Multi-Layer Immersion Cooling for Vapor Containment Without Bellows

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Solution Overview

Problem

Conventional dual-phase fluid immersion cooling systems face issues such as vapor leakage, space inefficiency due to bellows, and high manufacturing and operational costs, primarily because of the need for vapor balance mechanisms.

Innovation Solution

A fluid immersion cooling system with a dual-phase coolant fluid layer and one or more immiscible single-phase coolant fluid layers, where the dual-phase fluid has a lower boiling point and higher density, allowing vapor bubbles to rise into the single-phase layer for condensation and return as droplets, eliminating the need for bellows and reducing leakage risks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a conventional dual-phase fluid immersion cooling system is used, then cooling efficiency is achieved, but vapor leakage occurs and environmental harm is caused

Engineering Contradiction:
Improvecooling efficiencyVSAvoidvapor leakage
Core Design Contradiction:
TemperatureVSObject-generated harmful factors

Solution Approach 1:

The patent introduces a condenser as an intermediary component between the dual-phase coolant reservoir and the environment. The condenser captures vapor bubbles before they can leak into the environment, condenses them back to liquid form, and returns them to the reservoir. This mediator prevents harmful vapor leakage while maintaining the efficient dual-phase cooling process.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates a controlled environment by using an enclosed cooling system with inert or controlled atmosphere conditions. The system prevents vapor escape into the external environment by containing the cooling process within a closed loop, effectively creating an inert environment that prevents harmful emissions.

Inventive Principle:
Principle #39Inert atmosphere (Inert environment)

2Reliability

If bellows are added for vapor balance, then vapor control is improved, but device complexity and space requirements increase

Engineering Contradiction:
Improvevapor balance controlVSAvoidbellows mechanism
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the complex bellows mechanism from the system. Instead of using mechanical bellows for vapor balance, the invention relies on the natural phase change properties of the dual-phase coolant and passive condensation processes to maintain vapor-liquid equilibrium, thereby simplifying the device architecture.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The system achieves vapor balance through self-service mechanisms rather than active mechanical components. The dual-phase coolant naturally cycles between liquid and vapor phases, and the condenser passively condenses vapor back to liquid through heat transfer, eliminating the need for externally controlled bellows mechanisms.

Inventive Principle:
Principle #25Self-service

3Reliability

If bellows are used for vapor balance, then vapor control is achieved, but manufacturing and operational costs increase

Engineering Contradiction:
Improvevapor controlVSAvoidmanufacturing cost
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces expensive mechanical bellows components with simpler, more cost-effective passive condensation systems. The design uses readily available condenser technologies and eliminates the need for complex mechanical parts, thereby reducing both manufacturing costs and operational maintenance expenses.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent substitutes mechanical bellows systems with a thermal field-based condensation mechanism. Instead of using mechanical expansion and contraction of bellows to control vapor, the system uses heat transfer and phase change physics to achieve vapor balance, eliminating complex mechanical components and reducing costs.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

4Device complexity

If a simple cooling fan system is used, then device complexity is reduced, but cooling effectiveness for high heat-generating components is insufficient

Engineering Contradiction:
Improvecooling system simplicityVSAvoidcooling effectiveness
Core Design Contradiction:
Device complexityVSTemperature

Solution Approach 1:

The patent utilizes phase transitions of the dual-phase coolant (liquid to vapor and vapor back to liquid) as the core cooling mechanism. When high heat-generating components come into contact with the dual-phase coolant, the coolant absorbs heat through phase change, providing highly effective cooling without requiring complex mechanical systems like fans or pumps.

Inventive Principle:
Principle #36Phase transitions

Solution Approach 2:

The patent applies different coolant phases to different thermal zones. The dual-phase coolant in liquid form provides baseline cooling, while vapor bubbles form locally at high heat-generating components to enhance heat transfer. This localized phase change provides targeted cooling effectiveness where it is most needed.

Inventive Principle:
Principle #3Local quality

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 contains vapor bubbles, prevents leakage, conserves coolant, and reduces manufacturing and operational costs by eliminating the need for bellows and enhancing space efficiency.

Implementation Method 1

Heat from the components is dissipated to the dual-phase coolant fluid to generate vapor bubbles of the dual-phase coolant fluid

Methodology Applied
Scientific EffectPhase change: Phase Change

Implementation Method 2

heat generated by the electronic system turns a dual-phase coolant fluid into vapors

Methodology Applied
Scientific EffectEvaporation: Evaporation

Implementation Method 3

the vapor bubbles condense to droplets of the dual-phase coolant fluid

Methodology Applied
Scientific EffectCondensation: Condensation

Implementation Method 4

The vapor bubbles rise to a layer of a single-phase coolant fluid that is above the layer of the dual-phase coolant fluid

Methodology Applied
Scientific EffectPhysical containment: Physical Containment

Implementation Method 5

the dual-phase coolant fluid having a lower boiling point and higher density than the single-phase coolant fluid

Methodology Applied
Scientific EffectDensity gradient: Density Gradient

Implementation Method 6

The droplets fall down into the layer of the dual-phase coolant fluid

Methodology Applied
Scientific EffectGravitation: Gravitation

Data Source

PatentUS12396132B2Fluid immersion cooling system with multiple layers of coolant fluids and method of using same
Publication Date: 2025.08.19 SUPER MICRO COMPUTER INC(US)
  • US12396132B2 patent drawing
  • US12396132B2 patent drawing
  • US12396132B2 patent drawing

AI summary

A fluid immersion cooling system includes a fluid tank that contains a layer of a dual-phase coolant fluid and one or more layers of single-phase coolant fluids. The dual-phase and single-phase coolant fluids are immiscible, with the dual-phase coolant fluid having a lower boiling point and higher density than a single-phase coolant fluid. A substrate of an electronic system is submerged in the tank such that high heat-generating components are immersed at least in the layer of the dual-phase coolant fluid. Heat from the components is dissipated to the dual-phase coolant fluid to generate vapor bubbles of the dual-phase coolant fluid. The vapor bubbles rise to a layer of a single-phase coolant fluid that is above the layer of the dual-phase coolant fluid. The vapor bubbles condense to droplets of the dual-phase coolant fluid. The droplets fall down into the layer of the dual-phase coolant fluid.