Modular Liquid Cooling System with Split-Flow Manifolds
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Solution Overview
Problem
Existing liquid cooling systems for electrical components are costly to manufacture and require significant skilled labor for assembly, making them inefficient for applications where quick and simple configuration is necessary, especially in harsh environments.
Innovation Solution
A modular liquid cooling system comprising split-flow tubes, split-flow manifolds, and single-flow manifolds connected using simple components and O-rings, allowing for easy assembly and disassembly, optimized coolant flow paths, and accommodating high-pressure liquid coolants, which can be manufactured separately and assembled with electrical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex mechanical tubing configurations are used for liquid cooling, then cooling effectiveness is improved, but manufacturing cost and assembly complexity increase significantly
Solution Approach 1:
The cooling system is divided into modular components including manifold assemblies, coolant distribution manifolds, and individual cooling channels that can be manufactured separately and assembled together. This segmentation allows each component to be optimized independently while simplifying the overall assembly process and reducing manufacturing complexity.
Solution Approach 2:
The manifold assemblies are designed with universal connection interfaces and standardized mounting features that allow the same basic components to be used across different cooling configurations and applications. This multi-functionality reduces the variety of unique parts needed, simplifying inventory management and assembly procedures.
2Reliability
If traditional liquid cooling systems are manufactured with custom tubing configurations, then cooling performance is optimized, but labor costs and manufacturing time increase
Solution Approach 1:
The manifold assemblies and cooling channels are pre-manufactured with precise flow paths and connection interfaces before final assembly. This preliminary fabrication of critical cooling components ensures optimal cooling performance is built-in during manufacturing, while the modular design allows rapid final assembly without requiring complex custom tubing work in the field.
3Ease of manufacture
If modular components are used to simplify assembly, then manufacturing ease is improved, but system adaptability may be reduced
Solution Approach 1:
The modular cooling system employs standardized connection interfaces and interchangeable manifold assemblies that allow the system configuration to be dynamically adjusted based on specific application requirements. Components can be easily added, removed, or reconfigured without requiring custom fabrication, providing both assembly simplicity and configuration flexibility.
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 modular system reduces heat losses, allows for smaller components with lower temperature ratings, decreases shipping weight and material mass, and lowers costs by simplifying assembly and configuration, while maintaining effective cooling performance.
Implementation Method 1
Heat from components is dissipated into the cooling liquid and is carried away from the components that generate the heat
Implementation Method 2
liquid cooling systems include mechanical tubing or pipe configurations that form channels for directing cooling liquid along paths adjacent heat generating components
Data Source
AI summary
Cooling systems include a first passageway forming member that includes first and second ends and at least one connecting recess that opens into first and second passageways formed by the first passageway forming member. A second passageway forming member includes first and second ends and inlet and outlet ports proximate the first end such that the first end, including an elastomeric seal and the inlet and outlet ports, is sealably insertable in and removable from the at least one connecting recess, where the inlet port opens into the first passageway and the outlet port opens into the second passageway, and where, when the first end is inserted in the at least one connecting recess, the elastomeric seal is sandwiched between and in substantial contact with both the first end and the first passageway forming member.