Investigation of Liquid Cooling Plate for Server CPUs Based on Topology Optimization

In this study, a microchannel liquid cooling plate (LCP) is proposed for Intel Xeon 52.5 mm * 45 mm packaged architecture processors based on topology optimization (TO). Firstly, a mathematical model for topology optimization design of the LCP is established based on heat dissipation and pressure drop objectives. We obtain a series of two-dimensional (2D) topology optimization configurations with different weighting factors for two objectives. It is found that the biomimetic phenomenon of the topologically optimized flow channel structure is more pronounced at low Reynolds numbers. Secondly, the topology configuration is stretched into a three-dimensional (3D) model to perform CFD simulations under actual operating conditions. The results show that the thermal resistance and pressure drop of the LCP based on topology optimization achieve a reduction of approximately 20% - 50% compared to traditional serpentine and microchannel straight flow channel structures. The Nusselt number can be improved by up to 76.1% compared to microchannel straight designs. Moreover, it is observed that under high flow rates, straight microchannel LCPs exhibit significant backflow, vortex phenomena, and topology optimization structures LCPs also tend to lead to loss of effectiveness in the form of tree root-shaped branch flows. Suitable flow rate ranges for LCPs are provided. Furthermore, the temperature and pressure drop of experimental results are consistent with the numerical ones, which verifies the effectiveness of performance for topology optimization flow channel LCP.

Skin friction and heat transfer of liquid jet over a continuous moving horizontal hot plate

The skin friction and heat transfer occurring in the laminar boundary layerwhich caused by a vertical liquid jet impinging on a continuously moving horizontal plate werestudied. Similarity solutions for shear stress and heat distribution were obtained by using thehooting technique. The results show that the skin friction decreases with an increase of velocityparameter, the evolving of thermal boundary decrease with increasing in Prandtl number, but increasewith increasing of velocity parameter.

Experimental Verification of Model for Liquid-Cooled Staggered Pin Fin Heat Sinks with Top Bypass Flow

Pressure drops and heat transfer over staggered pin fin heat sinks with top bypass flow were experimentally evaluated. The authors considered liquid-cooling applications because there were few data available comparing to air-cooling applications. Empirical equations to predict heat transfer on the endwall were developed by obtaining experimental data on the copper base plate with acrylic pins. A new model for predicting pressure drops and heat transfer over staggered pin fin heat sinks with top bypass flow based on mass, momentum, and energy conservation within the two control volumes is proposed. The first control volume in the model is located within the finned area, and the second is located in the gap between the tip of the pins and the flow channel. This model combines two conditions according to the boundary-layer thickness. A comparison between experimental and calculated results revealed that dimensionless pressure drops and the Nusselt number could be predicted within 30% error for the former and 50% error for the latter.

Waste heat water pumping model with direct contact cooling

The performance of a patented water pumping model with steam-air power was presented, which operates automatically by direct contact cooling method. The main objective was to study feasibility of a pumping model for underground water. In this model, a heater installed within the heat tank represented sources of waste heat as energy input for finding appropriate conditions of the 10 L pump model. The system operation had five stages： heating, pumping, vapor flow, cooling, and water suction. The overall water heads of 3, 4.5, 6 and 7.5 m were tested. At the same time, it was found that the pump with 50% air volume is sufficient for pumping water to a desired level. In the experiment, the temperatures in the heating and pumping stages were 100-103 ℃and 80-90 ℃, respectively. The pressure in the pumping stage was 12-18 kPa, and the pressure in the suction stage was about-80 kPa, sufficient for the best performance. It could pump 170 L of water at a 2 m suction head, 120 L at a 3.5 m suction head, 100 L at a 5 m suction head, and 65 L at a 6.5 m suction head in 2 h. A mathematical model for larger pumps was also presented, which operates nearly the same as the present system. Economic analysis of the 10 L pump was also included.

Gas film/regenerative composite cooling characteristics of the liquid oxygen/liquid methane (LOX/LCH4) rocket engine

The thermal protection of rocket engines is a crucial aspect of rocket engine design.In this paper,the gas film/regenerative composite cooling of the liquid oxygen/liquid methane(LOX/LCH4)rocket engine thrust chamber was investigated.A gas film/regenerative composite cooling model was developed based on the Grisson gas film cooling efficiency formula and the one-dimensional regenerative cooling model.The accuracy of the model was validated through experiments conducted on a 6 kg/s level gas film/regenerative composite cooling thrust chamber.Additionally,key parameters related to heat transfer performance were calculated.The results demonstrate that the model is sufficiently accurate to be used as a preliminary design tool.The temperature rise error of the coolant,when compared with the experimental results,was found to be less than 10%.Although the pressure drop error is relatively large,the calculated results still provide valuable guidance for heat transfer analysis.In addition,the performance of composite cooling is observed to be superior to regenerative cooling.Increasing the gas film flow rate results in higher cooling efficiency and a lower gas-side wall temperature.Furthermore,the position at which the gas film is introduced greatly impacts the cooling performance.The optimal introduction position for the gas film is determined when the film is introduced from a single row of holes.This optimal introduction position results in a more uniform wall temperature distribution and reduces the peak temperature.Lastly,it is observed that a double row of holes,when compared to a single row of holes,enhances the cooling effect in the superposition area of the gas film and further lowers the gas-side wall temperature.These results provide a basis for the design of gas film/regenerative composite cooling systems.

High-Resolution Heat Transfer Coefficients Measurement for Jet Impingement Using Thermochromic Liquid Crystals

A high-resolution testing technique named liquid crystal thermography is used for the experimental study on jet array impingement to map out the distribution of heat transfer coefficients on the cooling surface. Effects of the impingement distance, the impinging hole arrangement and the initial crossflow on heat transfer characteristics are investigated. The thermal images show truly the features of local heat transfer for each jet impingement cooling. The applications of thermochromic liquid crystal are successful in the qualitative and quantitative measurement for heat transfer coefficients distribution.

STAR CCM+ CFD Simulations of Enhanced Heat Transfer in High-Power Density Electronics Using Forced Air Heat Exchanger and Pumped Fluid Loop Cold Plate Fabricated from High Thermal Conductivity Materials

As telecommunication and RF power electronics applications continue to push the envelope of waste heat dissipation, more and more, we see a need for active thermal control employing forced air electronic cooling fans in unison with pumped fluid loops in order to meet temperature and performance requirements. This research paper presents results of applying Computational Fluid Dynamics (CFD) commercial industry STAR-CCM+ software for heat transfer and fluid flow simulation of a novel heat exchanger/cold plate fabricated from k-core high thermal conductivity material in order to realize thermal control system hardware design for very much applications to very large power density (~1 kW/m2) electronics packaging scenarios. Trade studies involving different heat exchanger/cold plate materials, as well as vari- ous fault scenarios within a mock-up of a typical electronics system, are used to illustrate the upper bounds placed on the convective heat transfer coefficient. Agreement between our present findings and previous research in the field of electronics cooling is presented herein.

Cooling System Design and Thermal Analysis of Modular Stator Hybrid Excitation Synchronous Motor

Hybrid excitation synchronous motor has the advantages of uniform and adjustable electromagnetic field, wide speed range and high power density. It has broad application prospects in new energy electric vehicles, wind power generation and other fields. This paper introduces the basic structure of hybrid excitation motor with modular stator, and analyzes the operation principle of hybrid excitation motor. The cooling structure of the water-cooled plate is designed, and the effects of the thickness of the water-cooled plate and the number of water channels in the water-cooled plate on the heat dissipation capacity of the water-cooled plate are analyzed by theoretical and computational fluid dynamics methods. The effects of different water cooling plate structures on water velocity, pressure drop, water pump power consumption and heat dissipation capacity were compared and analyzed. The influence of different inlet flow velocity on the maximum temperature rise of each part of the motor is analyzed, and the temperature of each part of the motor under the optimal water flow is analyzed. The influence of the traditional spiral water jacket cooling structure and the water-cooled plate cooling structure on the maximum temperature rise of the motor components is compared and analyzed. The results show that the water-cooled plate cooling structure is more suitable for the modular stator motor studied in this paper. Based on the water-cooled plate cooling structure, the air-water composite cooling structure is designed, and the effects of the air-water composite cooling structure and the water-cooled plate cooling structure on the maximum temperature rise of each component of the motor are compared and analyzed. The results show that the maximum temperature rise of each component of the motor is reduced under the air-water composite cooling structure.

基于LBM的低导热材料板强化沸腾换热机理分析

为进一步强化沸腾换热,通过在固体加热器的上壁面附近嵌入多段低导热材料板,实现了沸腾换热的受热面上的温度随空间的交替变化。采用单组分多相LBM,考察了低导热材料板的数量和间隙间距对沸腾换热性能和气泡动力学的影响,从微观角度揭示了添加低导热材料板强化沸腾换热的机理。结果表明:气泡动态行为随间隙间距的增大而发生变化,会出现气泡合并、独立生长等气泡脱离过程。结合气泡动态行为、温度场和流场分析,发现气泡首先会在间隙受热面处成核生长,脱离气泡的涡流可以促进生长气泡在受热面的横向迁移和合并过程,在一定间隙间距范围,气泡会相互融合形成较大的液桥,液桥的存在能够促进受热面气泡根部周围微层的蒸发,推动了间隙受热面处的冷流体再润湿过程。添加多段低导热材料板,间隙处热量积聚、气泡合并形成液桥、间隙受热面的再润湿、气泡横向迁移和多气泡的快速合并等这些过程的共同作用强化了沸腾换热性能。

离子液脱硫技术中热平衡的研究与实践

介绍了离子液脱硫系统的工艺流程,分析了系统运行中的热交换过程,主要换热设备采用板式换热器,针对换热过程中出现的热平衡被破坏的情况及影响进行探讨,提出了保持离子液脱硫系统稳定运行的措施。

冷板阻热层对锂电池模组散热均匀性影响

锂电池模组温差过大引发电池间充放电、老化衰减速率不一致,致使其性能变差。为了进一步降低锂电池模组工作温差,提出一种设阻热层的新型冷板,即通过在冷板冷却液入口处与锂电池间增设阻热层增大热阻、抑制锂电池与冷板间热交换改善其散热均匀性。利用新型冷板对锂电池模组3 C放电冷却散热进行建模仿真计算,分析了并行流道、并联蛇形流道以及分叉型流道等3种不同流道冷板增设阻热层对锂电池模组放电散热均匀性影响,以及阻热层材料导热系数、厚度及覆盖面积对锂电池模组冷却散热均匀性影响。结果表明:在3种流道冷板上增设阻热层均能有效降低锂电池模组工作温差。随着阻热层材料导热系数减小,锂电池模组最高温度和温差均先减小后增加。随着阻热层厚度、阻热层覆盖面积增大,锂电池模组工作最高温度和温差均先减小后增大。采用长80 mm、宽80 mm、厚1 mm导热硅胶垫阻热层,分叉型流道冷板冷却锂电池模组3 C放电最高温度和温差降至306.55 K和4.89 K。

38 mm型CO_(2)致裂器内部参数对致裂器做功能力影响

为快速获得液态CO_(2)致裂器内部参数对致裂器做功能力的影响特征,优化提高液态CO_(2)致裂器做功能力,提高煤层瓦斯抽采效率,设计液态CO_(2)致裂器做功能力快速评估试验装置。使用煤矿用38 mm型致裂器进行4水平3因素的9组正交试验,分析液态CO_(2)致裂器发热管内部装药量、主管内液态CO_(2)填充量、泄能片厚度以及泄能头释放口径对于致裂器做功能力的影响主次顺序;进一步对其中最重要的影响因素进行固定变量试验,分析最重要影响因素对液态CO_(2)致裂器做功能力的影响特征。结果表明:对于煤矿用38 mm型CO_(2)致裂器,泄能片厚度对于液态CO_(2)致裂器做功能力的影响最大,发热管内部装药量次之,主管内液态CO_(2)填充量及泄能头释放口径影响最弱;液态CO_(2)致裂器做功能力随着泄能片的厚度增加而增加,但当泄能片厚度增加到一定程度时,液态CO_(2)致裂器做功能力增幅不够明显,达到一定厚度泄能片不会破裂,当38 mm型致裂器内部参数设置为CO_(2)质量0.33 kg、释放口径18 mm、装药量60 g、泄能片厚度2.0 mm时致裂器做功能力对应三硝基甲苯(TNT)当量为0.202 kg,相对当前工地使用参数做功能力提升21.9%。

Liquid Air Energy Storage for Decentralized Micro Energy Networks with Combined Cooling,Heating,Hot Water and Power Supply

Liquid air energy storage(LAES)has been regarded as a large-scale electrical storage technology.In this paper,we first investigate the performance of the current LAES(termed as a baseline LAES)over a far wider range of charging pressure(1 to 21 MPa).Our analyses show that the baseline LAES could achieve an electrical round trip efficiency(e RTE)above 60%at a high charging pressure of 19 MPa.The baseline LAES,however,produces a large amount of excess heat particularly at low charging pressures with the maximum occurred at~1 MPa.Hence,the performance of the baseline LAES,especially at low charging pressures,is underestimated by only considering electrical energy in all the previous research.The performance of the baseline LAES with excess heat is then evaluated which gives a high e RTE even at lower charging pressures;the local maximum of 62%is achieved at~4 MPa.As a result of the above,a hybrid LAES system is proposed to provide cooling,heating,hot water and power.To evaluate the performance of the hybrid LAES system,three performance indicators are considered:nominal-electrical round trip efficiency(ne RTE),primary energy savings and avoided carbon dioxide emissions.Our results show that the hybrid LAES can achieve a high ne RTE between 52%and 76%,with the maximum at~5 MPa.For a given size of hybrid LAES(1 MW×8 h),the primary energy savings and avoided carbon dioxide emissions are up to 12.1 MWh and 2.3 ton,respectively.These new findings suggest,for the first time,that small-scale LAES systems could be best operated at lower charging pressures and the technologies have a great potential for applications in local decentralized micro energy networks.

基于浸没式液冷的锂电池热管理研究进展

电池热管理系统对电动汽车的安全性至关重要。随着电池能量密度和放电功率的提高,传统散热方案已无法满足当前电池散热的要求。浸没式液冷电池热管理系统作为电动汽车动力电池组和动力系统的高效热管理解决方案之一,正受到越来越多的关注。本文综述了目前锂离子电池浸没式液冷技术,包括单相浸没式液冷和两相浸没式液冷;探讨了冷却液种类、排布方式、流速、压力等因素对系统性能的影响及浸没式液冷效率的评价方法。同时,分析了目前浸没式液冷技术在电池热管理中的行业趋势。最后,对于浸没式液冷在锂电池热管理中的应用进行了展望,为开发更高功率、更安全和更持久的电动汽车提供参考。

有轨电车超级电容模组液冷散热仿真分析

超级电容模组因其快速充放电和适应大功率需求的能力被视为有轨电车未来动力电源的发展趋势。然而,在运行和充放电过程中,超级电容模组会产生大量热量,并导致温度在短时间内迅速上升。为解决该问题,本工作提出一种采用微型通道液体冷却的热管理方式,其原理是利用液冷板微型通道内的低温流体对超级电容单体进行冷却,通过改变边界条件确保超级电容模组在不同散热工况下的工作温度始终保持在适宜的范围内。为了比较液冷板性能,本工作设计了三种液冷板微型通道的模型,并使用ANSYS仿真软件对其进行了数值模拟,建立了新型液冷板最高温度预测模型,研究了边界条件对新型液冷板性能的影响。结果表明,design-3液冷板模型具有较好的流动和散热性能,当提高冷却液入口质量流量时,可以有效降低超级电容单体的最大温差和最高温度,改善单体间的均温性。但随着冷却液入口质量流量增至0.35 kg/s后,超级电容单体最高温度降幅逐渐减小,对其散热性能改善有限,提高流量会使热管理系统能量损失增加;当提高冷却液入口温度时,超级电容单体间温差不断减小,但冷却液入口温度对单体的均温性影响不大。

电力电子器件用液冷针翅散热器的研究进展

随着大功率电力电子器件(如绝缘栅双极型晶体管,IGBT)轻量化、小型化和集成化的发展需求,其功率密度越来越大,导致其热流密度越来越高,亟需高效散热来满足其使用要求。传统空气冷却散热器结构简单、使用方便,但是散热能力较低,难以满足高热流密度的散热需求,目前主要采用液体冷却散热器,其中液冷针翅散热器是最常用的高效散热器。本文介绍了液冷针翅散热器的结构、液体工质、材料和制造等方面的研究进展,重点分析了液冷针翅散热器的流体通道结构、针翅结构对流动和传热性能的影响,并给出了液冷针翅散热器的发展建议。

锂电池肋片液冷板的传热与流动特性研究

对于锂离子电池热管理系统,在锂电池两侧插入带通道的冷板是一种有效的高温散热方法。针对电动汽车用方形锂电池,在传统并行流道冷板的基础上,设计了六种肋片强化换热冷板。通过数值模拟方法研究和比较了不同雷诺数下冷板的换热效果,同时计算了流场的压降、摩擦因子和速度等来分析其流动特性,最后采用综合考虑流体流动和传热特性的无量纲因子来判断冷板的综合性能。结果表明,不同雷诺数下六种肋片强化冷板散热性能均优于传统并行流道冷板,但压降也不可避免地增大,各个方案中矩形交错肋片液冷板的综合性能最优。

泵驱动的制冷剂相变冷板冷却系统实验研究

元器件的小型化和性能的提升使电子器件功率不断提高,优越的散热性能对于保证电子器件的可靠性具有重要意义。本文搭建了泵驱动的制冷剂相变冷板冷却实验系统,设计加工了4块不同材质(铜、铝)和流道高度(10、15 mm)的相变冷板,对散热功率为200~1000 W、热流密度为4.4~22.2 W/cm^(2)的集中热源在制冷能力为3~11 kW和不同热源位置时的冷板换热性能、阻力特性及泵功耗进行了研究。结果表明:相变冷板换热性能优越,在应对散热量为1 kW、热流密度为22.2 W/cm^(2)的集中热源时,传热系数最高可达26 kW/(m^(2)·℃),在系统总阻力小于20 kPa、制冷剂泵功耗小于20 W时可以实现模拟热源表面与制冷剂温差小于15℃,可以利用天然冷源进行散热,实现节能;相变冷板的换热特性可由翅片效率计算式和Kandlikar传热关联式进行描述,使用理论公式计算出的冷板温差与实际值偏差小于1℃,可以指导冷板流道设计。

液氧甲烷变推力发动机螺旋槽再生冷却传热特性研究

为探究宽工况范围下螺旋槽再生冷却的传热特性,基于微小通道内低温工质的相变传热模型,采用一维传热计算方法,对5 kN级液氧甲烷变推力发动机开展了螺旋槽再生冷却传热特性研究。结果表明:本文所采用的传热计算模型可用于传热预估,与试验结果相比,冷却剂温升误差为4.3%,压降误差为1.1%,喉部处外壁温误差为-11%,在工程计算可接受范围内;相比于直槽,螺旋槽再生冷却能有效降低燃气侧壁温,同时,在宽范围变推力条件下,实际功率水平越低,冷却剂温升、压降越小,喉部燃气侧壁温越低,但“传热恶化区”内的壁温最大值反而越高,当发动机推力由额定工况的75%调整至20%时,燃气侧壁温的最大值由1 351 K增大至1 399 K;综合考虑壁面温度及冷却剂的压力损失,本文对冷却通道开展优化设计,对比四种冷却通道方案的传热性能,其中,方案4为最优方案,20%额定功率水平工况时,冷却剂温升为491 K,压降为0.34 MPa,燃气侧壁温最大值也仅为1 297 K,较初始设计方案降低了102 K,远低于材料的极限温度。

基于串并对称式液冷流道的锂电池散热分析

针对锂离子电池均温性差和液冷系统能耗高等问题,以方形锂离子电池为研究对象,在电池单体模型验证的基础上,设计了串并对称式液冷流道的锂离子电池散热结构,对比了5种流道方案,在优选方案四的基础上,分析了液冷板中的液冷流速、铝板厚度组合和液冷系统的启动时间对电池散热效果和液冷系统能耗的影响.结果表明:与方案一的流道形状S0对比,方案四的流道形状S3能够将模组中电池单体的最大温差降低15%;此外,电池的最高温度随着液冷流速的增加呈现先减小后平缓的趋势;在保证液冷系统总质量不变的前提下,与初始的铝板厚度组合h0对比,调整后的铝板厚度组合h4可将电池模组的最大温差降低12%;电池在2.5C放电时,延迟液冷系统启动时间至563 s,既可以保证电池在最佳的工作温度范围内,又能节约液冷系统约39%的能耗成本.