coolant to penetrate and cool the surface uniformly without requiring excessively high jet velocities, thereby reducing the overall pressure drop while maintaining high heat transfer rates
3Temperature
If high heat flux is managed, then temperature uniformity improves, but device complexity increases
Solution Approach 1:
The channel geometry is designed with local variations including rib-roughened surfaces and strategically positioned nozzles that create localized high heat transfer coefficients. These local modifications are concentrated in regions where temperature uniformity is most critical, allowing the device to achieve improved temperature distribution without requiring complex geometry throughout the entire structure
Solution Approach 2:
Rib-roughened surfaces are introduced to add geometric complexity in the transverse dimension, creating multiple flow paths and enhancing mixing between adjacent jet streams. This dimensional addition promotes temperature uniformity by preventing hot spots in the regions between jets, while the ribs themselves can be simple geometric features that do not significantly increase manufacturing complexity
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
Enhances heat transfer and temperature uniformity, reducing stress failure and fatigue by improving local thermal treatment of hotspots, with fully foam-filled channels providing superior cooling efficiency and rib structures further enhancing local Nusselt numbers.
Implementation Method 1
at least one jet impingement of at least one thermal management liquid or gas, wherein the at least one jet inlet channel directs the at least one jet impingement of a liquid or a gas onto a surface of the at least one porous component or at least one foam component
Implementation Method 2
The coolant is injected to a target plate subject to a high heat flux or high temperature, resulting in a stagnation zone with low temperature and velocity and high rate of heat transfer
Implementation Method 3
at least one porous component or at least one foam component, wherein the at least one porous component or at least one foam component at least partially fills the at least one non-uniform channel area or uniform channel area
Implementation Method 4
The at least one porous component or at least one foam component at least partially fills the at least one non-uniform channel area or uniform channel area
Implementation Method 5
at least one heat spreader conductive plate, wherein the at least one non-uniform channel area or uniform channel area is bounded by the at least one jet inlet channel, the at least two exit channels, and the at least one heat spreader conductive plate
Data Source
AI summary
High efficiency heat management devices for use with electronic components, are disclosed and include: at least one jet inlet channel, at least one non-uniform channel area or uniform channel area, at least two exit channels, at least one heat spreader conductive plate, wherein the at least one non-uniform channel area or uniform channel area is bounded by the at least one jet inlet channel, the at least two exit channels, and the at least one heat spreader conductive plate, and at least one porous component or at least one foam component, wherein the at least one porous component or at least one foam component at least partially fills the at least one non-uniform channel area or uniform channel area.