HEAT SINK WITH OPPOSED ELEMENTS PROVIDING TEMPERATURE GRADIENT
20240068756 ยท 2024-02-29
Inventors
Cpc classification
F28D20/025
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28D15/043
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28D15/0275
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28F2250/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28D15/0266
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F28D15/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F28D15/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
The heat sink with opposed elements providing a temperature gradient has first and second thermally conductive elements disposed diametrically opposite each other on opposite sides of a chamber filled with a thermally conductive phase change material (PCM). The first and second thermally conductive elements ascend vertically from a thermoconductive base of the PCM chamber, which is adapted for mounting on the case of a heat source, such as an electronic component that generates heat or has heat applied thereto from its surroundings during operation. The first thermally conductive element is maintained hotter than the second thermally conductive element to provide a temperature gradient across the PCM chamber. The PCM melts as heat is absorbed. Convection currents are induced in the melting PCM that enhance heat absorption from the heat source while maintaining the heat sink at a relatively low temperature by dissipation of heat through the second thermally conductive element.
Claims
1. A heat sink with opposed elements providing a temperature gradient, said opposed elements including a first thermally conductive element and a second thermally conductive element, said heat sink comprising: a phase change material (PCM) chamber having a top wall, side walls, and a thermally conductive base adapted for mounting on a heat source requiring cooling; the first thermally conductive element attached to a side of the PCM chamber and extending vertically between the base and the top wall of the PCM chamber; the second thermally conductive element attached to a side of the PCM chamber and extending vertically opposite the first thermally conductive element, the second thermally conductive element having an upper end extending external to the PCM chamber and exposed to ambient air; a thermally conductive first phase change material (PCM) disposed in the PCM chamber, the first PCM having a phase change temperature at which the first PCM melts and changes from solid phase to liquid phase upon absorption of heat; and a cooling fan disposed above the top wall of the PCM chamber, the cooling fan being configured to blow cooling air against the upper end of the second thermally conductive element extending above the top wall of the PCM chamber to dissipate heat from the second thermally conductive element to the ambient air and to provide a temperature gradient extending across the PCM chamber between the first thermally conductive element and the second thermally conductive element; whereby the temperature gradient produces convection currents in the phase change material as the phase change material melts and changes from the solid phase to the liquid phase by absorption of heat from the base of the PCM chamber and from the first thermally conductive element to enhance heat transfer from the heat source to the heat sink.
2. The heat sink according to claim 1, wherein the first thermally conductive element has a top surface, the heat sink further comprising a layer of thermal insulation disposed on the top surface of the first thermally conductive element to retain heat in the first thermally conductive element.
3. The heat sink according to claim 1, further comprising a layer of thermal insulation disposed between the second thermally conductive element and the base of the PCM chamber to reduce direct heat transfer from the base to the second thermally conductive element, the second thermally conductive element being heated by heat transfer from the first phase change material in the PCM chamber, the heat transfer being enhanced by circulation of the first phase change material in the liquid phase in the PCM chamber.
4. The heat sink according to claim 1, wherein said second thermally conductive element is hollow.
5. The heat sink according to claim 4, further comprising a second phase change material disposed in said hollow second thermally conductive element.
6. The heat sink according to claim 5, wherein said second phase change material is a liquid PCM having a phase change temperature below the phase change temperature of said first phase change material, said second phase change material cycling between boiling and condensation in the cooler upper end of said second thermally conductive element, the cycling between boiling and condensation enhancing absorption of heat from said first phase change material.
7. The heat sink according to claim 5, wherein said second phase change material is a liquid PCM maintained in said hollow second thermally conductive element under a pressure sufficient to lower the boiling point of said second phase change material below the phase change temperature said first phase change material in the PCM chamber, said second phase change material cycling between boiling in said second thermally conductive element adjacent the PCM chamber and condensation in the cooler upper end of said second thermally conductive element, the cycling between boiling and condensation enhancing absorption of heat from the phase change material in the PCM chamber.
8. The heat sink according to claim 5, wherein said second phase change material is a solid PCM having a phase change temperature below the phase change temperature of said first phase change material, said second phase change material changing from a solid phase to a liquid phase at its phase change temperature.
9. The heat sink according to claim 5, wherein said second phase change material is a solid PCM having a phase change temperature below the phase change temperature of said first phase change material, said second phase change material changing from a first solid phase to a different solid phase at its phase change temperature.
10. The heat sink according to claim 5, wherein said hollow second thermally conductive element comprises a vapor chamber.
11. The heat sink according to claim 5, wherein said hollow second thermally conductive element comprises an array of heat pipes.
12. The heat sink according to claim 4, wherein said hollow second thermally conductive element comprises at least two hollow compartments stacked vertically at different height levels of said second element, the heat sink further comprising a corresponding plurality of phase change materials having different phase changes temperatures at which the phase change occurs lower than the phase change temperature of said first phase change material, each of the at least two compartments having a corresponding different one of the plurality of phase change materials disposed therein in order to regulate the temperature gradient at different height levels of said PCM chamber.
13. The heat sink according to claim 1, wherein said second thermally conductive element comprises a fin of solid material throughout, including the upper end extending above the top wall of said PCM chamber.
14. The heat sink according to claim 1, wherein said first thermally conductive element comprises a fin made of at least one thermally conductive metal.
15. The heat sink according to claim 1, wherein said first thermally conductive element comprises a fin made of at least two metals having different thermal conductivities stacked at different height levels of said first thermally conductive element in order to regulate the temperature gradient at different height levels of said PCM chamber.
16. The heat sink according to claim 1, wherein second thermally conductive element comprises a fin made of at least two metals having different thermal conductivities stacked at different height levels of said second thermally conductive element in order to regulate the temperature gradient at different height levels of said PCM chamber.
17. The heat sink according to claim 1, wherein said first thermally conductive element comprises a first side wall of said PCM chamber and said second thermally conductive element comprises an opposing second side wall of said PCM chamber.
18. The heat sink according to claim 1, wherein said first thermally conductive element comprises a stud made of at least one thermally conductive metal.
19. The heat sink according to claim 1, wherein the heat source requiring cooling is an electronic device.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0010]
[0011]
[0012]
[0013]
[0014]
[0015] Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] The heat sink with opposed elements providing a temperature gradient has first and second thermally conductive elements disposed diametrically opposite each other on opposite sides of a chamber filled with a thermally conductive phase change material (PCM). The first and second thermally conductive elements ascend vertically from a thermoconductive base of the PCM chamber, which is adapted for mounting on the case of a heat source, such as an electronic component that generates heat or has heat applied thereto from its surroundings during operation. The first thermally conductive element is maintained hotter than the second thermally conductive element to provide a temperature gradient across the PCM chamber. The PCM melts as heat is absorbed. Convection currents are induced in the melting PCM that enhance heat absorption from the heat source while maintaining the heat sink at a relatively low temperature by dissipation of heat through the second thermally conductive element.
[0017] The first thermally conductive element may or may not be in direct contact with the base of the PCM chamber and extends no higher than the top of the PCM chamber. The first thermally conductive element may be trimmed and thermally insulated at the top of the element to prevent dissipation of heat to the ambient air above the top of the PCM chamber (or dissipation of heat by conduction through the uninsulated top wall of the PCM chamber and then to the cooler ambient air above the PCM chamber) and to retain heat in the first thermally conductive element so that it has the higher temperature of the two thermally conductive elements. The first thermally conductive element receives heat transferred by conduction from the heat source through the thermally conductive base of the PCM chamber and thence through the bottom of the first element, or by conduction through the base of the PCM chamber and thence through the PCM, and further through the side of the first element. The first thermally conductive element may be made from a solid thermally conductive material, such as at least one metal. The first thermally conductive element is maintained with the higher temperature of the two thermally conductive elements.
[0018] The second thermally conductive element may be separated from the base of the PCM chamber by a layer of thermal insulation or may be insulated at its lower end or otherwise isolated from the base of the PCM chamber so that it is not heated directly by the heat source. The upper end of the second thermally conductive element may extend above the top of the PCM chamber and may be exposed to cool air from a cooling fan. In a first embodiment, the second thermally conductive element may be hollow. such as a vapor chamber or a plurality of pipes (e.g., heat pipes), and may contain a second phase change material having a low boiling point or vaporization temperature (which is higher than the temperature of the ambient air but lower than prevailing temperatures within the PCM chamber) so that the second phase change material undergoes cycles of vaporization and condensation as the second thermally conductive element absorbs heat from PCM in the PCM chamber and is cooled at its upper end, dissipating heat to the surrounding atmosphere. In a second embodiment, the second thermally conductive element may be a thermally conductive fin that extends above the top of the PCM chamber. In any event, when the second thermally conductive element is hollow and contains a second phase change material, the second phase change material remains separated from the first phase change material in the PCM chamber by the wall of the second thermally conductive element and/or the side wall of the PCM chamber so that the first and second phase change materials never mix.
[0019] As heat from the heat source is absorbed by the solid PCM in the PCM chamber, the solid PCM begins to melt, gradually changing to the liquid phase, beginning near the base of the PCM chamber and the higher temperature first thermally conductive element, while the PCM adjacent the top of the chamber and adjacent the lower temperature second thermally conductive element stay solid for a longer period of time. The temperature gradient between the first and second thermally conductive elements causes the PCM in the PCM chamber adjacent the second thermally conductive element to be denser than the PCM in the PCM chamber adjacent the first thermally conductive element. This difference in density results in a difference in buoyant forces as the PCM material in the PCM chamber melts (the PCM material in the PCM chamber also being hotter adjacent the base of the PCM chamber than at the upper end), with consequent circulation of convection currents in the PCM chamber, resulting in enhanced absorption of heat from the heat source and maintenance of lower temperature in the heat sink than with conventional heat sinks, presenting lower resistance to absorption of heat from the heat source.
[0020] As shown in
[0021] The first thermally conductive element 102 may be a rib or stud made from a thermally conductive metal, such as copper, aluminum, or alloys thereof. In some embodiments, the first thermally conductive element 102 may be made of materials having different thermal conductivities stacked at different levels along the height of the element 102 in order to control the degree of height or temperature gradient relative to the second thermally conductive element 104, thereby regulating the temperature in the PCM chamber 106 at different heights in the chamber 106. The first thermally conductive element 102 may be trimmed at its top end and have a layer of thermal insulation 116 at the top of the element 102 to help retain heat absorbed by the element 102 from the heat source 114 through the thermally conductive base 108 in order to maintain the temperature gradient relative to the second thermally conductive element 104.
[0022] Preferably, the bottom end of the first thermally conductive element 102 is connected directly to the thermally conductive base 108 that receives the heat from the heat source 114. However, in some configurations, the first thermally conductive element 102 may not be directly connected to the thermally conductive base, leaving only the rest of the vertical side of the first element 102 in direct contact with the PCM in the PCM chamber 106 or the thermally conductive wall of the PCM chamber 106 and receiving heat therefrom. This may depend on the intent of the designer and the anticipated level of temperature gradient, and hence the intensity of internal circulation required inside the chamber 106, as may be dictated by the application(s) at hand.
[0023] In the embodiment of the heat sink shown in
[0024]
[0025]
[0026] In operation, the second thermally conductive element 104 is prevented from absorbing heat directly by conduction through the thermally conductive base 108 of the heat sink 100 by the layer of thermal insulation 120. Instead, the second thermally conductive element 104 absorbs heat by conduction from unmelted PCM in the PCM chamber 106 and by convection due to the induced circulations within the molten phase change material (PCM) 112 in the PCM chamber 106, which has been melted by heat that comes from the hot source 114 below the heat sink and by heat absorbed from the first thermally conductive element 102. Also, the second thermally conductive element 104 absorbs heat by conduction from the unmelted part of the PCM 112 to the second PCM material 118 within the second element 104. The second phase change material 118 undergoes cycles of vaporization and condensation (a process that enhances the absorption of heat) as the second thermally conductive element 104 absorbs heat from the PCM chamber 106 and is cooled at its upper end, dissipating heat to the surrounding atmosphere by exposure of the upper end of the second thermally conductive element 104 to the atmosphere (as well as through the side of the second thermally conductive element 104 exposed to ambient air), which is at a lower temperature than the phase change temperature of the second PCM 118. The effect is to maintain the second thermally conductive element 104 at a lower temperature than the first thermally conductive element 102, ensuring a temperature gradient across the PCM chamber 106.
[0027] The temperature gradient between the first and second thermally conductive elements 102, 104 causes the molten part of the PCM 112 in the PCM chamber 106 adjacent the second thermally conductive element 104 to be denser than the molten part of the PCM 112 in the PCM chamber 106 adjacent the first thermally conductive element 102. This difference in density results in a difference in buoyant forces as the PCM material 112 in the PCM chamber 106 melts (the PCM material 112 in the PCM chamber 106 also being hotter adjacent the base 108 of the PCM chamber 106 than at the upper end), with consequent circulation of convection currents in the PCM chamber 106. This distribution may result in the flow of heat upward closely adjacent the first thermally conductive element 102, and a downward flow of cooler PCM 112 closely adjacent the second thermally conductive element 104, and may also result in a vortex of convection currents (depicted schematically at 124 in
[0028] Operation of the first embodiment of the heat sink 100 was tested by numerical computer simulations using the equations of computational fluid dynamics (CFD) on the assumption of a fairly high heat flux of 10 W/cm.sup.2. These simulations showed that the maximum temperature of the molten mass of PCM 112 (gallium in this simulation) adjacent the base 108 of the heat sink 100 did not exceed 320 K.
[0029] Three reasons may be advanced to explain why the temperature near the base 108 will always stay at low levels (which aids the base 108, and hence the heat source 114 requiring cooling). These reasons include (1) some of the heat will be dissipated to the conducting elements from the circulating molten PCM; (2) some of the heat will be dissipated from the circulating molten PCM to the vapor chamber walls, hence be dissipated to the outer ambient surroundings via the boiling process and the subsequent condensation of the resulting vapor that take place in the vapor chamber (the boiling of the liquid in the vapor chamber is taking place at cooler temperatures than the sink temperature and the ambient surroundings are cooler than the boiling temperature to facilitate effective condensation of resulting vapor); and (3) part of the heat absorbed by the circulating liquid PCM from the source will be conveyed to the un-melted solid PCM at low temperature (i.e., at the nominal melting temperature of the solid PCM in the sink). The above three mechanisms will assure low temperature in the molten PCM body, hence low temperature of the base and consequently of the heat source attached to the base of the sink.
[0030] As shown in
[0031] It should be noted that although the drawings show a single PCM chamber 106, the heat sink 100 or heat sink 200 may comprise a plurality of PCM chambers 106 of the same construction aligned horizontally or side-by-side over the heat source 114, depending on the required size of the heat sink, as shown in
[0032] It is contemplated that the heat sink with opposed elements providing temperature gradient includes embodiments exhibiting variations in the above description, including: the second element in
[0033] It is to be understood that the heat sink with opposed elements providing temperature gradient is not limited to the specific embodiments described above, but encompasses any and all embodiments within the scope of the generic language of the following claims enabled by the embodiments described herein, or otherwise shown in the drawings or described above in terms sufficient to enable one of ordinary skill in the art to make and use the claimed subject matter.