Universal XYZ-axis Leak Sensor for Liquid Cooling
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Solution Overview
Problem
Current liquid leak sensors in computing devices are limited in detecting leaks when the systems are mounted in orientations other than horizontal or coplanar, and they require installation before the heat exchanger, which complicates assembly and reduces flexibility.
Innovation Solution
A liquid cooling subsystem with a leak sensor comprising a main body and secondary body, each containing sensing areas, an opening for the heat exchanger, and a split feature allowing installation after the heat exchanger is mounted, enabling detection in both horizontal and vertical orientations and allowing separate installation of the sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the leak sensor is installed before the heat exchanger, then the sensor can be properly positioned, but the assembly process becomes more complex and less flexible
Solution Approach 1:
The leak sensor is divided into a main body and a secondary body that can be separated. The main body is installed on the base plate while the secondary body is attached to the heat exchanger, allowing independent installation of each component without requiring the sensor to be pre-assembled before the heat exchanger.
Solution Approach 2:
The foldable edge connects the main body and secondary body, allowing the sensor structure to adapt dynamically during assembly. The secondary body can be folded or adjusted to accommodate the heat exchanger positioning, providing flexibility in the assembly process while maintaining reliable sensor installation.
2Ease of manufacture
If the sensor is designed as a single rigid structure, then manufacturing is simpler, but it cannot accommodate different mounting orientations (horizontal or vertical)
Solution Approach 1:
The foldable edge enables the sensor to transition between different configurations and orientations. The main body and secondary body can be positioned at various angles relative to each other, allowing the sensor to accommodate both horizontal and vertical mounting orientations while maintaining a relatively simple manufacturing process for each individual component.
Solution Approach 2:
The foldable connection adds a dimensional degree of freedom to the sensor structure. Instead of being constrained to a single rigid plane, the sensor can now operate in multiple spatial orientations by folding along the edge, enabling adaptation to different mounting configurations without complicating the basic manufacturing of each body section.
3Reliability
If the sensor covers the entire base plate area, then leak detection coverage is maximized, but it interferes with heat exchanger installation and increases device complexity
Solution Approach 1:
The sensor is segmented into a main body that remains on the base plate and a secondary body that moves with the heat exchanger. This segmentation allows the sensor to maintain comprehensive leak detection coverage while accommodating the heat exchanger in the opening, as the secondary body can be positioned to detect leaks around and near the heat exchanger without interfering with its installation.
Solution Approach 2:
The foldable edge acts as an intermediary mechanism that mediates between the base plate-mounted main body and the heat exchanger. This allows the sensor to adapt its configuration to work around the heat exchanger opening, maintaining leak detection coverage without creating conflicts between sensor installation and heat exchanger placement.
4Ease of manufacture
If the sensor is installed in fixed positions only, then manufacturing and assembly are simpler, but it cannot detect leaks in various orientations
Solution Approach 1:
The foldable connection transforms the sensor from a fixed-position device to a dynamic structure that can be oriented in multiple positions. The main body and secondary body can be folded to different angles and orientations, allowing the sensor to detect leaks whether the system is mounted horizontally or vertically, while maintaining relatively simple manufacturing and assembly procedures for each configuration.
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 detects leaks in various orientations and allows for flexible installation, enhancing the reliability and ease of assembly of liquid cooling systems in computing devices.
Implementation Method 1
electronic components for connecting and electrically detecting fluid on the plurality of sensing areas
Data Source
AI summary
A liquid cooling subsystem and method of manufacturing a liquid cooling subsystem in an information handling system that includes a base plate, a heat exchanger mounted on the base plate, and an inlet coolant tube and outlet coolant tube operatively connected to the heat exchanger. The liquid cooling subsystem includes a liquid leak sensor disposed on the base plate that includes a main body and secondary body that each contain a plurality of sensing areas. The liquid cooling subsystem also includes electronic components for connecting and electrically detecting fluid on the plurality of sensing areas disposed on the main body. The liquid cooling subsystem also includes an opening in the main body that accommodates the heat exchanger and a split feature in the main body. The secondary body is connected to the main body along a foldable edge on an opposite side of the split feature.