The Design Process of The Water Cooling Plate For The New Energy Power Battery

The increasing heat loads of high-power electronics and the push for smaller packaging have shifted designers' perspectives. Liquid cooling is no more seen as a risk but somewhat a must. Liquid cold plates outperform more traditional air-cooled methods in high-heat flux utilizations.

 

In the liquid cooling process, a liquid cold plate is intended for the cooling system of a particular type of high-power battery to handle the problem of irregular temperature within and outside the battery.

 

The structure of the liquid cooling plate is built based on the thermal properties of the battery, and a coil-type liquid cooling plate structure is presented. The construction can ensure that the coolant first reaches the hot spot and then circulates it.

 

 

Water Cold Plate Data Research

Air cooling systems have improved over time to address larger densities with better efficiency. Still, there comes a limit where the air lacks the thermal transfer characteristics necessary to deliver sufficient cooling to high-density racks in an effective way.

 

As rack power grows, this can affect the performance and dependability of specialized servers and make them less energy efficient as time goes forward. When high-power racks are used, air cooling becomes uneconomical and unsustainable.

 

As a result, more companies are looking at the possibility of adding liquid to the rack to boost data capacity and efficiency. Liquid cooling utilizes water's or other fluids' enhanced heat transfer capabilities to provide efficient and cost-effective cooling of high-density racks.

 

Multiple factors will influence which strategy is most effective for a given facility. However, data center operators interested in liquid cooling have a similar challenge: integrating with data centers and building infrastructure to facilitate liquid supply to and from the data center.

 

Design Scheme of Water Cooling Plate

To efficiently operate concentrated electronic gadgets, various thermal management devices are employed. A heat sink is created by a liquid cooling plate encircled by solid walls.

Electronic equipment is exposed to cold surfaces thanks to the liquid cooling plates. The heat-carrying capacity, related heat transfer rates, and concentrated thermal areas on the plate surface are used to determine the performance of a cooling plate. SOLIDWORKS was used to create the liquid cooling plate design. In test channels, only pure water was utilized as a working fluid.

 

A comparison of flow distribution, temperature contours, pressure drop, and pumping power was performed for various channel layouts. In liquid cooling plates, it was discovered that channel arrangement is crucial. The conclusions of this study help determine the best cooling system design for high heat flux applications, such as electronic gadgets, computer processors, and automobile engines.

 

Water Cold Plate Design Input Analysis

New approaches for cooling electronic equipment are being developed. A liquid cooling system used in electrical components is known as a cold plate. The current work modifies the design of a cold plate to lower its cost while simultaneously increasing its heat dissipation rate.

 

For specific power inputs, water at various flow rates is provided, and the heat removal capability of each flow rate to that particular heat load is computed. Water has been the optimum operating fluid at all flow rates.

 

High mass flow rates are best achieved using methanol and acetone. Individual electrical components are affixed to the cold plate, which serves as a "cold wall." A defined approach for the design and performance assessment of a cold plate is followed, which is dependent on the heat loading and whether the heat loading is on one or both sides of the cold plate.

 

 

Water Cold Plate Structure Design

The cold plate is one of the most used devices for controlling the temperature of electrical equipment. A cold plate is a fluid flow area enclosed by metallic boundaries. The primary goal is to create fluid flow routes inside the room that extract heat from the electronic equipment while maintaining suitable temperatures for good performance.

 

The cold plate's job is to disperse heat from a concentric heat source with a 114-mm internal diameter and a 186-mm exterior diameter. The heat source is mounted atop a copper heat spreader and offers a total heat rate of 320 W.

 

After that, the heat source and heat spreader are attached to the top surface of the cold plate. Water with a 20°C input temperature and a flow rate of 3.5 L/min is made to flow through into the inner flow channels of the cold plate to disperse heat from the heat source.

 

Water Cold Plate Production Process

The water cold plate is made of metal and has water channels. It's constructed of a metal like copper or aluminum that comes into touch with the heating source and absorbs the heat it generates. Through the operation of the water pump, circulating fluid flows through the circulating pipeline. A water cooling system is one in which the liquid is water.

 

The water pipe links the water pump, the water block, and the water tank. Its purpose is to allow the circulating fluid to flow in a closed channel without leaking, allowing the liquid cooling system to function correctly.

 

The circulating fluid is kept in the water tank. As a heat sink, a heat exchanger is a device that transfers heat from one place to another. The heat is transferred from the circulating fluid to the large-surface-area heat sink, and the heat is removed from the air coming in by the heat sink's fan.

 

Water Cold Plate Quality Inspection

When choosing components for your liquid cooling loop, consider both material compatibility and individual performance. Although an aluminum-tube cold plate and a copper-tube heat exchanger may suit your thermal needs, it is not a stable cooling circuit.

 

Galvanic corrosion is possible when copper and aluminum are mixed in a cooling system because their electrochemical potentials are dissimilar. Galvanic corrosion eats away at the metal and eventually causes leaks.

 

Copper, bicarbonates, chlorides, and other contaminants can all be found in tap water, facilitating corrosion. Furthermore, recirculating the same fluid over time causes the dissolved oxygen to escape in a closed loop. The oxygen shortage that results will prevent the oxide layer from forming. If aluminum is kept away from oxygen and exposed to low-quality water for an extended period, it will rust.

 

Water Cold Plate test effect

The total thermal resistance of the cold plate, which is defined as the highest temperature variation divided by the net heat flow rate, was a key metric of importance. A cold plate was made by cutting nine parallel, rectangular slots into an aluminum base (1.65 cm 7.6 cm 40 cm) and then welding an aluminum cover plate on top to investigate the impact of water.

 

The temperature of the plate and the flowing fluid at the inlet, outflow and mid-plane were measured using 12 thermocouples. A 50/50 combination of ethylene glycol and water was used as the working fluid.

 

The overall thermal resistance was computed based on the temperature readings. A one-dimensional numerical model was also used to calculate the thermal resistance of the cold plate; the experimental observations and model predictions are in good agreement.

 

Conclusion

Winshare thermalloy is the liquid cooling expert, with a wide range of cold plate technologies, including Serpentine (tube in plate) designs, gun drilled techniques, and multi-piece designs with increased surface areas in the fluid path. We choose the connecting method of a multi-piece design to meet the design and volume required at Winshare thermalloy.