Spray Cold Plate Thermal Management for Startup Heat Spikes

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Solution Overview

Problem

Conventional thermal management systems, including dry methods and single-phase liquid systems, are inadequate for efficiently managing the heat produced by modern electronic devices during startup and transient power spikes.

Innovation Solution

A combination spray and cold plate thermal management system that includes a spray unit and a coolant reservoir with porous media, where the coolant reservoir stores waste coolant and is connected to the spray unit to receive and re-use it, ensuring effective thermal management during startup and normal operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional dry thermal management technology (forced air convection using fans and heat sinks) is used, then the system structure is simple, but it is not capable of efficiently thermally managing modern electronic devices during startup and transient power spikes

Engineering Contradiction:

Improvesystem structure simplicityVSAvoidthermal management efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent combines spray cooling technology with a cold plate system, merging the advantages of high heat flux removal capability of spray cooling with the thermal energy recovery capability of the cold plate to create a hybrid thermal management system that efficiently manages heat during startup and transient power spikes

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cold plate is pre-filled with coolant before system operation begins. During startup or transient power spikes, the coolant is already in position to immediately absorb heat from the heat-producing device, eliminating the thermal management gap that would exist if the system had to start from an empty state

Inventive Principle:

Principle #10Preliminary action

2Productivity

If spray cooling technology is used to efficiently manage heat, then thermal management efficiency is improved, but the system requires continuous operation to maintain effectiveness during startup periods

Engineering Contradiction:

Improvethermal management efficiencyVSAvoidthermal management continuity during startup

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The cold plate acts as an intermediary thermal management component that bridges the gap during startup periods. It provides immediate cooling capability before the spray cooling system becomes fully operational, ensuring continuous thermal management throughout the startup process

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the cold plate is pre-filled with coolant for startup thermal management, then thermal management during startup is improved, but the system consumes more coolant and requires larger reservoir capacity

Engineering Contradiction:

Improvethermal management during startupVSAvoidcoolant volume required

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The cold plate recovers thermal energy from the coolant after it has absorbed heat during startup or transient power spikes. This recovered thermal energy can be utilized elsewhere in the system, reducing the overall coolant consumption and the need for large reservoir capacity

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The cold plate serves multiple functions: it provides startup thermal management, recovers thermal energy from the coolant, and can potentially provide ongoing thermal management support. This multi-functionality reduces the overall coolant volume required compared to a single-purpose system

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 system effectively manages heat-producing devices during startup and transient power spikes by utilizing waste coolant stored in the porous media reservoir, providing continuous thermal management even after prolonged 'off' periods and during fluid flow interruptions.

Implementation Method 1

The coolant reservoir includes a porous media with coolant channels for storing a volume of the waste coolant

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

spray cooling technology is being adopted today as the most efficient option for thermally managing electronic systems

Methodology Applied

Scientific EffectEvaporative cooling: Evaporation

Implementation Method 3

a coolant reservoir thermally connected to the heat producing device

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS7992626B1Combination spray and cold plate thermal management system

Publication Date: 2011.08.09 PARKER INTANGIBLES LLC

AI summary

A combination spray and cold plate thermal management system for effectively thermally managing a heat producing device during startup. The combination spray and cold plate thermal management system includes a spray unit thermally managing a heat producing device and a coolant reservoir thermally connected to the heat producing device. The coolant reservoir includes a porous media with coolant channels for storing a volume of the waste coolant after spraying of coolant has terminated. The coolant reservoir is fluidly connected to the spray chamber within the spray unit to receive the waste coolant.