Multi-Loop Coolant Interface for Cold-Start Electronic Cooling Systems
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Solution Overview
Problem
Electronic systems face challenges in starting up at extremely low temperatures due to the freezing or high viscosity of traditional coolants, which prevents effective heat transfer and can lead to unstable operation or mechanical failures.
Innovation Solution
Implementing an intelligent cooling interface architecture with multiple coolant loops, where a low-viscosity coolant loop interfaces with a high-viscosity loop to manage heat transfer and maintain system stability, using real-time monitoring and control to ensure proper operation and prevent failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional coolants (PAO, PGW, EGW) are used in cold soaked conditions, then the cooling system can operate at lower temperatures, but the coolant freezes or becomes highly viscous preventing heat transport
Solution Approach 1:
The cooling system is divided into multiple independent coolant loops, each containing coolants with different freezing points and viscosity characteristics. This segmentation allows each loop to operate independently within its optimal temperature range, preventing the entire system from failing when one coolant reaches its operational limits.
Solution Approach 2:
The system changes the physical parameters of the coolant by using multiple coolant types with different properties (freezing points, viscosities, heat capacities). By selecting coolants with progressively lower freezing points for different loops, the system can progressively cool down to lower temperatures while maintaining fluid flow capability in at least one loop.
2Use of energy by stationary object
If electronic components are operated at full capacity during warm-up, then the system can generate sufficient heat to warm itself, but transient temperature gradients cause mechanical or structural failures
Solution Approach 1:
The system segments the thermal management function across multiple coolant loops that can be activated at different times and at different power levels. This allows progressive warming of different system zones, reducing thermal gradients and preventing structural failures while still generating sufficient heat through controlled operation of electronic components.
3Device complexity
If a single coolant loop is used, then the system structure is simpler, but the system cannot handle extreme temperature ranges from −60°C or lower
Solution Approach 1:
The cooling system is divided into multiple independent coolant loops, each containing coolants with different freezing points and viscosity characteristics. This segmentation allows each loop to operate independently within its optimal temperature range, preventing the entire system from failing when one coolant reaches its operational limits.
Solution Approach 2:
Each coolant loop is designed to be multi-functional, capable of operating across different temperature ranges and providing cooling coverage for various system components. The loops can work together or independently, providing universal cooling capability across the entire operational temperature range from −60°C to higher temperatures.
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
Enables electronic systems to start up safely at temperatures as low as −60°C or colder without using the system's heat, reducing transient temperature gradients and preventing mechanical failures, while ensuring stable operation and efficient heat removal.
Implementation Method 1
a first coolant loop (252) that interfaces with a second coolant loop (254) across a thermal interface (214)... removing heat from the circulating first coolant of the first coolant loop to the circulating second coolant of the second coolant loop across the thermal interface (214)
Data Source
AI summary
Systems and methods are provided to implement intelligent cooling interface architectures for cooling systems that employ a heat transfer interface between multiple separate coolant circulation loops. A heat transfer interface may be advantageously managed based on monitored real time operational parameters (e.g., operating conditions such as pressures, mass flow rates, temperatures, etc.) within one or more of the separate coolant loops. Diagnostics and prognostics may be performed to verify proper cooling system operation and to detect out-of-specification operational parameters based on expected or acceptable levels for these measurements in view of the heat load to be removed. In this way, the cooling system performance may be monitored to ensure proper operation and to anticipate and alert a user when cooling system operation is trending toward a failure condition.