Enabling Much Higher Power Densities in Aerospace Power Electronics with High Temperature Evaporative Spray Cooling

Turek, Louis; Rini, Daniel P.; Saarloos, Benjamin A.; Chow, L. C.

doi:10.4271/2008-01-2919

Cited by 5 publications

(3 citation statements)

References 5 publications

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“…Results indicated that the IGBT module could safely operate at a heat flux up to 140 W/cm 2 while maintaining the junction temperature below 125 • C. Then, they also tested the spray cooling system with 95 • C water as a coolant for thermal management of hybrid propulsion systems of aircraft. It was found that the temperature of IGBT cooled by a water spray was about 10 • C lower than the water-propylene glycol mixture [109]. Recently, Siddiqui et al [110] investigated the spray residue surface effects of the hybrid nanofluid on the spray cooling performance.…”

Section: Spray Coolingmentioning

confidence: 99%

Thermal Management Technologies Used for High Heat Flux Automobiles and Aircraft: A Review

Zhang

Wang

et al. 2022

Energies

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In recent years, global automotive industries are going through a significant revolution from traditional internal combustion engine vehicles (ICEVs) to electric vehicles (EVs) for CO2 emission reduction. Very similarly, the aviation industry is developing towards more electric aircraft (MEA) in response to the reduction in global CO2 emission. To promote this technology revolution and performance advancement, plenty of electronic devices with high heat flux are implemented on board automobiles and aircraft. To cope with the thermal challenges of electronics, in addition to developing wide bandgap (WBG) semiconductors with satisfactory electric and thermal performance, providing proper thermal management solutions may be a much more cost-effective way at present. This paper provides an overview of the thermal management technologies for electronics used in automobiles and aircraft. Meanwhile, the active methods include forced air cooling, indirect contact cold plate cooling, direct contact baseplate cooling, jet impingement, spray cooling, and so on. The passive methods include the use of various heat pipes and PCMs. The features, thermal performance, and development tendency of these active and passive thermal management technologies are reviewed in detail. Moreover, the environmental influences introduced by vibrations, shock, acceleration, and so on, on the thermal performance and reliability of the TMS are specially emphasized and discussed in detail, which are usually neglected in normal operating conditions. Eventually, the possible future directions are discussed, aiming to serve as a reference guide for engineers and promote the advancement of the next-generation electronics TMS in automobile and aircraft applications.

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Section: Spray Coolingmentioning

confidence: 99%

Thermal Management Technologies Used for High Heat Flux Automobiles and Aircraft: A Review

Zhang

Wang

et al. 2022

Energies

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“…Their spray cooling approach removed heat fluxes of up to 148 W/cm 2 without exceeding IGBT junction temperature of 125°C, greatly reduced the overall thermal resistance, and increased inverter power level up to 3.4X compared to conventional cold plates. Later, Turek et al [18] conducted experiments with pure water using the same setup, and found that water, at similar subcooling levels, provides several o C lower temperatures over the WPG. They concluded that the vapor generated by WPG boiling is nearly all water, leaving a higher concentration mixture at the surface, and resulting a local boiling point increase that diminishes the boiling performance.…”

Section: Introductionmentioning

confidence: 99%

Two-Phase Spray Cooling With Water/2-Propanol Binary Mixture: Investigation of Mass Diffusion Resistance

Obuladinne

Bostanci

2016

Volume 8: Heat Transfer and Thermal Engineering

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Two-phase spray cooling has been an emerging thermal management technique offering high heat transfer coefficients (HTCs) and critical heat flux (CHF) 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. The 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 liquidvapor phase change. When a certain application requires strict temperature and/or pressure conditions, thermophysical properties of the working fluid play a critical role in attaining proper efficiency, reliability, or packaging structure. However, some of the commonly used working fluids today, including refrigerants and dielectric liquids, have relatively poor properties and heat transfer performance. In such cases, utilizing binary mixtures to tune working fluid properties becomes an alternative approach.This study aimed to conduct an initial investigation on the spray cooling characteristics of practically important binary mixtures and demonstrate their capability for challenging high heat flux applications. The working fluid, water/2-propanol binary mixture at various concentration levels, specifically at x1 (liquid mass fraction of 2-proponal in water) of 0.0 (pure water), 0.25, 0.50, 0.879 (azeotropic mixture) and 1.0, represented both non-azeotropic and azeotropic cases. Tests were performed on a closed loop spray cooling system using a pressure atomized spray nozzle with a constant liquid flow rate at corresponding 20 o C subcooling conditions and 1 Atm pressure. A copper test section measuring 10 mm x 10 mm x 2 mm with a plain, smooth surface simulated high heat flux source. Experimental procedure involved controlling the heat flux in increasing steps, and recording the steady-state temperatures to obtain cooling curves in the form of surface superheat vs heat flux. The obtained results showed that pure water (x1=0.0) and 2-propanol (x1=1.0) provide the highest and lowest heat transfer performance, respectively. At a given heat flux level, the HTC values indicated strong dependence on x1, where the HTCs depress proportional to the concentration difference between the liquid and vapor phases. The CHF values sharply decreased at x1≥0.25.

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“…They reached a maximum heat flux of 263 W/cm 2 with 33 o C liquid and kept the simulated chip below 125 o C. Their pressure atomized nozzle used 0.78 L/min-cm 2 flow rate at 144 kPa pressure drop. Turek et al [9,10] also evaluated the capabilities of spray cooling for power inverter applications. They replaced the single phase liquid cooled base plate of a COTS power inverter module with a custom made base plate and integrated a spray nozzle array as illustrated in Fig.…”

Section: Introductionmentioning

confidence: 99%

Spray cooling of power electronics using high temperature coolant and enhanced surface

Bostanci

Saarloos

et al. 2009

2009 IEEE Vehicle Power and Propulsion Conference

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A spray cooling system was developed and tested for thermal management of power inverter modules utilized in automotive applications. System featured an array of 1x2 pressure atomized nozzles that used 90 o C antifreeze coolant with 0.15 L/min-cm 2 liquid flow rate and 145 kPa pressure drop. Two cm 2 simulated device, having an enhanced spray surface with micro scale structures, reached up to 400 W/cm 2 heat flux with only 14 o C surface superheat. These experimental results demonstrated the capability of greatly reducing the overall thermal resistance of the inverter modules that are commonly cooled with single phase convective systems. Performance of the presented system proved the spray cooling of power electronics as an attractive option that enables high power densities while maintaining satisfactory and uniform device temperatures. In addition, due to the use of high temperature coolant at low flow rates, spray cooling offers compact and efficient system design.

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Enabling Much Higher Power Densities in Aerospace Power Electronics with High Temperature Evaporative Spray Cooling

Cited by 5 publications

References 5 publications

Thermal Management Technologies Used for High Heat Flux Automobiles and Aircraft: A Review

Thermal Management Technologies Used for High Heat Flux Automobiles and Aircraft: A Review

Two-Phase Spray Cooling With Water/2-Propanol Binary Mixture: Investigation of Mass Diffusion Resistance

Spray cooling of power electronics using high temperature coolant and enhanced surface

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