Power Supply Cooling Using Latent Heat and Airflow
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Solution Overview
Problem
State-of-the-art air cooling technologies are inadequate for high power and high power density networking and computing equipment, necessitating improvements in internal fan cooling capabilities to prevent the need for external liquid cooling systems.
Innovation Solution
A latent heat of vaporization cooling method using a single-phase liquid-cooling-to-air closed-loop system with a central baseplate/cold-plate/heatsink, employing passive or active liquid pump flow control to maintain a constant maximum water temperature, storing heat in the liquid mass and only cooling excess heat via air, enhancing cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If traditional air cooling technology is used, then device simplicity is maintained, but cooling capacity is insufficient for high power density equipment
Solution Approach 1:
The patent utilizes the phase transition of water from liquid to vapor to absorb latent heat for cooling. The water is heated to its boiling point and then vaporized, absorbing a large amount of latent heat (approximately 2260 kJ/kg) in the process. The steam is then condensed back to liquid in a heat exchanger, releasing the heat to the surrounding air. This phase change mechanism provides high cooling capacity without requiring complex external liquid cooling systems.
Solution Approach 2:
The patent introduces water as an intermediary substance to transfer heat from the power supply components to the surrounding air. The water absorbs heat through phase change and then transfers it to the air via a heat exchanger (radiator), acting as a thermal mediator that enables efficient heat removal without direct contact between hot components and air.
2Power
If fan power is increased to improve cooling, then cooling capacity increases, but energy consumption increases
Solution Approach 1:
The patent employs phase transition of water to achieve high cooling capacity with minimal fan power. By utilizing the latent heat of vaporization and condensation, the system achieves efficient heat transfer that reduces the workload on fans, thereby lowering their power consumption compared to traditional air cooling systems that rely heavily on high-speed fans.
Solution Approach 2:
The patent replaces the mechanical cooling approach (relying on high-speed fan forced convection) with a thermal-phased approach (utilizing water phase change and natural convection). This substitution reduces dependence on mechanical fan power while achieving superior cooling efficiency through the thermodynamic properties of water.
3Productivity
If water temperature is increased to store more heat, then cooling efficiency improves, but temperature control becomes more difficult
Solution Approach 1:
The patent controls water temperature by utilizing its phase transition at a fixed boiling point. Instead of trying to maintain a variable high temperature, the system heats water to its boiling point and allows it to vaporize, at which point the temperature remains constant during the phase change. This natural temperature stabilization during phase transition simplifies temperature control while maximizing heat storage capacity.
Solution Approach 2:
The system incorporates temperature sensing and control mechanisms that monitor water temperature and adjust heating accordingly. When water approaches its boiling point, the system modulates heating power to maintain optimal conditions for phase change, ensuring efficient heat storage while preventing overheating through feedback control.
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
This approach significantly improves air cooling efficiency by reducing the need for fan power and increasing cooling capacity by 130-250%, allowing higher power density operation without external liquid cooling.
Implementation Method 1
storing heat in the liquid mass and only cooling excess heat via air
Implementation Method 2
storing heat in the liquid mass and only cooling excess heat via air
Implementation Method 3
a first plurality of fins attached to one or both sides of the external housing adjacent to the upper internal area and configured to provide convection air cooling
Implementation Method 4
an external liquid-air heat exchanger including one or more inlet ports coupled with the one or more outlet ports of the baseplate heatsink, an expansion chamber coupled with the one or more inlet ports of the external liquid-air heat exchanger and configured to receive hot steam/vapor and/or hot liquid
Data Source
AI summary
Presented herein are techniques to improve air cooling for higher power and power density power supply examples, including using latent heat of vaporization as a single-phase liquid-cooling-to-air closed-loop system. These techniques may not be limited to power supplies, but may be applicable to other air cooling requirements in assemblies and systems.