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.

Passive Two-Phase Cooling of Automotive Power Electronics

Passive Two-Phase Cooling of Automotive Power Electronics
Author:
Publisher:
Total Pages: 10
Release: 2014
Genre:
ISBN:

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Experiments were conducted to evaluate the use of a passive two-phase cooling strategy as a means of cooling automotive power electronics. The proposed cooling approach utilizes an indirect cooling configuration to alleviate some reliability concerns and to allow the use of conventional power modules. An inverter-scale proof-of-concept cooling system was fabricated, and tests were conducted using the refrigerants hydrofluoroolefin HFO-1234yf and hydrofluorocarbon HFC-245fa. Results demonstrated that the system can dissipate at least 3.5 kW of heat with 250 cm3 of HFC-245fa. An advanced evaporator design that incorporates features to improve performance and reduce size was conceived. Simulation results indicate its thermal resistance can be 37% to 48% lower than automotive dual side cooled power modules. Tests were also conducted to measure the thermal performance of two air-cooled condensers--plain and rifled finned tube designs. The results combined with some analysis were then used to estimate the required condenser size per operating conditions and maximum allowable system (i.e., vapor and liquid) temperatures.

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.

Two-Phase Spray Cooling with Water/2-Propanol Binary Mixtures for High Heat Flux Focal Source

Two-Phase Spray Cooling with Water/2-Propanol Binary Mixtures for High Heat Flux Focal Source
Author: Sai Sujith Obuladinne
Publisher:
Total Pages: 73
Release: 2016
Genre: Fluids
ISBN:

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Two-phase spray cooling has been an emerging thermal management technique offering high heat transfer coefficients and critical heat flux levels, near-uniform surface temperatures, and efficient coolant usage that enables to design of compact and lightweight systems. Due to these capabilities, spray cooling is a promising approach for high heat flux applications in computing, power electronics, and optics. Two-phase spray cooling inherently depends on saturation temperature-pressure relationships of the working fluid to take advantage of high heat transfer rates associated with liquid-vapor phase change. When a certain application requires strict temperature and/or pressure conditions, thermo-physical properties of the working fluid play a critical role in attaining proper efficiency, reliability, or packaging structure. However, some of the commonly used single-component working fluids have relatively poor properties and heat transfer performance. For example, water is the best coolant in terms of properties, yet in certain applications where the system operates at low temperature ambient, it cannot be implemented due to freezing risk. The common solution for this problem is to use the antifreeze mixtures (binary mixtures of water and alcohol) to reduce the freezing point. In such cases, utilizing binary mixtures to tune working fluid properties becomes an alternative approach. This study has two main objectives; (1) to experimentally investigate the two-phase spray cooling performance of water/2-propanol binary mixture, and (2) to numerically investigate the performance of an advanced heat spreader featuring high and directional thermal conductivity materials for high heat flux focal sources. The first part of the study involves experimental characterization of heat transfer performance. Tests are conducted on a small-scale, closed loop spray cooling system featuring a pressure atomized spray nozzle. The test section, made of copper, measures 10 mm x 10 mm x 2 mm with a plain, smooth surface. A cylindrical copper block, with a matching size square protrusion attached onto the back side of the test section, generates heat using cartridge heaters and simulates high heat flux source. Embedded thermocouples are used to determine the spray surface temperature. The working fluid, water/alcohol mixture, has various concentration levels of 2-propanol by mass fraction 0.0 (pure water), 0.25, 0.50, 0.879 (azeotrope) and 1.0 (pure alcohol)), representing both non-azeotropic and azeotropic cases. Spray cooling tests are performed with a constant flow rate of 5.6 ml/cm2.s at subcooled temperatures (̃20oC) and atmospheric pressure. Experimental procedure involves controlling the heat flux in increasing steps, and recording the corresponding steady-state temperatures to obtain cooling curves in the form of surface superheat vs. heat flux. The second part of the study investigates an advanced heat spreader design for thermal management of a high heat flux focal source. The heat spreader comprises of three layers: a copper layer that interfaces with the heat source, a high and directional thermal conductivity material (such as CVD diamond and Pyrolytic graphite) layer, and another copper layer that is exposed to two-phase spray cooling. The analysis applies various heat fluxes on the heat source side and the experimentally obtained heat transfer coefficients on the spray side of the spreader design to determine the temperature and heat flux distributions, and examine the potential capabilities of this configuration.

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.

Experimental and Analytical Study on Two-phase Impingement Cooling with and Without Electric Field

Experimental and Analytical Study on Two-phase Impingement Cooling with and Without Electric Field
Author: Xin Feng
Publisher:
Total Pages:
Release: 2007
Genre: Electronic dissertations
ISBN:

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Among the thermal management solutions for power electronics, two-phase jet or spray impingement cooling are two promising candidates. In this study, electrohydrodynamic atomization (EHDA) method is used to generate spray and jet from the same capillary. This approach enables us to compare the heat transfer coefficient and critical heat flux (CHF) in consistent conditions. Two nondimensional parameters are first developed to lay out the various EHDA modes of ethanol. The experimental results show that the EHDA cooling could enhance the heat transfer coefficient in most conditions, while it could not benefit CHF because the electric repulsive force causes a wide spray angle and less impinging mass flux on the surface. Single and multi micro jet impingement cooling (MJIC) are investigated. Based on the experimental observation and analytical works, a semi-theoretical CHF correlation is proposed based on force and energy balance. The experimental data of water and ethanol are predicted very well by the new model. It also shows the potential to explain the unique feature on the CHF curves of saturated HFE7000 and subcooled ethanol. By using multi MJIC, heat transfer coefficient and CHF might be improved, which mainly depend on fluids and testing conditions.

Two-Phase Spray Cooling of Hybrid Vehicle Electronics

Two-Phase Spray Cooling of Hybrid Vehicle Electronics
Author:
Publisher:
Total Pages: 12
Release: 2008
Genre: Heat
ISBN:

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Spray cooling is a feasible cooling technology for hybrid vehicle electronics; HFE 7100 is a promising coolant.

Two-Phase Spray Cooling of Hybrid Vehicle Electronics

Two-Phase Spray Cooling of Hybrid Vehicle Electronics
Author:
Publisher:
Total Pages: 0
Release: 2008
Genre:
ISBN:

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Spray cooling is a feasible cooling technology for hybrid vehicle electronics; HFE 7100 is a promising coolant.