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Integral Modeling Is First Step for ATS Engineers

Integral Modeling

ATS engineers utilize integral or analytical modeling as a first step to solving thermal management issues in a design. [Advanced Thermal Solutions, Inc.]

In July, Future Facilities, a CAD software company, released the results of a survey it conducted of more than 350 electrical engineers (the link to the story is below) on how thermal management relates to reliability in electronics design. The survey coincided with the release of the company’s newest version of its thermal simulation software 6SigmaET.

Forty percent of the surveyed engineers believed thermal simulations for their projects to be too time-consuming or complex. Sixty-two percent of the engineers said that they would rather over-design a project than optimize thermal performance in the design process. In fact, 33 percent of the engineers called thermal issues an “irritation” and would prefer to not deal with them.

Tom Gregory, Product Manager at 6SigmaET, concluded, “It’s clear that a lot of engineers still don’t feel comfortable creating thermal simulations of their designs, a fact which is not being helped by the complex nature of most thermal simulation tools currently on the market.”

The engineers at Advanced Thermal Solutions, Inc. (ATS), a leading-edge engineering and manufacturing company focused on the thermal management of electronics, have long demonstrated that thermal solutions are a critical component to electronics design and that incorporating thermal management early in the design process will lead to a more cost-effective and reliable product.

By incorporating thermal management into the design process engineers optimize time between failure for individual components as well as the overall system. They actually reduce the cost of the system by limiting the need to overdesign it. Well thought out thermal solutions increase the likelihood that the final design will succeed and meet the specifications that were set out at the beginning of the project.

The survey results pointed to CFD analysis as the jumping off point for thermal solutions. But an easier and more efficient way to start the process is with an integral or analytical model, using pencil and paper or a spreadsheet.  In its 3-Core Design Process, ATS has utilized integral modeling as its first step to quickly and easily provide first order solutions and determine whether a design will succeed in meeting its thermal requirements.

Integral modeling, as Dr. Kaveh Azar, founder, President, and CEO of ATS, explained in a webinar (the link is below), utilizes standard equations based on the basic laws that govern thermal engineering: Conservation of Mass, Conservation of Momentum, Conservation of Energy, and Equation of State (i.e. the Ideal Gas Law).

Determining pressure, temperature, and air velocity differentials throughout a system and plugging those numbers into equations that most engineers will remember from undergraduate and graduate training will define the problem that will be faced in designing the system.

Dr. Azar said, “When I focus on integral modeling as I go through the process, you’ll see how easy it is and how broad-spectrumed the applications of these are and this is going to form the first foundation for any kind of analysis that we do in electronics cooling.”

Integral modeling is applicable to any domain and will give a substantiated, independent model to ensure the system is built within the proper parameters. Taking this early step saves time and money that may have been wasted on designing a system that ultimately would not work. Integral modeling also establishes parameters under which the system can be built to save costs after deployment.

Dr. Azar explained, “If we design it for the worst case scenario, we always have the adequate margins and as a result have lesser cost of deployment.”

It is a competitive market. Integral modeling is a quick first step to ensure thermal solutions are part of a design to save on component and system costs. A few quick calculations will have a major impact on the project’s bottom line.

The survey results from Future Facilities can be found at http://www.thermalnews.com/main/news/40-percent-of-electronics-engineers-find-thermal-simulation-too-complex-and-time-consuming.

For more information about the importance of integral modeling and practical applications, watch the webinar with Dr. Kaveh Azar of Advanced Thermal Solutions, Inc. below:

Does the process of thermal design for your next project seem daunting?  Contact us.  ATS offers a  free four-hour consultation in its lab.  Email ATS at ats-hq@qats.com.

ATS’ Standard Board Level Heat Sinks for PCB

We’ve just released our new line of standard board level heat sinks. These stamped heat sinks are ideal for PCB application, especially where TO-220 packages are used. Available now through Digi-Key Electronics​ or at this link from ATS http://www.qats.com/eShop.aspx?produc…

 

To play MIT’s Space Invaders Remix, click here https://scratch.mit.edu/projects/1979…

Digital News Gets Support from ATS

With Thermal Engineer day approaching (7/24) we here at ATS would like to thank all of the PR firms and digital news magazines who covered our new clipKIT campaign.

thermal technology - digital news - electronics businessAs a token of our appreciation, we have provided a link to our customers and viewers to download our clipKIT data sheet for all your attachment needs. HERE.

 

Understanding Loop Heat Pipes

Looped heat pipes (LHPs) are two-phase heat transfer devices that employ the same capillary pumping of a working fluid as used in conventional heat pipes. LHPs can transfer heat efficiently up to several meters at any orientation in the gravity field. When placed horizontally, this distance can extend to several tens of meters.

The development of the LHP was driven mainly by a limit of conventional heat pipes in which the wick system abruptly decreases its heat transfer capacity, if the evaporator is raised higher than the condenser. This need was acutely felt in aerospace applications where the heat generated by the electronics had to be transferred efficiently away for dissipation purposes. But the device needed to be much less sensitive to changes in orientation in the gravity field. Figures 1a and 1b show the schematic of an LHP [1].

The development of looped heat pipes dates from 1972.    Qpedia_0508_Loop_Heat_Pipes_Figure1Figure 1. Schematic of Principle of Operation of a Loop Heat Pipe [1, 2].

The first such device, with a length of 1.2m, a capacity of about 1 kW, and water as its working fluid, was created and tested successfully by the Russian scientists Gerasimov and Maydanik from the Ural Polytechnic Institute. With heat needing to be transported over a longer distance, and because the working fluid circulation in a heat pipe is directly proportional to the surface tension coefficient and inversely proportional to the effective pore radius of the wick, a different system for heat transport was required when the evaporator was above the condenser. This is shown in Figure 1.

The capillary head must be increased to compensate for pressure losses when the liquid is moving to the evaporator while operating against gravity. This can only be done by decreasing the effective pore radius of the wick. However, the increase in hydraulic resistance is approximately proportional to the square of the pore radius. As a result, it has not been possible to build a heat pipe of sufficient length that is capable of operating efficiently against gravity. Thus, there was incentive to develop LHPs, and they are now finding further application in modern electronics.

As stated, a number of limits impact the performance of an LHP. Qing et. al. [3] performed a detailed investigation of three key parameters on the performance of a looped heat pipe for use in cryogenics applications. This LHP is shown in Figure 2.

1) Effect of Wick Pore Size – It is well known that the maximum capillary pressure produced by the primary wick depends on both the effective pore size and the surface tension of the working fluid. In general, the smaller the pore size and the larger the surface tension, the higher the maximum capillary pressure. A smaller pore size will also result in larger flow resistance which will limit heat transfer capability. The pore sizes considered were 2 and 10 μm.
Figure 2. Schematic of an LHP for Cryogenics Application [3].
When the pore size of the primary wick is larger (10mm), the heat transfer capability of the LHP can reach 26 W only when a smaller reservoir (60cc) is used. Its ability to operate against gravity is greatly weakened. With a wick pore size of 2mm, the LHP can transfer a heat load of 26 W under horizontal orientation no matter what size reservoir volume is used.

Qpedia_0508_Loop_Heat_Pipes_Figure2Figure 2. Schematic of an LHP for Cryogenics Application [3].

2. Effect of Reservoir Size – It is interesting to see how the LHP will function with different reservoir sizes. As shown in Figure 3, the combination of gravity and reservoir size has a direct impact on the heat transfer capability of the LHP. Under adverse gravity, the heat transfer capability of the LHP is 12 W using the larger reservoir and only 5W using the smaller one.Qpedia_0508_Loop_Heat_Pipes_Figure3
Figure 3. Heat Transfer Capability of LHPs with 2mm and 10mm Pore Diameters in Horizontal Orientation [3].

3. Effect of Working Fluid – Fluids have different surface tensions that impact the heat transport capability of the LHP.

Figure 4 demonstrates this capability: Qpedia_0508_Loop_Heat_Pipes_Figure4
Figure 4. Heat Transfer Capability of an LHP When the Working Fluid is Oxygen [3].

Though not shown in Figure 4, when the working fluid is oxygen instead of nitrogen, the heat transfer capability can be up to 50 W under horizontal orientation with the other experimental conditions remaining the same.

LHP Applications
This discussion has highlighted the functionality and importance of design parameters on the performance of LHPs. While this discussion concerns an aerospace application, LHPs have been used for standard electronics as well. Maydanik gives several examples where miniature LHPs are used for microelectronics [1]. Figure 5 shows the “use of flat disk-shaped evaporators in LHPs. The scheme and the external view of such evaporators 10 and 13mm
thick, whose thermo-contact surface is made in the form of a flange 45 mm in diameter for fixing the heat source. The results of development of ammonia LHPs 0.86m and 1m long with a vapor and a liquid line 2mm in diameter equipped with such evaporators of stainless steel. In trials the devices demonstrated serviceability at any orientations in 1-g conditions. The maximum capacity was, respectively, 90–110 W and 120–160 W, depending on the orientation, and the value of the minimum thermal resistance 0.30 K/W and 0.42 K/W.”

Qpedia_0508_Loop_Heat_Pipes_Figure5
Figure 5. Photo and Schematic of Flat, Disk-Shaped Evaporators in an LHP [1].

Another design is shown in Figure 6, where miniature LHPs are made from stainless steel and copper and the working fluids are ammonia and water . The ammonia LHP has a 5mm diameter evaporator with a titanium wick, and 2mm diameter lines for vapor and liquid.. The water LHP is equipped with a 6mm diameter evaporator and 2.5mm diameter lines. The effective length of the devices is about 300mm.

Qpedia_0508_Loop_Heat_Pipes_Figure6
Figure 6. Miniature LHPs [1].

Each has a finned condenser, 62mm long, whose total surface is about 400cm2. The condensers are cooled by a fan providing an air flow rate of 0.64 m3/min, at a temperature of 22 ± 2°C.
Tests show that the maximum capacity of the ammonia LHP is 95 W at an evaporator wall temperature of 93°C. The maximum capacity for the water LHP was not achieved, but at the same temperature it was equal to 130 W. The minimum thermal resistance values of the LHP, 0.12 K/W and 0.1K/W, were obtained at heat loads of 70 W and 130 W, respectively. It should be noted that the ammonia LHP demonstrated a higher value of for heat transfer coefficient in the evaporator, which reached 78,000 W/m2K at a heat flow density of 21.2 W/cm2 at the surface of an interface with an area of 4 cm2. For the water LHP, these values were, respectively, 31,700 W/m2K and 35 W/cm2. In this case, at the surface of the evaporator’s active zone, the heat flow density was much higher. For the ammonia LHP it was 44.5 W/cm2, and for the water was 69.1 W/cm2 [3].

Qpedia_0508_Loop_Heat_Pipes_Figure7
Figure 7. Photo and Schematic of a CPU Cooler Based on an LHP [4, 5].

Another example of LHPs in microelectronics is shown in Figure 7. Here, an LHP was designed for cooling a 25-30 W processor with a total weight of 50g. This LHP was based on copper-water with an evaporator diameter of 6mm.
In conclusion, LHPs may resolve many of the drawbacks seen in conventional heat pipes and provide additional capabilities. As shown by Maydanik, the capillary mechanism, in conjunction with the reservoir size and the use of different fluids, can bring significant advantages that may not readily be seen in heat pipes. Some of these include:

  • the use of fine-pored wicks,
  • maximum decrease in the distance of the liquid motion in the wick,
  • organization of effective heat exchange during the evaporation and condensation of a working fluid, and,
  • maximum decrease in pressure losses in the transportation (adiabatic) section.

Along with the advantages gained from LHPs, the use of liquids in electronics and potential operational instability must be considered carefully. Operational instability, if not managed, could conceivably create thermal cycling on the electronics component being cooled. As with heat pipes,operational dry out or the loss of fluid due to leakage could render the LHP inoperable. Otherwise, LHPs appear to be an attractive supplement to the arsenal of cooling options available to the design engineer. ■

References:
1. Maydanik, Y.., Loop Heat Pipes, Applied Thermal Engineering, 2005.
2. Muraoka, I., Ramos, F., Vlassov, V., Analysis of the Operational Characteristics and Limits of a Loop Heat Pipe with Porous Element in the Condenser, International Journal of Heat and Mass Transfer, V44, 2001.
3. Mo, Q., Jingtao, L., Jinghui, C., Investigation of the Effects of Three Key Parameters on the Heat Transfer Capability of a CLHP, Cryogenics V47, 2007.
4. Chang, C., Huang, B., Maydanik, Y., Feasibility of a Mini LHP for CPU Cooling of a Notebook PC, Proc. of 12th Int. Heat Pipe Conference, Moscow, Russia, May 2002.
5. Pastukhov, V., Maydanik, Y., Vershinin, C., Korukov, M., Miniature Loop Heat Pipes for Electronic Cooling

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Next Webinar Shows How to Properly Measure and Analyze Temperatures in Electronic Systems

ATS WebinarsThe upcoming webinar “How to Perform and Understand Temperature Measurement in Electronic Systems” will be held this Thursday, September 12, 2013 at 2pm ET. The free, prerecorded technical presentation will deepen attendees understanding of the importance of temperature measurement in electronic systems. Attendees will learn about each of the instruments needed for measuring temperature and interpreting temperature data. Key locations will be identified where thermal testing should be conducted in order to obtain the most accurate and actionable results.

The webinar will be taught by Dr. Kaveh Azar, CEO of Advanced Thermal Solutions, Inc. Since 1985, Dr. Azar has been an active participant in the electronics thermal community and has served as the organizer, general chair and the keynote speaker at national and international conferences sponsored by ASME, IEEE and AIAA. In addition, he has been the recipient of the IEEE SEMITHERM Significant Contributor Award in the thermal management of electronics systems.

Dr. Kaveh Azar

Dr. Kaveh Azar

Dr. Azar has been an invitee to national bodies such as NSF, NIST and NEMI for organizing government and industry research goals in electronics cooling. He has also been an adjunct professor at a number of universities, including Northeastern University, and lectures worldwide in analytical and experimental methods in electronics cooling.

He holds more than 36 national and international patents, and has published more than 75 articles, 3 book chapters and a book entitled Thermal Measurements in Electronics Cooling. Dr. Azar has also served as the editor in chief of Electronics Cooling Magazine, the premier resource for practitioners in the field of electronics thermal management, from the publications founding in 1995 to 2006.

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