Multi-Zone Heat Exchanger for Electronic Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional heat exchangers are inadequate for cooling high heat flux electronic components in electric and hybrid-electric vehicles due to their design, which results in localized hot spots and inefficient heat transfer.
Innovation Solution
A heat exchanger with a multi-zone heat transfer surface featuring alternating heat transfer-reducing and heat transfer-augmenting zones, where the heat transfer surface includes corrugations of varying lengths and flow-blocking zones to enhance turbulence and heat transfer efficiency, specifically targeting hotspots generated by electronic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional heat exchangers use large projected area for heat transfer, then heat transfer area is increased, but heat flux becomes relatively low due to heat being transferred over a large area
Solution Approach 1:
The heat transfer surface is divided into multiple zones with different properties: heat transfer-augmenting zones with enhanced surface area (corrugations, fins) for high heat flux regions, and heat transfer-reducing zones with blocked or reduced heat transfer for low heat flux regions. This local differentiation allows the system to concentrate heat transfer capacity where needed while reducing it where not needed, thereby increasing overall heat flux without requiring proportionally large total area.
2Stability of the object's composition
If conventional heat exchangers are designed for continuous heat sources, then heat transfer is distributed evenly, but localized hot spots from discrete electronic components cannot be effectively cooled
Solution Approach 1:
Different zones of the heat transfer surface are designed with different thermal characteristics to match the discrete heat source distribution. Heat transfer-augmenting zones are positioned directly beneath electronic components to provide enhanced cooling capacity where hot spots occur, while heat transfer-reducing zones are positioned in areas without heat sources to prevent overheating and improve overall efficiency.
Solution Approach 2:
The heat transfer surface is segmented into multiple independent zones with distinct functions. Each zone can be independently optimized for its specific thermal requirements, allowing the system to handle discrete, localized heat sources effectively rather than treating the entire surface uniformly.
3Productivity
If compact heat exchangers are used to increase heat flux, then heat transfer efficiency improves, but the ability to handle discrete localized heat sources is reduced
Solution Approach 1:
The heat transfer surface incorporates zones with locally optimized properties: some areas have enhanced heat transfer capabilities (corrugations, fins, increased surface area) to handle high heat flux from electronic components, while other areas have reduced or blocked heat transfer. This local differentiation allows the compact exchanger to efficiently handle discrete localized heat sources while maintaining overall compactness.
Solution Approach 2:
The heat transfer surface is designed with dynamic flow patterns that can be optimized for different operating conditions. Flow blocking zones and variable heat transfer zones allow the system to adapt fluid flow distribution to match the discrete heat source configuration, improving versatility while maintaining compact dimensions.
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 solution effectively increases heat transfer across areas in direct thermal contact with electronic components, improving cooling efficiency and addressing the challenge of localized hot spots in electric and hybrid-electric vehicles.
Implementation Method 1
heat transfer across the portion of the at least one of the spaced apart walls disposed in thermal contact with the at least one heat transfer-augmenting zone is increased relative to heat transfer across the portion of the at least one of the spaced apart walls disposed in thermal contact with the at least one heat transfer-reducing zone
Implementation Method 2
the heat transfer surface includes corrugations of varying lengths and flow-blocking zones to enhance turbulence and heat transfer efficiency
Data Source
AI summary
A heat exchanger with a multi-zone heat transfer surface is disclosed. The heat exchanger includes a fluid flow passage extending between and interconnecting a fluid inlet and a fluid outlet. A heat transfer surface is disposed within the fluid flow passage wherein the heat transfer surface includes at least one heat transfer-reducing zone disposed in thermal contact with a portion of at least one of the walls of the fluid flow passage and at least one heat transfer-augmenting zone disposed in thermal contact with a portion of the at least one of the walls of the fluid flow passage. The configuration of the heat transfer-augmenting zones with the heat-transfer-reducing zones is such that heat transfer across the surface of the heat exchanger in contact with the heat transfer-augmenting zones is increased relative to the heat transfer across the surface of the heat exchanger in contact with the heat transfer-reducing zones.