Phase-Change Thermal Clipping for Sealed Electronics Cooling
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Solution Overview
Problem
Existing thermal management systems for electronic components in harsh environments, such as deserts, face issues with overheating, equipment failure due to sand and dust intrusion, and high energy consumption, necessitating improved cooling methods that prevent foreign body intrusion and reduce energy use.
Innovation Solution
A thermal management system comprising a main compartment, a heat exchanger, and an auxiliary compartment with phase-change material and thermoelectric cooling, forming a sealed unit that transfers thermal energy externally without external air supply, using a phase-change material with a melting point between 40°C and 50°C and thermally insulating material with low conductivity, and optionally incorporating fans and thermoelectric cooling modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If active cooling by ventilation or air conditioning is used, then thermal management of electronic components is improved, but sand and dust intrusion and excessive energy consumption occur
Solution Approach 1:
The patent extracts the harmful function of external air intake (which causes sand and dust intrusion) while preserving the useful function of thermal management. The sealed enclosure removes the connection between internal electronic components and external environment, eliminating the intrusion pathway while maintaining cooling through internal heat exchange mechanisms
Solution Approach 2:
The patent introduces a heat exchanger as an intermediary component that enables thermal energy transfer between internal air and external environment without direct air exchange. This mediator allows heat rejection while maintaining the sealed barrier against sand and dust particles
2Temperature
If active cooling by ventilation or air conditioning is used, then thermal management of electronic components is improved, but energy consumption increases excessively
Solution Approach 1:
The patent implements passive cooling mechanisms where the system cools itself without requiring external energy input for active refrigeration. The sealed enclosure with internal heat exchangers and phase change materials enables automatic thermal regulation through natural convection and phase transition processes, eliminating the need for energy-consuming air conditioning systems
Solution Approach 2:
The patent utilizes phase change materials that absorb and release thermal energy during phase transitions (solid-liquid-solid). This latent heat storage mechanism provides automatic thermal buffering that reduces peak cooling demands and eliminates the need for continuous energy input required by conventional active cooling systems
3Adaptability or versatility
If the equipment operates in harsh environments with temperature variations, then adaptability is improved, but thermal stabilization becomes difficult
Solution Approach 1:
The patent incorporates thermal mass and phase change materials in advance within the sealed enclosure to prepare for temperature variations. These pre-positioned thermal buffering components absorb excess heat during temperature rises and release heat during temperature drops, providing proactive thermal stabilization before extreme conditions affect the electronic components
Solution Approach 2:
The patent employs composite thermal management structures combining sealed enclosures, heat exchanger materials, and phase change materials with specific thermal properties. This composite approach creates a multi-layered thermal management system that simultaneously provides insulation, heat transfer, and thermal buffering capabilities to maintain stability in harsh environments
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
Achieves thermal stabilization of electronic components, prevents foreign body intrusion, and significantly reduces energy consumption and equipment failure risks, with a mean time between failures enhanced by the system's efficient thermal regulation.
Implementation Method 1
at least one thermal absorption block comprising a phase-change material and configured to absorb the thermal energy generated by at least one electronic system
Implementation Method 2
a heat exchanger in aerodynamic communication with the main compartment, capable of transferring the thermal energy generated by at least one electronic system outside the equipment
Implementation Method 3
at least the auxiliary compartment is covered at least partially with a thermally insulating material having a thermal conductivity between 0.025 W/mK and 0.05 W/mK
Data Source
Figure 1
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AI summary
The equipment (10) comprises: - a main compartment (20) including at least one electronic system (22) capable of generating thermal energy; - a heat exchanger (40) in aerodynamic communication with the main compartment (20), capable of transferring the thermal energy generated by at least one electronic system (22) outside the equipment (10); - an auxiliary compartment (60) in aerodynamic communication with the main compartment (20) and the heat exchanger (40) and including at least one thermal absorption block (72) comprising a phase change material and configured to absorb the thermal energy generated by at least one electronic system (22).