liquid cooled thermal management systems for electronic
equipment
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by
andy hass, industrial business unit manager, colder products company
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the trend toward faster, more
compact electronic equipment with increased power capacity is not going away.
neither is the need to find ways to cool it. companies involved in the design
and manufacture of high-value electronic equipment that generates heat �€“ such
as servers, medical imaging systems and super computers �€“ know that effectively
cooling these systems is critically important and that liquid cooling of these
electronics offers huge benefits over air cooled systems. connectors, material
types and coolant composition are just some of the elements that must be
considered when designing a liquid cooling system for electronic equipment.
liquid cooling overview
there are different ways to manage
the cooling of electronics and finding the best solution for each type of
equipment can be a challenge. manufacturers of chip testers, lasers and
oncology equipment have been using liquid cooling for many years. these types
of equipment circulate liquid through a cold plate to remove heat, using a
remote heat exchanger, in order to maintain desired system temperature. this
same concept can be applied to cooling larger equipment such as super computers
and mri equipment.
since even the smallest of spills
can cause irreparable damage to electronics, and subsequently expensive
equipment downtime, these systems need to be leak free. designing thermal
management systems with hard-plumbed components can produce a leak-free cooling
solution. however, when maintenance is required, there can be significant
downtime. in addition, these systems are generally inflexible and don�€™t allow
for design changes or extensions, which may hamper engineers�€™ efforts to
quickly bring the next product version to market.
as an alternative, fluid line
connectors such as quick disconnect couplings, can be integrated to make
maintenance friendly systems. quick disconnect couplings used in liquid cooling
systems also provide ultra-low spillage rates (the amount of liquid released
upon disconnect), which can prevent costly equipment damage or downtime.
why use a quick disconnect
coupling?
quick disconnect couplings bring
several advantages to liquid cooling system design. first, a coupling enables
coolant lines to be easily disconnected for maintenance. for example, if a
mechanical or electronic component needs to be repaired or replaced, fluid
lines can be quickly disconnected, even under pressure. the system then can be
serviced and the lines reconnected with minimal downtime and no loss of fluid.
quick disconnect couplings also increase system safety with low air inclusion
(the amount of air allowed into the system upon connection). this eliminates
the potential for a large air bubble to enter the system, which could cause
inconsistent cooling and system failure. couplings also increase ease of assembly
and enable modular design.
another benefit of using quick
disconnect couplings to connect fluid lines in liquid cooling systems is that
they can be mechanically keyed or color coded to help prevent accidental tubing
misconnects. highly visible color coding keeps connection confusion to a
minimum and can add distinctive visual appeal to high-tech electronics and
computer systems.
available in either metal or plastic, there are a
variety of connectors suitable for liquid cooling applications.
design considerations
when designing couplings or
connectors into a liquid cooling system, it is important to consider material
type. available in either metal or plastic, there are a variety of connectors
suitable for liquid cooling applications. each material has unique benefits, so
it is important to review the system in its entirety to determine which will
work best in the final design.
metal connectors are often chosen
over plastic due to their durability. however, there are other considerations
when incorporating a metal connector into a liquid cooled system, such as the
potential for galvanic corrosion. if the final design incorporates other
components of a different metal, corrosion could jeopardize the integrity of
the cooling fluid.
it is important to review basic
chemical compatibility of all the components of the system to ensure that no
chemical attack will occur. plastic connectors are lighter than metal couplings
but offer a level of strength and durability appropriate for most low-pressure
liquid cooling systems.
some manufacturers combine metal
and plastic in their connection solutions: plastic, high-flow valves
incorporated into a metal housing result in a high-flow, cost-effective and
durable coupling. these types of non-spill couplings can be an especially
effective solution in critical applications such as liquid cooling of super
computers and other equipment where actual (or perceived) durability and
superior performance are required.
for the equipment owner, quick
disconnect couplings make maintenance of liquid cooled equipment much more cost
effective since they add flexibility and leak-free operation to the system.
reduced service calls and service call duration can have a significant impact
on total ownership cost. couplings also make the equipment easier for operators
to use through ergonomic, leak-free and flexible connections that are visually
easy to identify.
plastic, high-flow valves incorporated into a metal
housing result in a high-flow, cost-effective and durable coupling.
future migration to smaller
equipment
next-generation equipment for
medical device, consumer electronics, fuel cell and printing applications will
require more advanced and consumer friendly liquid cooling systems. electronic
equipment is getting smaller and smaller, yet generating more and more heat. as
a result, the opportunities for using liquid cooled components are rising,
along with the need to engineer thermal management systems that are flexible,
safe and leak free.
designing effective cooling systems
for high-value electronics will pay dividends in better performance and reduced
downtime, repair and replacement costs for owners. for the electronics
equipment manufacturers, these factors may provide a compelling competitive
advantage.
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about
the author: andy hass has contributed to the success of colder for more than 13
years in a variety of capacities, included new and custom product development
and business development. andy holds a bachelor of science degree in mechanical
engineering from the university of minnesota institute of technology and an mba
from the university of st. thomas.
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