Stacked Sheet-Metal Cooler Assembly for Compact Edge Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional manifold microchannel cold plates are complex and bulky, hindering economical mass production and are not suitable for applications with large cooling area requirements, such as electric vehicle batteries and fuel cell stacks.
Innovation Solution
A cooler assembly comprising four stacked stamped sheet metal plates: a base plate, a macro-channel plate with corrugated ridges and valleys, an insert plate with alternating raised channels and recesses, and a cover plate, which are thermally coupled to form a vertically stacked arrangement for efficient heat removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional manifold microchannel cold plates are used, then cooling effectiveness for small footprint devices is improved, but manufacturing complexity and production cost increase
Solution Approach 1:
The cold plate is divided into multiple stamped metal plate layers (first plate, second plate, third plate) that are stacked together. Each layer contains simplified channel structures that collectively form the complete cooling network, avoiding the need for complex monolithic geometries
Solution Approach 2:
The cooling channels are extended from two-dimensional planar structures into three-dimensional stacked configurations. Fluid pathways traverse through multiple vertical layers, enabling complex cooling patterns to be achieved through simple stacked plates rather than complex in-plane geometries
2Temperature
If conventional manifold microchannel cold plates are used, then cooling performance is improved, but packaging volume increases
Solution Approach 1:
Multiple cooling channel structures are nested within each other across different plate layers. The stacked configuration allows cooling channels to be arranged in a compact vertical arrangement, reducing the overall horizontal footprint and packaging volume
Solution Approach 2:
The cooling network utilizes the vertical dimension by stacking multiple plates with thicknesses of 0.5-5mm each. This vertical stacking consolidates what would otherwise require large horizontal space into a compact vertical arrangement, reducing packaging volume
3Temperature
If conventional manifold microchannel cold plates are used, then cooling capability is improved, but manufacturing cost and production difficulty increase
Solution Approach 1:
The cold plate is segmented into multiple separate stamped metal plates that can be manufactured independently using standard stamping processes. This segmentation enables economical mass production of each layer before final assembly, avoiding the need for complex monolithic manufacturing
Solution Approach 2:
Complex mechanical machining or additive manufacturing processes are replaced with simple stamping operations. Each plate layer is formed by stamping metal sheets with channel patterns, which is aĉç, high-volume manufacturing process suitable for cost-effective mass production
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 reduces cold plate packaging volume, lowers manufacturing costs, and enables economical mass production, providing effective cooling solutions for large cooling area applications.
Implementation Method 1
A liquid coolant, such as a cooling fluid, may be introduced to the heat management device, where it receives heat from the heat management device, primarily through convective and/or conductive heat transfer
Implementation Method 2
A liquid coolant, such as a cooling fluid, may be introduced to the heat management device, where it receives heat from the heat management device, primarily through convective and/or conductive heat transfer
Implementation Method 3
The cooler assembly includes a base plate, a macro-channel plate, an insert plate, and a cover plate. The macro-channel plate has a corrugated portion defined by a plurality of alternating ridges and valleys... The inner surface abutting the plurality of alternating ridges of the macro-channel plate
Data Source
AI summary
Embodiments herein are directed to a cooler assembly. The cooler assembly includes a base plate, a macro-channel plate, and an insert plate. The base plate has a first surface opposite second surface. The macro-channel plate has a corrugated portion defined by a plurality of alternating ridges and valleys extending in a first direction. Each of the plurality of alternating ridges have an elongated slot fluidly coupling the macro-channel plate to the base plate. The insert plate has an inner surface and opposite outer surface. The inner surface abutting the plurality of alternating ridges. The insert plate has a plurality of alternating raised channel portions and recesses. Each of the plurality of recesses has an elongated passage fluidly coupling the insert plate to the macro-channel plate. Each of the plurality of alternating raised channel portions and recesses extending in a second direction that is perpendicular to the first direction.