Exemplary embodiments pertain to the art of heat exchangers, and more particularly to heat exchangers for cooling power electronics.
Power electronics devices such as motor drives generate waste heat during operation of the device. Additionally, when the power electronics devices heat up, the operational efficiency of the devices can degrade adding to the amount of heat generated. When utilized in a refrigeration system to drive, for example, a compressor of the refrigeration system, effective thermal integration of these devices can be important aspect to the system's overall efficiency and reliability. Consequently, a goal of the system integrator is to maintain these components within a range of operating temperatures which will maximize the system efficiency. Accordingly, there remains a need in the art for heat exchangers configured to closely integrate with power electronic devices which can maintain optimal temperatures for these components under a variety of load conditions.
According to an embodiment, a cooling system for cooling at least one heat-generating electronic device includes a heat removal device having a surface that is thermally couplable to the at least one heat-generating electronic device. The heat removal device includes an inlet area and at least one jet impingement feature fluidly coupled to the inlet area. The at least one jet impingement feature is positioned to direct a primary cooling fluid toward the surface that is thermally coupled to the at least one heat-generating electronic device.
In addition to one or more of the features described herein, or as an alternative, in further embodiments the heat removal device includes a heat exchanger having an outlet header and the surface that is thermally coupled to the at least one heat-generating electronic device is arranged within the outlet header. The primary cooling fluid and a secondary cooling fluid are arranged in a heat transfer relationship within the at least one heat exchanger.
In addition to one or more of the features described herein, or as an alternative, in further embodiments the heat exchanger includes an inlet header and a plurality of heat exchange tubes extending between the inlet header and the outlet header. The at least one jet impingement feature is separate from and fluidly coupled to the plurality of heat exchange tubes.
In addition to one or more of the features described herein, or as an alternative, in further embodiments the heat exchanger further comprises an inlet header and a plurality of heat exchange tubes extending between the inlet header and the outlet header. The at least one jet impingement feature is integral with at least one of the plurality of heat exchange tubes.
In addition to one or more of the features described herein, or as an alternative, in further embodiments a fluid movement device is operable to move the secondary cooling fluid through the heat removal device.
In addition to one or more of the features described herein, or as an alternative, in further embodiments the fluid movement device is a fan and the secondary cooling fluid is air.
In addition to one or more of the features described herein, or as an alternative, in further embodiments the heat removal device includes a plurality of heat exchangers. Each of the plurality of heat exchangers is located at and is thermally coupled to a respective heat-generating electronic device.
In addition to one or more of the features described herein, or as an alternative, in further embodiments at least some of the plurality of heat exchangers are arranged in series relative to a flow of the primary cooling fluid.
In addition to one or more of the features described herein, or as an alternative, in further embodiments at least some of the plurality of heat exchangers are arranged in parallel relative to a flow of the primary cooling fluid.
In addition to one or more of the features described herein, or as an alternative, in further embodiments the primary cooling fluid provided to the inlet area is a two-phase liquid.
In addition to one or more of the features described herein, or as an alternative, in further embodiments the primary cooling fluid provided to the heat removal device is a single-phase liquid.
According to an embodiment, a method of cooling an assembly including at least one heat-generating electronic device and at least one peripheral heat-generating device includes cooling a secondary cooling fluid via a primary cooling fluid, flowing the cooled secondary cooling fluid over the at least one peripheral heat-generating device, and expelling the primary cooling fluid at a surface of a heat removal device thermally coupled to the at least one heat-generating electronic device via at least one jet impingement feature to cool the at least one heat-generating electronic device.
In addition to one or more of the features described herein, or as an alternative, in further embodiments the heat removal device is a heat exchanger and cooling the secondary cooling fluid via the primary cooling fluid occurs within a plurality of heat exchanger tubes of the heat exchanger.
In addition to one or more of the features described herein, or as an alternative, in further embodiments providing the secondary cooling fluid to the heat exchanger via a fluid movement device.
In addition to one or more of the features described herein, or as an alternative, in further embodiments providing the primary cooling fluid to another heat removal device located at and thermally coupled to the at least one heat-generating electronic device. The another heat removal device is arranged downstream from and in series with the heat removal device relative to a flow of the primary cooling fluid.
In addition to one or more of the features described herein, or as an alternative, in further embodiments providing the primary cooling fluid to another heat removal device located at and thermally coupled to the at least one heat-generating electronic device. The another heat removal device is arranged in parallel with the heat removal device relative to a flow of the primary cooling fluid.
The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
Referring to
Another example of a refrigeration system 20 is illustrated in
In an embodiment, the economizer heat exchanger 32 is a brazed plated fin heat exchanger. However, other suitable types of heat exchangers are also within the scope of the disclosure. Further, the economizer heat exchanger 32 is a refrigeration fluid-refrigeration fluid heat exchanger and therefore has a plurality of distinct fluid flow paths formed therein. In the illustrated, non-limiting embodiment, the economizer heat exchanger 32 has a first flow path and a second flow path, respectively.
In the illustrated, non-limiting embodiment, the inlet 36 of the first flow path of the economizer heat exchanger 32, also referred to herein as the “main flow path,” is arranged in direct fluid communication with an outlet 34 of the condenser 26. Alternatively, or in addition, the outlet 38 of the main flow path of the economizer heat exchanger 32 may be arranged directly upstream from and in fluid communication with an inlet of the expansion device 28.
In operation, a first portion R1 of the refrigeration fluid output from the condenser 26 is provided to the main flow path of the economizer heat exchanger 32 via a main conduit 40. Although the main flow path is illustrated as a single pass through the economizer heat exchanger 32, it should be understood that in other embodiments the main flow path may include a plurality of passes through the economizer heat exchanger 32. At the outlet 38 of the main flow path of the economizer heat exchanger 32, the first portion R1 of the refrigeration fluid is configured to flow to the expansion device 28. From the expansion device 28, the refrigeration fluid is expanded within the evaporator 30. The first portion R1 of refrigeration fluid output from the evaporator 30 is provided via a first compressor inlet path to a primary suction inlet 42 of the compressor 24. Accordingly, the fluid loop of the first portion R1 of the refrigeration fluid includes the compressor 24, condenser 26, main flow path of the economizer heat exchanger 32, expansion device 28, and the evaporator 30.
An economizer expansion device 44 may be arranged within the refrigeration circuit 22 in fluid communication with the condenser 26. The economizer expansion device 44 is operable to expand and cool the refrigeration fluid provided thereto. Although the economizer expansion device 44 is illustrated as being disposed within an economizer conduit 45 fluidly coupled to an extending from the main conduit 40 at a location upstream from the first inlet 36, it should be understood that an economizer conduit 45 fluidly connected to the outlet 34 of the condenser 26 in another suitable manner is also contemplated herein.
Located downstream from the economizer expansion device 44 is the inlet 46 of a second flow path of the economizer heat exchanger 32, also referred to herein as the “economizer flow path.” Further, the outlet 48 of the second flow path of the economizer heat exchanger 32 may but need not be directly connected to an economizer inlet or port 50 of the compressor 24. In the illustrated, non-limiting embodiment, the inlet 36 of the main flow path and the inlet 46 of the economizer flow path are arranged at adjacent sides of the economizer heat exchanger 32. However, in other embodiments, it should be understood that the inlets 36, 46 of both flow paths could alternatively be arranged at the same side of the economizer heat exchanger 32 or at opposite sides thereof. Similarly, the outlets 38, 48 of both the main flow path and the economizer flow path may be arranged at opposite sides, the same side, or adjacent sides depending on the desired flow configuration of the economizer heat exchanger 32. Further, although the economizer flow path is illustrated as a single pass, it should be understood that in some embodiments, the economizer flow path may include a plurality of passes through the economizer heat exchanger 32.
Within the economizer flow path, a second portion R2 of the refrigeration fluid is configured to absorb heat from the first portion R1 of the refrigeration fluid within the main flow path, thereby cooling the first portion R1 of the refrigeration fluid. As a result of this heat transfer, the second portion R2 of the refrigeration fluid within the economizer flow path may become a vapor. From the outlet 48 of the economizer flow path, the second portion R2 of the refrigeration fluid is provided to the economizer suction inlet 50 located at an intermediate portion of the compressor 24. Accordingly, the second portion R2 of the refrigeration fluid bypasses the expansion device 28 and the evaporator 30 of the refrigeration circuit 22. Within the compressor 24 the first portion R1 and the second portion R2 of refrigeration fluid are mixed before being provided to the discharge port 52 to repeat the cycle. Accordingly, the fluid loop of the second portion R2 of the refrigeration fluid includes the compressor 24, condenser 26, economizer expansion device 44, and economizer flow path of the economizer heat exchanger 32. It should be understood that the refrigeration systems 20 illustrated and described herein are intended as an example only, and that a refrigeration system 20 having another configuration is within the scope of the disclosure.
With continued reference to both
In other embodiments, the cooling system 60 need not be integral with or a part of the vapor compression cycle of a refrigeration system 20. Rather, the cooling system 60 may be a separate fluid loop and may use any suitable cooling fluid therein. In the illustrated, non-limiting embodiment of
With reference now to
A primary cooling fluid C1 and a secondary cooling fluid C2 are arranged in a heat transfer relationship at the heat exchanger 74. In the non-limiting embodiment illustrated in
In an embodiment, at least one jet impingement feature, such as a nozzle, jet, or orifice, hole, or opening formed in a plate 110, and in some embodiments a plurality of jet impingement features 110 are arranged within the outlet header 104, such as within an inlet area of the outlet header 104. Each jet impingement features 110 is fluidly coupled to at least one fluid flow path of one or more heat exchanger tubes 100. An outlet end of the jet impingement features 110 may be aimed at a surface of the outlet header 104 thermally coupled to at least one selected heat-generating device 62, such as a bottom surface of the outlet header 104 for example. Although the one or more jet impingement features 110 are illustrated and described herein as being separate from the heat exchange tubes 100, in an embodiment, an outlet end of the heat exchange tubes 100 may be contoured such that one or more jet impingement features 110 are integral therewith. The jet impingement features 110 may be configured as a free surface type or submerged type or confined-submerged type. Furthermore, the jet or flow expelled from the jet impingement features 110 may be of any geometrical shape in the cross-section such as circular, polygonal, star-shaped etc.
In some embodiments, the heat exchanger 74 is directly coupled to a surface of the at least one selected heat-generating device 62. In such a direct connection, a thermal interface material may, but need not be arranged between a surface 112 of the at least one selected heat-generating electronic device 62 and an adjacent surface 114 of the heat removal device 74 to facilitate the transfer of heat from the at least one selected heat-generating device 62 to the heat removal device 74.
The inlet header 102 of the heat exchanger 74 may be fluidly connected to a first fluid inlet 120 and the outlet header 104 may be fluidly connected to a first fluid outlet 122 to form a first flow path of the primary cooling fluid C1. In operation, the primary cooling fluid C1, such as a refrigerant for example, is provided from the first fluid inlet 120 into the inlet header 102 of the heat exchanger 74. The primary cooling fluid C1 provided to the inlet header 102 may be a single phase, such as a cool or cold liquid for example, or may be two-phase (i.e., a combination of liquid and vapor). From the inlet header 102, the primary cooling fluid C1 flows through the plurality of heat exchange tubes 100 of the heat exchanger 74 toward the outlet header 104.
The secondary cooling fluid C2 is configured to flow through the gaps 106 defined between adjacent heat exchanger tubes 100. In the illustrated, non-limiting embodiment, the secondary cooling fluid C2 is a flow of air moved (in a direction extending into the plane of the page) by the at least one fluid movement device, such as fan 31. In an embodiment, the is associated with at least one of a condenser 26 or evaporator 30 of the refrigeration system 20. However, it should be understood that any fluid, including a liquid, may be used as the secondary cooling fluid C2. In the illustrated, non-limiting embodiment, a plurality of fins 126 is arranged within the gaps 106 defined between adjacent heat exchanger tubes 100; however, embodiments that do not include such fins are also contemplated herein. Within the plurality of passages of the heat exchange tubes 100, heat from the secondary cooling fluid C2 is transferred to the primary cooling fluid C1. The resulting cooled secondary cooling fluid C2 provided at an outlet of the heat exchanger 74 may be configured to flow over the neighboring or peripheral heat-generating devices, such as within the variable frequency drive for example.
At least a portion of the now slightly warmer primary cooling fluid C1 is output from the plurality of heat exchange tubes 100 to the one or more jet impingement features 110 arranged within the outlet header 104. Within the jet impingement features 110, the flow rate of the primary cooling fluid C1 is increased such that the primary cooling fluid C1 is expelled from an outlet of the jet impingement features at a surface of the outlet header 104 vertically aligned with the selected heat-generating device 62.
At least a portion of the heat from the at least one selected heat-generating device 62 is transferred from the heat-generating device 62 to the primary cooling fluid C1. The continuous impingement of the primary cooling fluid C1 on the surface of the outlet header 104 thermally coupled to the heat-generating device 62 transfers heat from the surface of the outlet header 104 to the primary cooling fluid C1, thereby cooling the at least one selected heat-generating device 62.
Depending on the temperature of the secondary cooling fluid C2, the primary cooling fluid C1 may partially evaporate or may remain in a liquid state as it flows through the plurality of heat exchange tubes 100 of the heat exchanger 74 toward the outlet header 104. If the primary cooling fluid C1 is partially evaporated, the velocity of the primary cooling fluid C1 expelled from the one or more jet impingement features 110, which will enhance the heat transfer that occurs from the surface of the outlet header 104 to the primary cooling fluid C1. In an embodiment, after impinging on the surface 114, the primary cooling fluid C1 is configured to start boiling or evaporating, and in some embodiments, is in a completely vapor state. After contacting the surface of the outlet header 104, the resulting warm, superheated vaporprimary cooling fluid C1 then exits the outlet header 104 of the heat exchanger 74 and flows toward the first fluid outlet 122.
With reference now to
In each of the configurations disclosed in
The term “about” is intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof.
While the present disclosure has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims.
This application claims the benefit of U.S. Provisional Application Nos. 63/507,223, filed Jun. 9, 2023, and 63/605,688 filed Dec. 4, 2023, the contents of each are incorporated by reference herein in their entirety.
Number | Date | Country | |
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63507223 | Jun 2023 | US | |
63605688 | Dec 2023 | US |