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
Engineering 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
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.
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.
2Reliability
If bellows are added for vapor balance, then vapor control is improved, but device complexity and space requirements increase
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.
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.
3Reliability
If bellows are used for vapor balance, then vapor control is achieved, but manufacturing and operational costs increase
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.
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.
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
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.
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.
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
Implementation Method 2
heat generated by the electronic system turns a dual-phase coolant fluid into vapors
Implementation Method 3
the vapor bubbles condense to droplets of the dual-phase coolant fluid
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
Implementation Method 5
the dual-phase coolant fluid having a lower boiling point and higher density than the single-phase coolant fluid
Implementation Method 6
The droplets fall down into the layer of the dual-phase coolant fluid
Data Source
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.


