Monolithic Redundant-Loop Cold Plate Core with Planar Pathways
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Solution Overview
Problem
Current redundant cooling loops in vehicles require stacked arrangements where heat must traverse through a failed loop to reach the secondary loop, compromising efficiency and reliability.
Innovation Solution
A monolithic redundant loop cold plate core with intermixed, non-linear cooling loops formed via additive manufacturing, allowing side-by-side coolant pathways without the need for stacked configurations, enhancing heat transfer and redundancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stacked cooling loop arrangements are used, then redundancy is achieved, but heat must traverse through the first cooling loop to reach the second cooling loop, reducing efficiency
Solution Approach 1:
The patent transitions from a vertical stacked arrangement (one loop above another) to a lateral side-by-side arrangement within the same plane. This dimensional reconfiguration allows the second cooling loop to access heat laterally rather than vertically through the first loop, eliminating the inefficiency of heat traversal while preserving redundancy.
Solution Approach 2:
The cooling loops are segmented into distinct lateral pathways within the heat exchanger core, with each loop having its own dedicated passage. This segmentation is enabled by fin walls that divide the core into separate zones, allowing independent heat access for each loop without interference or traversal requirements.
2Reliability
If stacked cooling loops are used, then redundancy is provided, but the structure requires multiple layers increasing device complexity
Solution Approach 1:
The patent consolidates multiple cooling loops into a single lateral plane rather than stacking them vertically across multiple layers. This reduces structural complexity by eliminating the need for multi-layer construction while maintaining redundancy through side-by-side loop configuration within the same plane.
Solution Approach 2:
Multiple cooling loops are merged into a single planar structure rather than being separated into stacked layers. The fin walls and monolithic core integrate all loops into one unified structure, simplifying the overall device architecture while preserving the redundant cooling pathways.
3Reliability
If conventional stacked cooling loops are used, then redundancy is achieved, but manufacturing precision is compromised due to assembly requirements
Solution Approach 1:
Multiple cooling loops are combined into a single monolithic structure manufactured as one integrated piece using additive manufacturing. This eliminates the need for separate assembly of stacked components, thereby removing alignment tolerance accumulation and ensuring precise geometric relationships between all cooling loops from a single manufacturing process.
Solution Approach 2:
The additive manufacturing process serves multiple functions simultaneously: it creates the monolithic core structure, forms all cooling loop passages, and integrates fin walls in a single manufacturing operation. This universal manufacturing approach eliminates the need for multiple assembly steps and ensures consistent precision across all structural elements.
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
Ensures efficient heat transfer and redundancy by eliminating the need for heat to pass through a failed loop, maintaining functionality even if one loop fails, with increased surface area and turbulence for improved thermal management.
Implementation Method 1
heat transfer
Implementation Method 2
coolant pathways
Data Source
Figure 1~3
Figure 4
Figure 5
AI summary
A monolithic redundant loop cold plate core includes a core structure (110) and a first cooling loop (200) formed in the core structure. The first cooling loop including one or more first cooling loop passageways (280) extending across a heat exchanger core in one or more passes. The one or more passes include at least a first pass. The monolithic redundant loop cold plate core includes a second cooling loop (300) formed in the core structure. The second cooling loop including one or more second cooling loop passageways (380) extending across the heat exchanger core in the one or more passes. The one or more first cooling loop passageways are intermixed in an alternating side-by-side arrangement with the one or more second cooling loop passageways in a single cooling plane. The monolithic redundant loop cold plate core is a single piece including a unitary structure.