Liquid-Cooled UPS Heat Sink Retrofit for High Power Density

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Solution Overview

Problem

Single-phase UPS systems face limitations in high-power density applications due to air cooling's lower thermal capacity and noise generation, making them bulky and inefficient for AI servers.

Innovation Solution

Convert air-cooled UPS systems to liquid-cooled systems by adding or replacing air-cooled heat sinks with liquid-cooled heat sinks, integrating them with liquid coolers and housings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If air cooling is used in UPS systems, then the system is simpler to implement, but the thermal capacity is insufficient for high-power density applications

Engineering Contradiction:

Improveease of implementationVSAvoidthermal capacity

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The patent transitions from air cooling (pneumatic) to liquid cooling (hydraulic) by implementing a liquid cooling system with coolant circulation. This resolves the contradiction by providing superior thermal capacity through liquid's higher specific heat capacity, enabling the UPS to handle high-power density applications while maintaining manageable temperatures.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Device complexity

If air cooling is used in UPS systems, then the cooling mechanism is simpler, but the system size increases due to required air circulation space

Engineering Contradiction:

Improvecooling mechanism complexityVSAvoidsystem size

Core Design Contradiction:

Device complexityVSVolume of stationary object

Solution Approach 1:

The liquid cooling system replaces air circulation with liquid coolant flow through compact channels and heat exchangers. This hydraulic approach achieves superior cooling efficiency in a reduced volume, eliminating the need for large air circulation spaces and reducing the overall system footprint.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Device complexity

If air cooling is used in UPS systems, then the cooling system is less complex, but noise generation increases

Engineering Contradiction:

Improvecooling system complexityVSAvoidnoise generation

Core Design Contradiction:

Device complexityVSObject-generated harmful factors

Solution Approach 1:

The liquid cooling system replaces noisy air movement with quiet liquid circulation. The hydraulic system uses pumped coolant flow through heat exchangers, eliminating the need for high-speed fans and air circulation mechanisms that generate significant noise, thereby creating a quieter operating environment.

Inventive Principle:

Principle #29Pneumatics and hydraulics

4Adaptability or versatility

If air cooling is used in UPS systems, then the cooling approach is more conventional, but power quality and efficiency deteriorate at elevated temperatures

Engineering Contradiction:

ImproveconventionalityVSAvoidpower quality

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The liquid cooling system maintains superior power quality and efficiency by keeping semiconductor temperatures lower through effective heat removal. The hydraulic cooling approach provides more stable thermal management, ensuring consistent electrical performance and reducing temperature-related degradation of power quality.

Inventive Principle:

Principle #29Pneumatics and hydraulics

5Adaptability or versatility

If air cooling is used in UPS systems, then the design is more traditional, but the thermal density is insufficient for high-power applications

Engineering Contradiction:

Improvedesign traditionalityVSAvoidpower density

Core Design Contradiction:

Adaptability or versatilityVSPower

Solution Approach 1:

The liquid cooling system enables high power density applications by providing superior thermal management. The hydraulic cooling approach removes heat more efficiently from power electronics, allowing higher power concentrations in compact spaces without compromising thermal management, thus resolving the power density limitation of air-cooled designs.

Inventive Principle:

Principle #29Pneumatics and hydraulics

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 power density, efficiency, and reduces noise, while improving reliability and durability in high-humidity environments, suitable for AI servers and HPC servers.

Implementation Method 1

a liquid-cooled heat sink thermally coupled to at least one of the one or more elements of the power component

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

coupling to the liquid-cooled heat sink to a liquid cooler

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20260052660A1Single-phase UPS liquid cooling

Publication Date: 2026.02.19 VERTIV CORP

AI summary

A method may include removing a housing of the power component, wherein removing the housing reveals an air-cooled heat sink. A method may include thermally coupling the liquid-cooled heat sink to one or more elements of the power component. A method may include coupling the liquid-cooled heat sink to a liquid cooler. A method may include replacing the housing.