A Two-phase Cooling Method Using R134a Refrigerant to Cool Power Electronics Devices

A Two-phase Cooling Method Using R134a Refrigerant to Cool Power Electronics Devices
Author:
Publisher:
Total Pages:
Release: 2004
Genre:
ISBN:

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Power electronics are vital to the operation and performance of hybrid-electric vehicles (HEVs) because they provide the interface between the energy sources and the traction drive motor. As with any "real" system, power electronic devices have losses in the form of heat energy during normal switching operation, which has the potential ability to damage or destroy the device. Thus, to maintain reliability of the PE system, the heat energy produced must be removed. Present HEV cooling methods provide adequate cooling effects, but lack sufficient junction temperature control to maintain long-term reliability. This thesis is based on using the automobile's air conditioning system as an alternative to conventional power electronics cooling methods for hybrid-electric vehicle applications. This thesis describes the results from a series of experiments performed on a circuit containing an IGBT, gate controller card, and snubber while submerged in an automotive refrigerant bath (R134a). The circuit was then tested while being cooled using a mock automotive air conditioning system. Tests were performed on custom made thin-film resistors while being cooled by the same mock air conditioning system. The thin-film resistors were arranged to resemble a six-switch, three-phase inverter in steady-state operation. Lastly, an active IGBT junction cooling technique is described and simulated, which incorporates direct cooling of the junction of the power electronic device rather than its case. The results from the simulation indicate the exposed junction IGBT technique would benefit the device by reducing the junction temperature, increasing forward current ratings, and increasing reliability.

Emerging Two-Phase Cooling Technologies for Power Electronic Inverters

Emerging Two-Phase Cooling Technologies for Power Electronic Inverters
Author: J. S. Hsu
Publisher:
Total Pages:
Release: 2005
Genre:
ISBN:

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In order to meet the Department of Energy's (DOE's) FreedomCAR and Vehicle Technologies (FVCT) goals for volume, weight, efficiency, reliability, and cost, the cooling of the power electronic devices, traction motors, and generators is critical. Currently the power electronic devices, traction motors, and generators in a hybrid electric vehicle (HEV) are primarily cooled by water-ethylene glycol (WEG) mixture. The cooling fluid operates as a single-phase coolant as the liquid phase of the WEG does not change to its vapor phase during the cooling process. In these single-phase systems, two cooling loops of WEG produce a low temperature (around 70 C) cooling loop for the power electronics and motor/generator, and higher temperature loop (around 105 C) for the internal combustion engine. There is another coolant option currently available in automobiles. It is possible to use the transmission oil as a coolant. The oil temperature exists at approximately 85 C which can be utilized to cool the power electronic and electrical devices. Because heat flux is proportional to the temperature difference between the device's hot surface and the coolant, a device that can tolerate higher temperatures enables the device to be smaller while dissipating the same amount of heat. Presently, new silicon carbide (SiC) devices and high temperature direct current (dc)-link capacitors, such as Teflon capacitors, are available but at significantly higher costs. Higher junction temperature (175 C) silicon (Si) dies are gradually emerging in the market, which will eventually help to lower hardware costs for cooling. The development of high-temperature devices is not the only way to reduce device size. Two-phase cooling that utilizes the vaporization of the liquid to dissipate heat is expected to be a very effective cooling method. Among two-phase cooling methods, different technologies such as spray, jet impingement, pool boiling and submersion, etc. are being developed. The Oak Ridge National Laboratory (ORNL) is leading the research on a novel floating refrigerant loop that cools high-power electronic devices and the motor/generator with very low cooling energy. The loop can be operated independently or attached to the air conditioning system of the vehicle to share the condenser and other mutually needed components. The ability to achieve low cooling energy in the floating loop is attributable to the liquid refrigerant operating at its hot saturated temperature (around 50 C+). In an air conditioning system, the liquid refrigerant is sub-cooled for producing cool air to the passenger compartment. The ORNL floating loop avoids the sub-cooling of the liquid refrigerant and saves significant cooling energy. It can raise the coefficient of performance (COP) more than 10 fold from that of the existing air-conditioning system, where the COP is the ratio of the cooled power and the input power for dissipating the cooled power. In order to thoroughly investigate emerging two-phase cooling technologies, ORNL subcontracted three university/companies to look into three leading two-phase cooling technologies. ORNL's assessments on these technologies are summarized in Section I. Detailed descriptions of the reports by the three university/companies (subcontractors) are in Section II.

Two-Phase Spray Cooling with HFC-134a and HFO-1234yf for Thermal Management of Automotive Power Electronics Using Practical Enhanced Surfaces

Two-Phase Spray Cooling with HFC-134a and HFO-1234yf for Thermal Management of Automotive Power Electronics Using Practical Enhanced Surfaces
Author: Sulaiman Saleh Altalidi
Publisher:
Total Pages: 78
Release: 2017
Genre: Automobiles
ISBN:

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The objective of this research was to investigate the performance of two-phase spray cooling with HFC-134a and HFO-1234yf refrigerants using practical enhanced heat transfer surfaces. Results of the study were expected to provide a quantitative spray cooling performance comparison with working fluids representing the current and next-generation mobile air conditioning refrigerants, and demonstrate the feasibility of this approach as an alternative active cooling technology for the thermal management of high heat flux power electronics (i.e., IGBTs) in electric-drive vehicles. Potential benefits of two-phase spray cooling include achieving more efficient and reliable operation, as well as compact and lightweight system design that would lead to cost reduction. The experimental work involved testing of four different enhanced boiling surfaces in comparison to a plain reference surface, using a commercial pressure-atomizing spray nozzle at a range of liquid flow rates for each refrigerant to determine the spray cooling performance with respect to heat transfer coefficient (HTC) and critical heat flux (CHF). The heater surfaces were prepared using dual-stage electroplating, brush coating, sanding, and particle blasting, all featuring "practical" room temperature processes that do not require specialized equipment. Based on the obtained results, HFC-134a provided a better heat transfer performance through higher HTC and CHF values compared to HFO-1234yf at all tested surfaces and flow rates. While majority of the tested surfaces provided comparable HTC and modestly higher CHF values compared to the reference surface, one of the enhanced surfaces offered significant heat transfer enhancement.

Embedded Cooling Of Electronic Devices: Conduction, Evaporation, And Single- And Two-phase Convection

Embedded Cooling Of Electronic Devices: Conduction, Evaporation, And Single- And Two-phase Convection
Author: Madhusudan Iyengar
Publisher: World Scientific
Total Pages: 479
Release: 2024-01-10
Genre: Technology & Engineering
ISBN: 9811279381

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This book is a comprehensive guide on emerging cooling technologies for processors in microelectronics. It covers various topics such as chip-embedded two-phase cooling, monolithic microfluidic cooling, numerical modeling, and advances in materials engineering for conduction-limited direct contact cooling, with a goal to remedy high heat flux issues.The book also discusses the co-design of thermal and electromagnetic properties for the development of light and ultra-high efficiency electric motors. It provides an in-depth analysis of the scaling limits, challenges, and opportunities in embedded cooling, including high power RF amplifiers and self-emissive and liquid crystal displays. Its analysis of emerging cooling technologies provides a roadmap for the future of cooling technology in microelectronics.This book is a good starting point for the electrical and thermal engineers, as well as MS and PhD students, interested in understanding and collaboratively tackling the complex and multidisciplinary field of microelectronics device (embedded) cooling. A basic knowledge of heat conduction and convection is required.

Floating Refrigerant Loop Based on R-134a Refrigerant Cooling of High-Heat Flux Electronics

Floating Refrigerant Loop Based on R-134a Refrigerant Cooling of High-Heat Flux Electronics
Author: K. T. Lowe
Publisher:
Total Pages:
Release: 2005
Genre:
ISBN:

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The Oak Ridge National Laboratory (ORNL) Power Electronics and Electric Machinery Research Center (PEEMRC) have been developing technologies to address the thermal issues associated with hybrid vehicles. Removal of the heat generated from electrical losses in traction motors and their associated power electronics is essential for the reliable operation of motors and power electronics. As part of a larger thermal control project, which includes shrinking inverter size and direct cooling of electronics, ORNL has developed U.S. Patent No. 6,772,603 B2, ''Methods and Apparatus for Thermal Management of Vehicle Systems and Components'' [1], and patent pending, ''Floating Loop System for Cooling Integrated Motors and Inverters Using Hot Liquid Refrigerant'' [2]. The floating-loop system provides a large coefficient of performance (COP) for hybrid-drive component cooling. This loop (based on R-134a) is integrated with a vehicle's existing air-conditioning (AC) condenser, which dissipates waste heat to the ambient air. Because the temperature requirements for cooling of power electronics and electric machines are not as low as that required for passenger compartment air, this adjoining loop can operate on the high-pressure side of the existing AC system. This arrangement also allows the floating loop to run without the need for the compressor and only needs a small pump to move the liquid refrigerant. For the design to be viable, the loop must not adversely affect the existing system. The loop should also provide a high COP, a flat-temperature profile, and low-pressure drop. To date, the floating-loop test prototype has successfully removed 2 kW of heat load in a 9 kW automobile passenger AC system with and without the automotive AC system running. The COP for the tested floating-loop system ranges from 40-45, as compared to a typical AC system COP of about 2-4. The estimated required waste-heat load for future hybrid applications is 5.5 kW and the existing system could be easily scaleable for this larger load.

Two-Phase Flow in Refrigeration Systems

Two-Phase Flow in Refrigeration Systems
Author: Junjie Gu
Publisher: Springer Science & Business Media
Total Pages: 167
Release: 2013-08-17
Genre: Science
ISBN: 1461483239

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Two-Phase Flow in Refrigeration Systems presents recent developments from the authors' extensive research programs on two-phase flow in refrigeration systems. This book covers advanced mass and heat transfer and vapor compression refrigeration systems and shows how the performance of an automotive air-conditioning system is affected through results obtained experimentally and theoretically, specifically with consideration of two-phase flow and oil concentration. The book is ideal for university postgraduate students as a textbook, researchers and professors as an academic reference book, and by engineers and designers as handbook.

Encyclopedia of Two-Phase Heat Transfer and Flow IV

Encyclopedia of Two-Phase Heat Transfer and Flow IV
Author: John R Thome
Publisher: World Scientific Publishing
Total Pages: 1372
Release: 2018-05-18
Genre: Technology & Engineering
ISBN: 9813234385

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Set IV is a new addition to the previous Sets I, II and III. It contains 23 invited chapters from international specialists on the topics of numerical modeling of pulsating heat pipes and of slug flows with evaporation; lattice Boltzmann modeling of pool boiling; fundamentals of boiling in microchannels and microfin tubes, CO2 and nanofluids; testing and modeling of micro-two-phase cooling systems for electronics; and various special topics (flow separation in microfluidics, two-phase sensors, wetting of anisotropic surfaces, ultra-compact heat exchangers, etc.). The invited authors are leading university researchers and well-known engineers from leading corporate research laboratories (ABB, IBM, Nokia Bell Labs). Numerous 'must read' chapters are also included here for the two-phase community. Set IV constitutes a 'must have' engineering and research reference together with previous Sets I, II and III for thermal engineering researchers and practitioners.