Liquid Cooling Leak Sensor Using Wicking-Based Electrical Detection

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Solution Overview

Problem

Existing liquid cooling systems in information handling systems face challenges in accurately detecting leaks, as conventional leak detection methods, such as leak sense ropes, can cause conductor shorts due to bending issues, leading to false alarms or missed detections.

Innovation Solution

A liquid cooling leak sensor unit comprising a cold liquid reservoir, a non-conductive material, a rigid conductive component, and a wicking material, which transfers leaked cooling liquid to the conductive component, allowing a leak sense controller board to detect electrical changes for precise leak detection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional leak sense ropes are used for leak detection, then leak detection capability is provided, but conductor shorts occur due to bending issues leading to false alarms or missed detections

Engineering Contradiction:

Improveleak detection accuracyVSAvoidconductor shorts

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent introduces a wicking material as an intermediary between the liquid reservoir and the rigid conductive component. This wicking material absorbs and transfers leaked liquid to the conductive component, serving as a mediator that prevents direct contact between the liquid and conductors, thereby eliminating conductor shorts while maintaining leak detection capability through electrical resistance or capacitance changes

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the mechanical bending-based leak detection method (leak sense ropes that physically bend to detect leaks) with an electrical field-based detection method. By using the rigid conductive component in proximity to the liquid reservoir and detecting electrical resistance or capacitance changes, the system eliminates mechanical bending issues that caused conductor shorts while maintaining effective leak detection

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If rigid conductive component is placed near liquid reservoir for electrical detection, then leak detection precision is improved, but risk of direct liquid contact and conductor damage increases

Engineering Contradiction:

Improveleak detection precisionVSAvoidliquid contact damage

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The wicking material serves as a protective intermediary layer between the rigid conductive component and the liquid reservoir. It allows the conductive component to be positioned close to the reservoir for precise electrical detection while preventing direct liquid contact that would cause conductor damage or false readings

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The wicking material acts as a sacrificial, replaceable component that absorbs liquid exposure. This disposable-like element protects the expensive rigid conductive component and liquid reservoir from direct contact damage, allowing the wicking material to be replaced if saturated while preserving the main system components

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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

The system effectively detects liquid leaks before damage occurs by monitoring electrical resistance or capacitance changes, preventing conductor shorts and ensuring accurate leak detection.

Implementation Method 1

The wicking material may transfer liquid from the cold liquid reservoir to the rigid conductive component

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

The leak sense controller board may detect a leak in the cold liquid reservoir in response to an electrical change between the rigid conductive component and the cold liquid reservoir

Methodology Applied

Scientific EffectElectrical resistance change: Electrical Resistance

Implementation Method 3

monitoring electrical resistance or capacitance changes

Methodology Applied

Scientific EffectCapacitance change: Capacitance

Data Source

PatentUS12504344B2Liquid cooling leak sensor

Publication Date: 2025.12.23 DELL PROD LP

AI summary

A liquid cooling leak sensor unit for an information handling system includes a cold liquid reservoir, a non-conductive material, a rigid conductive component, a wicking material, and a leak sense controller board. The non-conductive material is in physical communication with the cold liquid reservoir. The rigid conductive component is in physical communication with the non-conductive material. The wicking material is in between and in physical communication with both the cold liquid reservoir and with the rigid conductive component. The wicking material transfers liquid from the cold liquid reservoir to the rigid conductive component. The leak sense controller board is coupled to both the rigid conductive component and the cold liquid reservoir. The leak sense controller board detects a leak in the cold liquid reservoir in response to an electrical change between the rigid conductive component and the cold liquid reservoir.