Liquid Cooled Solutions
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What is a Cold Plate?
A cold plate, sometimes referred to as a water block, is a metal block (typically aluminum or copper) that possesses internal tubing to allow liquids to flow through it. The plate’s functionality is to provide localized cooling of power electronics. It does so by transferring heat from a device to a liquid (such as water or antifreeze) that flows to a remote heat exchange, and then dissipates into the ambient or to another liquid in a secondary cooling system. In layman’s terms, when a cold plate is placed on an electronic component that requires cooling, it absorbs and dissipates the heat from the component to the liquid that is then cycled through the system.
Compared to air cooling, liquid cold plates enable major reductions in the volume and weight of power electronics. Use of a cold plate is “the next step” when air-cooling falls short, often because thermal performance can no longer be economically met within the desired footprint.
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Types of Cold Plates
Exposed Tube Cold Plates
Exposed tube cooled plates provide high-performance cooling in a smaller system.
Copper, copper-nickel, or stainless steel tubes are pressed into proprietary channels in an aluminum plate. A thermal epoxy is applied around the tube to provide optimal thermal transfer. The cold plates transfer heat from the device to the liquid in the tube, which is then moved through the closed loop system, dissipating the heat.
With an exposed tube liquid cold plate, the coolant tube is in direct contact with the device providing minimal thermal resistance and increased performance. Exposed tube cold plates are traditionally the cheapest of the liquid cooling technologies.
Buried Tube Cold Plate
A buried tube liquid cold plate has the ability to cool both sides of the cold plate. The tubes are protected from the outside environment. Generally, a copper tube is buried in an aluminum substrate machined by Mersen. Next, a punched copper tube is pressed by a punching machine (this pressing is deeper than that of the exposed tube cold plate). Some engineers prefer the epoxy layer above the tube to protect the tube from leakage.
This cooling principle is best suited for high-power switching devices, such as chip, LED, and power battery cooling systems.
Deep Drilled Cold Plates
Deep drilled cold plates have multiple cooling channels drilled directly through the length of the plate. Tubing is inserted and expanded to create secure metal-to-metal contact, optimizing the thermal transfer properties and providing double-sided cooling. To further enhance cooling performance, a device called a “turbulator” can be added, which increases the flow velocity in the channels.
The benefits of deep drilled cold plate cooling are numerous:
- Allows for double-sided cooling
- Optimizes thermal transfer
- Turbulators can be added to enhance performance
- Smaller chance of leaks
You may be surprised to learn that few thermal engineering companies offer deep drilled cold plate applications, even though there is still a demand for it! Mersen has the capabilities and acumen to accomplish deep plate drilling capabilities.
Vacuum Brazed Cold Plates
Vacuum brazing occurs when two cooling plates with internal channels and fin structures (often “folded” fins or “skived” fins) are sealed together inside a vacuum chamber for heating.
A filler metal with a lower melting point is melted into the joints of the cold plate via capillary action under the corresponding technological conditions, and connects two plates with internal channels and fin structures to form an internal flow channel. The vacuum system can be connected to the workpiece so that the pressure inside the workpiece is lower than the atmospheric pressure during vacuum brazing.
This cooling thermal module is frequently utilized in power generation, electric car batteries, fuel cell components, and other applications. Vacuum brazing has a higher cost , but also very high reliability.
Vacuum brazing poses many advantages:
- Highly repeatable and controllable batch processing
- Uniform material characteristics during and after brazing
- Significant flexibility with design, as it is not limited by the bending radius limitations of pressure tube cold plate
Dip Brazed Cold Plates
Dip brazed cold plates are as advantageous as vacuum-brazed cold plates, though the method of their creation differs. Here, instead of heating in a vacuum furnace, the two metal pieces are cleaned with chemicals, then go into a bath of molten salt (an aluminum brazing flux), heated up to near lava-level temperatures. The filler metal is pre-placed as close to the joints as possible.
Assembly is immersed or dipped, the molten flux comes in contact with all internal and external surfaces simultaneously. This liquid heat is extremely fast and uniform.
Tell Us About Your Application Needs
Not every cold plate system is appropriate for all devices that require cooling. Design and analysis cover a spectrum of performance features and considerations – from height and weight to temperature uniformity.
Mersen has the capability to customizable specific cold plate design, depending on your application needs, including key factors such as:
- Tube path
- Manifolds
- Connectors
As always, our designs seek to minimize your operating and manufacturing costs. Contact us to discuss your needs today!
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Air heat sink vs liquid cold plate: What’s the difference?
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How do air heat sinks work?
Air heat sinks, leveraging the ambient air as a cooling medium, are widely used for their simplicity and cost-effectiveness.
They dissipate heat through natural convection or forced air systems, making them suitable for a variety of applications where moderate cooling is sufficient. -
How do liquid cold plates work?
Liquid cold plates offer a more direct and efficient method of cooling, using a liquid coolant to transfer heat away from sensitive components. This approach is particularly effective in high-power or high-density applications where air cooling is insufficient.
Liquid cold plates can achieve lower temperatures and more precise temperature control, but they come with increased complexity and cost. -
How to choose between air heat sink and liquid cold plate?
Choosing the right cooling solution—between air heat sinks and liquid cold plates—crucially influences the efficiency, reliability, and performance of power electronics systems. This decision hinges on several factors, each reflecting the unique demands of the application.
Cooling capacity and efficiency: If the system generates a high amount of heat or operates in a high-temperature environment, liquid cold plates are often more effective. Their superior cooling capacity and efficiency are ideal for tightly packed or high-power components. Air heat sinks might suffice for applications with lower thermal loads or where ambient air can effectively dissipate the heat.
Space and weight constraints: Air heat sinks, while simpler, can be bulkier and heavier due to the need for large surface areas for effective heat dissipation. In contrast, liquid cold plates offer a more compact and potentially lighter solution, crucial in space-constrained environments such as aerospace or automotive applications.
Precision and control: Liquid cooling systems provide greater precision and control over system temperatures, which is vital for applications requiring stringent temperature management. This level of control is harder to achieve with air cooling, especially in variable ambient conditions.
Cost and complexity: Air heat sinks typically have lower upfront costs and simpler designs, making them attractive for applications where simplicity is valued. Liquid cold plates, though potentially offering superior performance, come with higher initial costs and complexity, including the need for pumps, reservoirs, and maintenance to prevent leaks or corrosion. -
Which cooling solutions for inverters should you choose?
Choosing the right cooling solutions for inverters is crucial for maintaining system efficiency and preventing overheating. Mersen offers a range of cooling solutions tailored to the specific needs of power electronics, ensuring that your inverter operates at optimal temperatures.
Addressing high-temperature challenges of SiC power modules
Cooling for SiC is essential to address the high-temperature challenges presented by silicon carbide components. Mersen’s cooling solutions for silicon carbide are designed to handle the high thermal conductivity of SiC, ensuring that these components are kept at safe operating temperatures.
Maximizing inverter lifespan with efficient cooling solutions
The longevity of inverters is significantly enhanced by efficient cooling solutions. Mersen’s cooling solutions for inverters are engineered to manage the heat generated during operation, which is crucial for maintaining performance and preventing thermal-related failures. When choosing a cooling solution for inverters, consider the thermal design power and the ambient operating conditions to ensure optimal heat dissipation.
Optimizing heat management: the importance of heat sinks for power electronics
Heat sinks are an essential cooling solution component in power electronics for managing excessive heat. When choosing a heat sink for power electronics, consider the material, size, and design to ensure it aligns with the thermal requirements of your system.
Enhancing durability: why cooling for silicon carbide module is essential
The durability of silicon carbide components is greatly enhanced by effective cooling. Mersen’s cooling solutions for silicon carbide are specifically engineered to manage the heat generated by SiC components, which is vital for preserving their longevity and performance in power electronics applications.
Prolonging IGBT lifespan through effective cooling
Effective cooling is essential for prolonging the lifespan of IGBTs (Insulated Gate Bipolar Transistors). Mersen’s cooling solutions for IGBTs are designed to manage the heat generated by these high-efficiency switches, ensuring that they operate within their thermal limits for a longer service life.
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