Water Cooling Cold Plates

COUGAR ELECTRONICS is able to design with any type of water cooling cold plates. Liquid cooling plates are generally considered as the most efficient solution for high power and high flux density. However this solution is not passive and needs energy to supply the pump.

General principle

The loop of the working fluid is an assembly of the following components :

  • Liquid cold plate : in contact with the components to cool
  • Pump
  • Expansion tank
  • Liquid/air exchanger

The working fluid is generally a mix of water and glycol, or a dielectric oil. Circulation of the liquid is made by the pump and the expension tank.

Cold plate allowed the fluid to flow close to the electronic components. Turbulators can be set up inside the plate to reinforce thermal exchange in the active area.

Heated liquid dissipates calories in the air thanks to thermal exchanger, before starting for a new cycle.

Our sister companies CECLA METAL PROCESS and ARCEL are experts in designing and manufacturing cold plates.

Several technologies can be proposed for your application.

Standard design for Press Pack Stacks

WP7

  • Material: Copper CuA1
  • Hockey Puck diameter: max 48mm
  • Nickel Plated
  • Length: 1,97in / 50mm

WP7 Data Sheet

WP9

  • Material: Copper CuA1
  • Hockey Puck diameter: max 48mm
  • Nickel Plated
  • Length: 1,97in / 50mm

WP9 Data Sheet

WPAL200

  • Material: Copper CuA1
  • Hockey Puck diameter: max 75mm
  • Nickel Plated
  • Length: 7,87in / 200mm

WPAL200 Data Sheet

SIM63 Electrically Insulated Cold Plate

  • Material: Copper CuA1 or Aluminium
  • Hockey Puck diameter: max 75mm
  • Nickel Plated
  • Length: 7,87in / 200mm

SIM63 Data Sheet

Standard design for IGBT

WPM

The ultimate thermally efficient and cost competitive solution for IGBT cooling !

  • Material: Extruded Aluminium
  • Water blade concept
  • Double sides use
    • Compatible IGBT on main side
      • ECONOPACK+
      • ECONODUAL
      • MEGA POWER DUAL
      • PRIMEPACK
    • Compatible modules on second side
      • Diode module
      • ISOTOP housing
      • 80mm pitch module
  • Surface finishing: raw, nickel, anodization…
  • Length: following your need !

The WPM design started from this noticing: all the cheap extruded cold plates are designed with basic round channels. Those solutions are cheap but do not lead to very thermally efficient cooling.
WPM is using the unique water blade concept: the water flows in one layer on all the width of the semiconductor, creating the perfect balance between turbulence and pressure drop.
You get a high thermally performing solution, with a the very competitive price of the extrusion !

WPM Data Sheet

Custom design cold plate

An engineering team dedicated to your need

We are specialists in the design of water cooled solutions. Our engineering team has more than 20 years of experience in the field for designing innovative solution dedicated to the success of your projects !

We are using the latest 3D and thermal numerical simulation tools to insure the performance of our product before manufacturing.

Drilled Cold Plate

The base plate is drilled with orthogonal and parallel channels. The liquid flows in the channel network. Impermeability is achieved by the use of screwed or welded caps.

This technology can be advised for the following cases :

  • Small dimensions <20in
  • Low quantities

Tubular Cold Plate

Tubular cold plates are made with the assembly of a bent tube and a base plate. The electronic components are set up on the base plate.

Tube can be made of the following materials:

  • Aluminium
  • Copper
  • Stainless steel

Brazed Cold Plate

Aluminium brazing allowed to make very smart assemblies of aluminium parts, by fusion of local aluminum braze filler. This process is generally made in controlled or vacuum atmosphere. Brazed cold plates are very interesting for complex and efficient applications. This process is now becoming more and more affordable.

A fluid channel is milled on a base plate, following components map. Turbulators can be integrated under the components to reinforce the thermal exchange and temperature homogeneity.

A cap is brased on the milled face in order to make the cold plate hermetic.

This technology is adapted for the following applications:

  • Medium and mass series
  • Complexe and efficient applications

Water Cooling Cold Plate

Heat pipes coolers are like the Loch Ness monster... lot's of people are speaking about, but few people have really tested them! This technology sounds a little bit mysterious for people coming from a pure electronics background ! How can such a thing (looking like a basic copper tube), would be able to convey something like 1000 time more calories than the best typical thermal conductor in electronics : copper ! You will certainly find the answer in our dedicated page to the heat pipe functioning, or to heat pipe page on wikipedia, if you want to go deeper in the subject. [caption id="attachment_1877" align="aligncenter" width="685"]Heat Pipe functionning Heat Pipe functionning[/caption]

Thermal management challenges in power electronics

As it was explained in our market analysis article about SIC semiconductors, power electronics is currently at the beginning of a revolution. Semiconductors are now able to work up to incredibly high frequency (50 to 100kHz), with excellent efficiency, and low losses. Because working at high frequency leads to reducing size and weight, this revolution increasesthe density of power losses. New thermal management challenges are in front of us. But good news, heat pipes are here to help solving them ! Here are the main reasons why ?

Heat pipe advantages

  • High thermal conductivity. Because heat pipes are using one of the most efficient way to convey calories : phase change, their high thermal conductivity will be the best advantage to solve your thermal management issues.
[caption id="attachment_1880" align="aligncenter" width="300"]Heat Pipe thermal conductivity simulation Heat Pipe thermal conductivity simulation[/caption]
  • Temperature range. It is mainly depending from the working fluid inside the heat pipe. Considering most of the power electronics application going from 50 to 200 degC, you will not find a better fluid than water. Good news, water is not dangerous and not explosive as you may know... Bad news, water is electrically conductor as you may know too. Electronics designer never sleeps soundly when water flows close to their components ! If you feel a bit of apprehension, read our next point.
 
  • Reliability. Heat pipes are excellent in reliability because they use no mooving mechanical parts and need no energy like electricity. No worry about maintaining the motor or the filter of your pump like in a cooling loop. The difference of temperature is the only "motor" which garanty an endless  functionning. Heat pipes are commonly used in aerospace application and railway, where life cycle of the product can be up to 50 years !
[caption id="attachment_1861" align="aligncenter" width="300"]Railway Heat Pipe Cooler Railway Heat Pipe Cooler[/caption] We hope this article have contributed to better understanding of heat pipes.

Contact us

For any question, enquiry, contact COUGAR ELECTRONICS here. Our thermal engineers will be happy to help :-)
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