Microchannel Heat Exchanger With Split-Flow Cooling
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Solution Overview
Problem
Existing fluid heat exchange systems face challenges in providing improved thermal performance, especially in small form factors with low-profile designs, fewer fluid connections, and low-pressure-loss flow transitions.
Innovation Solution
The innovations include low-profile pump housings and heat sink designs with microchannels and recessed grooves that facilitate improved heat-transfer and pressure-loss performance, integrating components while minimizing system components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional heat exchange systems are used, then thermal performance can be achieved, but the system size and profile height increase
Solution Approach 1:
The heat exchange system is segmented into multiple microchannels within a compact heat sink structure, allowing thermal performance to be maintained while reducing overall profile height. The microchannels are arranged in a dense pattern to maximize heat transfer surface area within the constrained vertical space.
Solution Approach 2:
The pump assembly is integrated within the housing structure, with the impeller nested inside the pump housing that is itself integrated into the overall heat exchange assembly. This nesting approach allows the pump to occupy minimal additional space while maintaining its cooling function.
2Adaptability or versatility
If multiple system components are used, then functional requirements can be met, but device complexity increases
Solution Approach 1:
The pump and heat sink are merged into a single integrated assembly, with the pump housing structurally connected to the heat sink base. This merging eliminates the need for separate mounting brackets, additional fluid connections, and multiple assembly steps, thereby reducing device complexity while maintaining all required cooling functions.
Solution Approach 2:
The housing structure serves multiple functions: it provides structural support, contains the pump assembly, facilitates fluid distribution through integrated manifolds, and enables thermal dissipation through the heat sink. This multi-functionality reduces the need for separate dedicated components for each function.
3Speed
If conventional flow transitions are used, then fluid can be moved, but pressure loss increases
Solution Approach 1:
The flow transition passages are designed with curved surfaces rather than sharp angles, particularly at the inlet to the microchannels and at the pump outlet. These curved transitions reduce flow separation and turbulence, thereby minimizing pressure loss while maintaining effective fluid flow through the system.
4Ease of operation
If multiple fluid connections are used, then flow distribution can be improved, but manufacturing complexity increases
Solution Approach 1:
The fluid distribution system merges multiple connection points into integrated manifolds that are formed as single-piece structures within the heat sink base. This approach maintains the ability to distribute flow to multiple microchannels while eliminating the need for separate fittings, welds, or adhesive bonds that would 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
The solutions enhance thermal performance and reduce pressure loss in fluid heat exchange systems, achieving efficient cooling in compact designs with reduced fluid resistance.
Implementation Method 1
a plurality of microchannels for directing heat transfer fluid over the heat spreader plate
Implementation Method 2
a heat spreader plate including an intended heat generating component contact region
Data Source
AI summary
A fluid heat exchanger includes: a heat spreader plate including an intended heat generating component contact region; a plurality of microchannels for directing heat transfer fluid over the heat spreader plate, the plurality of microchannels each having a first end and an opposite end and each of the plurality of microchannels extending substantially parallel with each other microchannel and each of the plurality of microchannels having a continuous channel flow path between their first end and their opposite end; a fluid inlet opening for the plurality of microchannels and positioned between the microchannel first and opposite ends, a first fluid outlet opening from the plurality of microchannels at each of the microchannel first ends; and an opposite fluid outlet opening from the plurality of microchannels at each of the microchannel opposite ends, the fluid inlet opening and the first and opposite fluid outlet openings providing that any flow of heat transfer fluid that passes into the plurality of microchannels, flows along the full length of each of the plurality of microchannels in two directions outwardly from the fluid inlet opening. A method of cooling a heat generating component uses a fluid heat exchanger that splits a mass flow of coolant.