U.S. patent application number 10/761119 was filed with the patent office on 2004-09-02 for cooling apparatus boiling and condensing refrigerant with low height and easily assembled.
Invention is credited to Sako, Yuuji, Sugito, Hajime, Tanaka, Hiroshi.
Application Number | 20040168447 10/761119 |
Document ID | / |
Family ID | 32913148 |
Filed Date | 2004-09-02 |
United States Patent
Application |
20040168447 |
Kind Code |
A1 |
Sugito, Hajime ; et
al. |
September 2, 2004 |
Cooling apparatus boiling and condensing refrigerant with low
height and easily assembled
Abstract
A cooling apparatus boiling and condensing a refrigerant is
disclosed, wherein a heat-generating member mounted on the upper
surface thereof can also be cooled. A plurality of intermediate
plates (130A to 130E) are stacked between an upper plate (110) and
a lower plate (120). A plurality of apertures (131 to 134) formed
in the intermediate plates define a first space (140) for
hermetically sealing the refrigerant and a second space (150)
through which an external cooling fluid flows in proximity to the
first space. A heat-generating member (10) is mounted on the outer
surface of at least the lower plate, and heat is exchanged between
the refrigerant heated and boiled by the heat-generating member and
the external cooling fluid. An upper portion (150A) of the second
space is formed in proximity to the inner surface of the upper
plate.
Inventors: |
Sugito, Hajime;
(Nagoya-city, JP) ; Sako, Yuuji; (Hazu-gun,
JP) ; Tanaka, Hiroshi; (Toyoake-city, JP) |
Correspondence
Address: |
HARNESS, DICKEY & PIERCE, P.L.C.
P.O. BOX 828
BLOOMFIELD HILLS
MI
48303
US
|
Family ID: |
32913148 |
Appl. No.: |
10/761119 |
Filed: |
January 20, 2004 |
Current U.S.
Class: |
62/114 ;
257/E23.098 |
Current CPC
Class: |
H01L 2924/0002 20130101;
H01L 23/473 20130101; F28D 15/0266 20130101; F25B 23/006 20130101;
H01L 2924/0002 20130101; H01L 2924/00 20130101; F25B 25/00
20130101 |
Class at
Publication: |
062/114 |
International
Class: |
F25B 001/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 23, 2003 |
JP |
2003-015327 |
Feb 28, 2003 |
JP |
2003-053628 |
Mar 5, 2003 |
JP |
2003-058898 |
Aug 21, 2003 |
JP |
2003-297747 |
Claims
1. A cooling apparatus boiling and condensing a refrigerant,
comprising: an upper plate; a lower plate; a plurality of
intermediate plates stacked between said upper plate and said lower
plate; a first space defined by a plurality of apertures formed in
said intermediate plates for hermetically sealing a refrigerant
therein; a second space through which an external cooling fluid
flows in proximity to said first space; and at least a
heat-generating member mounted on an outer surface of at least said
lower plate of said upper plate and said lower plate; wherein heat
is exchanged between said external cooling fluid and said
refrigerant boiled by the heat of said heat-generating member; and
wherein an upper surface of said second space is formed in
proximity to an inner surface of said upper plate.
2. A cooling apparatus boiling and condensing a refrigerant
according to claim 1, wherein an area where said upper surface of
said second space is in proximity to said inner surface of said
upper plate is formed in a position corresponding to the area of
said heat-generating member which may be mounted on said upper
plate.
3. A cooling apparatus boiling and condensing a refrigerant
according to claim 1, wherein a lower surface of said second space
is formed in proximity to an inner surface of said lower plate.
4. A cooling apparatus boiling and condensing a refrigerant
according to claim 1, wherein said first space includes a plurality
of first small spaces communicating with each other; wherein said
second space includes a plurality of second small spaces
communicating with each other; and wherein said first small spaces
and said second small spaces are arranged to coexist with each
other.
5. A cooling apparatus boiling and condensing a refrigerant
according to claim 4, wherein said heat-generating member includes
a plurality of internal heat sources generating heat, and wherein
said heat sources of said heat-generating member mounted on said
lower plate are arranged in positions corresponding to the
positions of said first small spaces.
6. A cooling apparatus boiling and condensing a refrigerant
according to claim 4, wherein said heat-generating member includes
a plurality of internal heat sources, and wherein said heat sources
of said heat-generating member mounted on said upper plate are
arranged in positions corresponding to the positions of said second
small spaces.
7. A cooling apparatus comprising: a multilayer structure of a
plurality of plate members; wherein a fluid path communicating with
outside through communication ports is formed in said multilayer
structure of said plurality of said plate members; and wherein the
heat of a heat-generating member mounted on the surface of said
cooling apparatus is discharged into a heat receiving medium
flowing in and out by way of said communication ports and flowing
in said fluid path thereby to cool said heat-generating member; and
wherein said communication ports are formed in the surface at the
end portions of said plate members along the direction in which
said plate members extend.
8. A cooling apparatus according to claim 7, wherein said
communication ports are each formed as a rectangle with notches of
the same shape in the same positions at the end portions of a
plurality of adjacent ones of said plate members.
9. A cooling apparatus according to claim 7, wherein a pipe member
through which said heat receiving medium flows is projected outward
from each of said communication ports.
10. A cooling apparatus according to claim 9, wherein each of said
pipe members is connected to the corresponding one of said
communication ports through a connecting member.
11. A cooling apparatus according to claim 10, wherein each of said
connecting members is arranged in such a manner as to cover said
corresponding communication port and has a through hole through
which the corresponding one of said pipe members is inserted.
12. A cooling apparatus according to claim 11, wherein said through
hole is circular in shape.
13. A cooling apparatus according to claim 10, wherein said
connecting member has a projected portion, and said multilayer
structure of said plurality of said plates is formed with a fitting
recess to be fitted with said projected portion.
14. A cooling apparatus according to claim 13, wherein said
connecting member is a tabular metal member bent into L shape to
form said projected portion.
15. A cooling apparatus according to claim 10, wherein said
multilayer structure of the plurality of said plate members is
formed with a recess corresponding to the shape of said connecting
member, and said connecting member is inserted into said
recess.
16. A cooling apparatus according to claim 7, wherein said
multilayer structure of the plurality of said plate members has a
refrigerant bath section for storing the refrigerant therein and a
heat exchange section for exchanging heat between said refrigerant
and said heat receiving medium flowing through said fluid path, and
wherein said refrigerant stored in said refrigerant bath section is
boiled and gasified by the heat received from said heat-generating
member and discharges the latent heat of said refrigerant vapor
into said heat receiving medium flowing in said fluid path in said
heat exchange section thereby to cool said heat-generating
member.
17. A cooling apparatus boiling and condensing a refrigerant,
comprising: a refrigerant bath section having a first
heat-generating member mounted on the surface thereof for storing a
refrigerant therein; a refrigerant diffusion section for diffusing
said refrigerant boiled by the heat received from said first
heat-generating member; and a heat exchange section interposed
between said refrigerant bath section and said refrigerant
diffusion section and including a first space communicating with
said refrigerant bath section and said refrigerant diffusion
section and through which said refrigerant flows, and a second
space through which an external cooling fluid flows; wherein said
heat exchange section includes a multilayer structure of a
plurality of tabular members having a plurality of apertures
corresponding to said first space and said second space; and
wherein said refrigerant bath section is formed integrally by
forging or casting.
18. A cooling apparatus boiling and condensing a refrigerant
according to claim 17, wherein said refrigerant bath section
includes at least one of a screw portion for mounting said first
heat-generating member and a mounting portion for mounting a
predetermined mating member.
19. A cooling apparatus boiling and condensing a refrigerant
according to claim 17, wherein said refrigerant bath section has
therein a plurality of first ribs for increasing the area of heat
transfer with said refrigerant.
20. A cooling apparatus boiling and condensing a refrigerant
according to claim 17, wherein the inner bottom surface of said
refrigerant bath section is formed with a plurality of first
depressions.
21. A cooling apparatus boiling and condensing a refrigerant
according to claim 20, wherein said first ribs are arranged in said
plurality of said first depressions.
22. A cooling apparatus boiling and condensing a refrigerant
according to claim 19, wherein said first ribs are formed as
concavities in such a manner as to open from the center toward the
outer periphery of said refrigerant bath section.
23. A cooling apparatus boiling and condensing a refrigerant
according to claim 17, wherein said refrigerant diffusion section
is formed integrally by forging or casting.
24. A cooling apparatus boiling and condensing a refrigerant
according to claim 23, wherein said refrigerant diffusion section
is formed with at least selected one of a screw portion for
mounting a second heat-generating member and a mounting portion for
mounting a predetermined mating member.
25. A cooling apparatus boiling and condensing a refrigerant
according to claim 17, wherein a second heat-generating member is
mounted on the surface of said refrigerant diffusion section, and
wherein said refrigerant diffusion section has therein a plurality
of second ribs extending from said second heat-generating member
side toward said second space side and in contact with said heat
exchange section.
26. A cooling apparatus boiling and condensing a refrigerant
according to claim 25, wherein said second ribs are formed as
concavities in such a manner as to open to the outer periphery from
the center of said refrigerant diffusion section.
27. A cooling apparatus boiling and condensing a refrigerant
according to claim 25, wherein said surface of said heat exchange
section in contact with said second ribs is formed with a plurality
of second depressions, and wherein said second ribs are arranged in
said plurality of second depressions.
28. A cooling apparatus boiling and condensing a refrigerant
according to claim 17, wherein at least selected one of said
refrigerant bath section and said refrigerant diffusion section has
therein a third space through which said external cooling fluid
flows from said second space, and wherein a sacrificial member
active against said external cooling fluid is arranged on the inner
surface of said refrigerant bath section or said refrigerant
diffusion section having said third space.
29. A cooling apparatus according to claim 28, wherein said
sacrificial member formed on the inner surface of at least said
refrigerant bath section of said refrigerant bath section or said
refrigerant diffusion section has a porous structure.
Description
BACKGROUND OF THE INVENTION
[0001] Field of the Invention
[0002] The present invention relates to a cooling apparatus for
cooling a heat-generating member such as a semiconductor device, or
in particular to a cooling apparatus boiling and condensing a
refrigerant for cooling a heat-generating member, such as a
semiconductor device, by the boiling heat transfer through a
refrigerant.
[0003] The present applicant has previously proposed, in the prior
art, a cooling apparatus boiling and condensing a refrigerant
(which may hereinafter be referred to simply as the cooling
apparatus) designated by numeral 100 in FIG. 46. The cooling
apparatus 100 has a multilayer structure of a plurality of stacked
tabular members with a plurality of apertures, and comprises a
refrigerant bath section 110, a heat exchange section 120 and a
refrigerant diffusion section 130. A refrigerant path 101
communicates between the refrigerant bath section 110, the heat
exchange section 120 and the refrigerant diffusion section 130.
Also, cooling water paths 102 are formed in the heat exchange
section 120. A heat-generating member 10 is mounted on the lower
surface of the refrigerant bath section 110. The refrigerant in the
refrigerant bath section 110 is boiled and gasified by the
heat-generating member 10, and rises through the heat exchange
section 120. After being diffused in the refrigerant diffusion
section 130, the refrigerant flows down the heat exchange section
120. In the process, the refrigerant is condensed into liquid state
by the cooling water flowing through the cooling water paths 102
and returns to the refrigerant bath section 110. In this way, the
heat of the heat-generating member 10 is transferred from the
refrigerant to the cooling water thereby to cool the
heat-generating member 10.
[0004] This configuration eliminates both the need of the tubes and
the fins thus far used for the heat exchange section 120 and the
need of assembling and inserting the tubes into the refrigerant
bath section 110. As a result, the strict dimensional control of
the parts is not required, and the parts production is facilitated.
Also, the employment of the multilayer structure makes possible the
assembly work to proceed from one direction and therefore
facilitates the automation of the assembly process. Further, the
elimination of the conventionally required tubes also eliminates
the need of a structure for restricting the insertion length of the
tubes inserted into the refrigerant bath section 110. Thus, the
volume ratio which the refrigerant bath section 110 represents, of
the whole cooling apparatus 100, is reduced and the heat radiation
area is increased for an improved radiation performance.
[0005] With the cooling apparatus 100 shown in FIG. 46, however, in
the case where a second heat-generating member is mounted on the
upper surface of the refrigerant diffusion section 30 from the
viewpoint of the mountability and effective space utilization of
the heat-generating member 10, the refrigerant vapor in the
refrigerant diffusion section 130 constitutes a thermal resistance
so that the liquefied refrigerant in the refrigerant bath section
110 fails to be boiled and the heat-generating member mounted on
the upper surface of the refrigerant diffusion section 130 cannot
be cooled.
[0006] Also, in the cooling apparatus 100, the multilayer structure
of the tabular members can easily realize a complicated internal
structure having the refrigerant path 101 and the cooling water
paths 102 of the heat exchange section 120. Nevertheless, the
refrigerant bath section 110 or the refrigerant diffusion section
130, through which only the refrigerant flows, leads to a high
assembly cost (greater number of assembly steps). Further, the
provision of a plurality of the apertures in the tabular members
increases the wasteful material and poses the problem of an
increased material cost.
[0007] A conventional cooling apparatus 200 of the prior art shown
in FIG. 47, on the other hand, is configured of a multilayer
structure including a plurality of plate members 210, 220, 230, and
comprises a refrigerant bath section 201, a heat exchange section
202 and a refrigerant diffusion section 203, wherein the apertures
(not shown) formed in the plate members 230 make up a hermetically
enclosed space (not shown) for sealing the refrigerant therein and
a cooling water path (not shown) through which the cooling water
flows from an external source. A cooling water inlet 206 and a
cooling water outlet 207 at the ends of the cooling water path are
formed on the upper surface of the multilayer structure of the
plate members. The inlet 206 is connected with an inlet pipe 260,
and the outlet 207 is connected with an outlet pipe 270.
[0008] In cooling the heat-generating member 10 mounted on the
lower surface of the refrigerant bath section 201, the refrigerant
stored in the refrigerant bath section 201 is boiled and gasified
by the heat received from the heat-generating member 10, so that
the latent heat of the refrigerant vapor is discharged into the
cooling water in the heat exchange section 202 introduced from the
inlet pipe 260 and, through the cooling water path, flowing out
from the outlet pipe 270.
[0009] The conventional cooling apparatus 200 described above poses
the problem that, as the cooling water inlet 206 and the cooling
water outlet 207 are formed on the upper surface of the multilayer
structure, the real height of the cooling apparatus 200 along the
direction of the stack of the plate members is increased once the
pipe members such as the inlet pipe 260 and the outlet pipe 270 are
connected. An increased height of the cooling apparatus 200 may
inconveniently make it impossible to install the apparatus in a
space with a small height.
SUMMARY OF THE INVENTION
[0010] In view of the problems described above, an object of this
invention is to provide a cooling apparatus boiling and condensing
a refrigerant, in which a heat-generating member, if mounted on the
upper surface, can be cooled.
[0011] Another object of the invention is to provide a cooling
apparatus, in which the height along the stack of plate members is
suppressed.
[0012] Still another object of the invention is to provide a
cooling apparatus boiling and condensing a refrigerant, which can
be produced with a lower assembly cost and a lower material
cost.
[0013] In order to achieve the objects described above, the present
invention employs the technical means described below.
[0014] According to a first aspect of the invention (FIGS. 1 to
10), there is provided a cooling apparatus boiling and condensing
refrigerant comprising an upper plate (110), a lower plate (120), a
plurality of intermediate plates (130A to 130E) stacked between the
upper plate (110) and the lower plate (120), a plurality of
apertures (131 to 134) formed in the intermediate plates (130A to
130E), a first space (140) formed by the plurality of the apertures
(131 to 134) for sealing a refrigerant, a second space (150) formed
in proximity to the first space (140) through which an external
cooling fluid flows, and a heat-generating member (10) mounted at
least on the outer surface of the lower plate (120) among the lower
plate (120) and the upper plate (110), wherein heat is exchanged
between the refrigerant boiled by the heat of the heat-generating
member (10) and the external cooling fluid, and wherein the upper
portion (150A) of the second space (150) is formed in proximity to
the inner surface of the upper plate (110).
[0015] In this cooling apparatus (100), the heat of the
heat-generating member (10a) mounted on the outer surface of the
lower plate (120) is transferred to the refrigerant in the first
space (140) and further exchanged with the external cooling fluid
in the second space (150) in proximity to the outer surface of the
upper plate (110) thereby to cool the heat-generating member (10a).
A heat-generating member (10b), if mounted on the outer surface of
the upper plate (110) to improve the mounting density and secure
effective space utilization, etc. can be cooled by the external
cooling fluid in the second space (150) in proximity to the outer
surface of the upper plate (110).
[0016] In a first modification of the first aspect of the
invention, an area where the upper portion (150A) of the second
space (150) is in proximity to the inner surface of the upper plate
(110) corresponds to the area of the heat-generating member (10b)
which may be mounted on the upper plate (110), so that the
heat-generating member (10b) mounted on the upper plate (110) can
be cooled more effectively.
[0017] In a second modification of the first aspect of the
invention, the lower portion (150B) of the second space (150) may
be formed in proximity to the inner surface of the lower plate
(120), so that the heat-generating member (10a) mounted on the
lower plate (120) can be cooled also by the external cooling fluid
in the second space (150) and therefore the amount of the
refrigerant sealed in the first space (140) can be reduced.
[0018] In a third modification of the first aspect of the
invention, the first space (140) includes a plurality of first
small spaces (141) communicating with each other, the second space
(150) includes a plurality of second small spaces (151)
communicating with each other, and the first small spaces (141) and
the second small spaces (151) are arranged to coexist and to be
mixed each other.
[0019] As a result, the area in which the refrigerant boiled and
gasified in the first space (140) and the external cooling fluid in
the second space (150) are in proximity to each other is increased
for an improved heat exchange efficiency.
[0020] In a fourth modification of the first aspect of the
invention, the heat-generating members (10) each has a plurality of
heat sources (11) therein, and the heat sources (11) of the
heat-generating member (10a) mounted on the lower plate (120) are
preferably arranged in positions corresponding to the first small
spaces (141).
[0021] As a result, the refrigerant in the first space (140) is
easily boiled and gasified, and the heat exchange with the external
cooling fluid in the second space (150) is promoted for an improved
cooling performance.
[0022] In a fifth modification of the first aspect of the
invention, the heat sources (11) of the heat-generating member
(10b) mounted on the upper plate (110) are preferably arranged in a
position corresponding to the second small spaces (151).
[0023] As a result, the thermal resistance between the heat sources
(11) of the heat-generating member (10b) and the external cooling
fluid in the second space (150) is reduced, thereby improving the
cooling performance.
[0024] According to a second aspect of the invention, there is
provided a cooling apparatus (FIGS. 11 to 18) having a multilayer
structure of a plurality of plate members (110, 120, 130), and a
fluid path (105) formed in the multilayer structure having the
plurality of the plate members (110, 120, 130) and communicating
with an external environment through communication ports (106,
107);
[0025] wherein the heat of the heat-generating members (10) mounted
on the surfaces of the cooling apparatus is discharged into a heat
receiving medium introduced in and out by way of the communication
ports (106, 107) and flowing through the fluid path (105) thereby
to cool the heat-generating members (10); and
[0026] wherein the communication ports (106, 107) are formed on the
surface of the end portion of the plate members (110, 120, 130)
along the direction of extension thereof.
[0027] Even in the case where pipe members or the like are
connected to the communication ports (106, 107), the height along
the direction of the stack of the plate members (110, 120, 130) is
hardly increased. Thus, the height along the direction of the stack
of the plate members (110, 120, 130) can be suppressed.
[0028] In a first modification of the second aspect of the
invention, the communication ports (106, 107) are formed as a
rectangle by notches (133C, 133D) cut to the same shape in the same
positions at the end portions of the plurality of adjacent ones of
the plate members (130C, 130D).
[0029] This configuration eliminates both the need of forming
notches at different positions at the end portions of a plurality
of the plate members and the need of forming notches of different
shapes. Therefore, the communication ports (106, 107) can be easily
formed.
[0030] In a second modification of the second aspect of the
invention, pipe members (160, 170) through which a heat receiving
medium flows are projected outward from the communication ports
(106, 107).
[0031] As a result, the heat receiving medium smoothly flows
through the fluid path (105).
[0032] In a third modification of the second aspect of the
invention, the pipe members (160, 170) are connected to the
communication ports (106, 107), respectively, through a connecting
member (180).
[0033] As a result, the pipe members (160, 170) can be readily
coupled to the side surface of the end portions of the plurality of
the plate members (110, 120, 130).
[0034] In a fourth modification of the second aspect of the
invention, each connecting member (180) is arranged in such a
manner as to cover the corresponding one of the communication ports
(106, 107) and has a through hole (183) into which the
corresponding one of the pipe members (160, 170) is inserted.
[0035] In this configuration, the pipe members (160, 170) can be
easily, securely connected to the communication ports (106, 107),
respectively, by being inserted into the corresponding through
holes (183) of the connecting members (180), respectively, arranged
in such a manner as to cover the communication ports (106,
107).
[0036] In a fifth modification of the second aspect of the
invention, each through hole (183) is circular in shape.
[0037] With this configuration, the pipe members (160, 170), which
are generally cylindrical in shape, can be easily connected by
insertion.
[0038] In a sixth modification of the second aspect of the
invention, each connecting member (180) is formed with a projected
portion (182), and the multilayer structure having a plurality of
the plate members (110, 120, 130) is formed with a fitting recess
(104a) adapted to be fitted with the projected portion (182) of the
connecting member (180).
[0039] With this configuration, the projected portion (182) is
fitted in the recess (104a) so that the connecting member (180) can
be easily set in position with respect to the multilayer structure
of the plurality of the plate members (110, 120, 130).
[0040] In a seventh modification of the second aspect of the
invention, the connecting member (180) is a metal plate member
(180) bent in L shape and formed with the projected portion
(182).
[0041] With this configuration, by bending a tabular metal member
into L shape in press or the like, the projected portion (182) can
be easily formed.
[0042] In an eighth modification of the second aspect of the
invention, the multilayer structure of a plurality of the plate
members (110, 120, 130) is formed with a recess (104) conforming to
the shape of the corresponding connecting member (180), and the
connecting member (180) is inserted in the recess (104).
[0043] With this configuration, the projection of the connecting
member (180) from the multilayer structure of the plate members
(110, 120, 130) is suppressed.
[0044] In a ninth modification of the second aspect of the
invention, the multilayer structure of the plurality of the plate
members (110, 120, 130) includes a refrigerant bath section (101)
for storing the refrigerant therein, and a heat exchange section
(102) for exchanging heat between the refrigerant and a heat
receiving medium flowing through the fluid path (105), wherein the
refrigerant stored in the refrigerant bath section (101) receives
heat from the heat-generating member (10) and is boiled and
gasified, so that the latent heat of the refrigerant vapor is
discharged into the heat receiving medium flowing through the fluid
path (105) in the heat exchange section (102) thereby to cool the
heat-generating members (10).
[0045] A cooling apparatus having a high cooling efficiency
utilizing the latent heat transfer of the refrigerant is required
to comprise a refrigerant bath section (101) and the like, and
therefore the height along the direction of stack of the plate
members (110, 120, 130) is liable to increase. This invention, in
contrast, in which the height of the plate members (110, 120, 130)
along the direction of stack thereof can be effectively suppressed
can provide advantageous effects.
[0046] According to a third aspect of the invention, there is
provided a cooling apparatus boiling and condensing a refrigerant
(hereinafter, referred to as the cooling apparatus),
comprising:
[0047] a refrigerant bath section (110) for storing a refrigerant
therein and having a first heat-generating member (10) mounted on
the surface thereof;
[0048] a refrigerant diffusion section (130) for diffusing the
refrigerant boiled by the heat received from the first
heat-generating member (10); and
[0049] a heat exchange section (120) interposed between the
refrigerant bath section (110) and the refrigerant diffusion
section (130) and formed with a first space (121A) which
communicates with the refrigerant bath section (110) and the
refrigerant diffusion section (130) and through which the
refrigerant flows, and a second space (122A) through which the
external cooling fluid flows;
[0050] wherein the heat exchange section (120) is formed as a
multilayer structure having a plurality of tabular members (120A to
120D) having apertures (121, 122) corresponding to the first space
(121A) and the second space (122A), respectively; and
[0051] wherein the refrigerant bath section (110) is formed
integrally by forging or casting.
[0052] As a result, the heat exchange section (120) having a
complicated internal structure of the first space (121A) and the
second space (122A) can be easily formed as a multilayer structure
of a plurality of the tabular members (120A to 120D). Also, with
regard to the refrigerant bath section (110) in which only the
refrigerant flows, the multilayer of the tabular members (120A to
120D) is eliminated thereby to reduce the assembly cost, while at
the same time eliminating the wasteful material corresponding to
the apertures (121, 122) for a lower material cost.
[0053] In a first modification of the third aspect of the
invention, at least one screw portion (114), for mounting the first
heat-generating member (10) to the refrigerant bath section (110),
and a mounting portion for mounting a predetermined mating member
thereto can be easily formed on the refrigerant bath section (110).
Specifically, in the case where the refrigerant bath section (110)
has a multilayer structure of a plurality of tabular members, the
screw portion would be required to be formed after forming the
whole of the cooling apparatus (100) integrally. This requires a
very difficult machining process. Also, in forming the mounting
portion, another member is required to be coupled.
[0054] In a second modification of the third aspect of the
invention, first ribs (115) for enlarging a heat transfer area with
the refrigerant are integrally formed in the refrigerant bath
section (110), thereby improving the performance inexpensively
(promoting the boiling of the refrigerant).
[0055] In a third modification of the third aspect of the
invention, a plurality of first depressions (116) are formed in the
internal bottom surface of the refrigerant bath section (110).
[0056] As a result, even in the case where the cooling apparatus
(100) is mounted on a vehicle, for example, and is tilted by the
position of the vehicle while running, all the refrigerant is not
concentrated at a lower place but can be held in the first
depressions (116), thereby preventing the deterioration of the
boiling action of the refrigerant. The first depressions (116),
unlike the multilayer structure, can be easily formed at the same
time as the refrigerant bath section (110).
[0057] In a fourth modification of the third aspect of the
invention, the first ribs (115) are arranged in a plurality of the
first depressions (116), respectively.
[0058] As a result, in the case where the cooling apparatus (100)
is tilted, the area of heat transfer from the first heat-generating
member (10) through the first ribs (115) to the refrigerant held in
the first depressions (116) is increased thereby to promote the
boiling of the refrigerant.
[0059] In a fifth modification of the third aspect of the
invention, the first ribs (115) are formed as concavities open to
the outer periphery from the center of the refrigerant bath section
(110).
[0060] As in the third modification of the invention described
above, even in the case where the cooling apparatus (100), mounted
on, for example, a vehicle, is tilted as the vehicle changes in
position while running, all the refrigerant is not concentrated at
a lower place, but can be held in the concave portions of the first
ribs (115), thereby preventing the boiling action of the
refrigerant from being reduced. Incidentally, coupled with the
fourth modification of the third aspect of the invention described
above, the first depressions (116) and the concave portions of the
first ribs (115) combine to hold a large amount of the refrigerant,
thereby further improving the effect of preventing the reduction in
the boiling action of the refrigerant.
[0061] In a sixth modification of the third aspect of the
invention, the refrigerant diffusion section (130) is formed
integrally by forging or casting, and therefore, as in the third
aspect of the invention, can be formed at low cost.
[0062] In a seventh modification of the third aspect of the
invention, as in the first modification of the third aspect of the
invention described above, the refrigerant diffusion section (130)
is formed easily with at least one screw portion (137) for mounting
the second heat-generating member (10a) to the refrigerant
diffusion section (130) and a mounting portion (139) for mounting a
predetermined mating member thereto.
[0063] In an eighth modification of the third aspect of the
invention, the refrigerant diffusion section (130) has therein
second ribs (138) extending toward the second space (122A) from the
second heat-generating member (10a) into contact with the heat
exchange section (120).
[0064] As a result, the heat of the second heat-generating member
(10a) can be efficiently transferred to the external cooling fluid
in the second space (122A) through the second ribs (138) and,
therefore, the cooling performance is improved in the case where
the second heat-generating member (10a) is mounted on the
refrigerant diffusion section (130) side.
[0065] In a ninth modification of the third aspect of the
invention, the second ribs (138) are formed as concave portions
open to the outer periphery from the center of the refrigerant
diffusion section (130).
[0066] In a tenth modification of the third aspect of the
invention, a plurality of second depressions (128) are formed on
the surface of the heat exchange section (130) in contact with the
second ribs (138), which in turn are arranged in the plurality of
the second depressions (128).
[0067] As a result, in the case where the cooling apparatus (100)
is tilted, the heat of the second heat-generating member (10a) can
be transferred to the refrigerant held in the second depressions
(128) (the refrigerant can be boiled), thereby making it possible
to cool the second heat-generating member (10a) efficiently.
Incidentally, coupled with the ninth modification of the third
aspect, a larger amount of refrigerant can be held by the second
depressions (128) and the concave portions of the second ribs (138)
combined. Thus, the effect of preventing the reduction in the
boiling action of the refrigerant can be improved.
[0068] In an 11th modification of the third aspect of the
invention, a third space (133A) through which the external cooling
fluid flows from the second space (122A) is formed in at least one
of the refrigerant bath section (110) and the refrigerant diffusion
section (130), and a sacrificial member (170) against the external
cooling fluid is arranged on the internal surface of the
refrigerant bath section (110) or the refrigerant diffusion section
(130), in which the third space (133A) is formed.
[0069] As a result, in the case where the external cooling fluid is
caused to flow in the refrigerant bath section (110) or the
refrigerant diffusion section (130), the entire surface covered by
the sacrificial member (170) can be corroded first. Therefore, the
thickness of the refrigerant container is not required to be
increased unnecessarily taking the local corrosion by the external
cooling fluid into consideration, thereby making it possible to
improve the corrosion resistance of the refrigerant bath section
(110) or the refrigerant diffusion section (130) against the
external cooling fluid.
[0070] In a 12th modification of the third aspect of the invention,
the sacrificial member (170) arranged on the internal surface of
the refrigerant bath section (110), apart from the refrigerant
diffusion section (130), has a porous structure.
[0071] As a result, the boiling of the refrigerant is promoted by
increasing the heat transfer area in the refrigerant bath section
(110).
[0072] The reference numerals shown in the parentheses above
indicate the correspondence with specific means included in the
embodiments described later.
[0073] The present invention may be more fully understood from the
description of the preferred embodiments of the invention set forth
below, together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0074] FIG. 1 is a diagram schematically showing a system
configuration of a cooling apparatus boiling and condensing a
refrigerant according to this invention.
[0075] FIG. 2 is a front view showing the external appearance of
the cooling apparatus boiling and condensing a refrigerant
according to a first embodiment of the invention.
[0076] FIG. 3 is a plan view showing the external appearance of the
cooling apparatus boiling and condensing a refrigerant according to
the first embodiment of the invention.
[0077] FIG. 4 is a sectional view taken in line A-A in FIG. 3.
[0078] FIG. 5A is a plan view showing an upper plate.
[0079] FIG. 5B is a plan view showing an intermediate plate.
[0080] FIG. 5C is a plan view showing an intermediate plate.
[0081] FIG. 6A is a plan view showing an intermediate plate.
[0082] FIG. 6B is a plan view showing an intermediate plate.
[0083] FIG. 6C is a plan view showing an intermediate plate.
[0084] FIG. 7 is a plan view showing a lower plate.
[0085] FIG. 8 is a sectional view showing the cooling apparatus
according to a second embodiment of the invention.
[0086] FIG. 9 is a sectional view showing the cooling apparatus
according to a third embodiment of the invention.
[0087] FIG. 10 is a sectional view showing the cooling apparatus
according to another embodiment of the invention.
[0088] FIG. 11 is a general elevational view showing a cooling
apparatus according to a fourth embodiment of the invention.
[0089] FIG. 12 is an enlarged view of the portion A in FIG. 11.
[0090] FIG. 13A is a plan view showing an upper plate.
[0091] FIG. 13B is a plan view showing an intermediate plate.
[0092] FIG. 13C is a plan view showing an intermediate plate.
[0093] FIG. 14A is a plan view showing an intermediate plate.
[0094] FIG. 14B is a plan view showing an intermediate plate.
[0095] FIG. 14C is a plan view showing an intermediate plate.
[0096] FIG. 15A is a plan view showing an intermediate plate.
[0097] FIG. 15B is a plan view showing a lower plate.
[0098] FIG. 16 is a diagram for explaining the assembled state of
the essential parts of a cooling apparatus according to the fourth
embodiment of the invention.
[0099] FIG. 17 is an enlarged view of the essential parts of a
cooling apparatus according to a fifth embodiment of the
invention.
[0100] FIG. 18 is a diagram for explaining the assembled state of
the essential parts of a cooling apparatus according to a sixth
embodiment of the invention.
[0101] FIG. 19 is a front view showing the external appearance of a
cooling apparatus according to a seventh embodiment of the
invention.
[0102] FIG. 20 is a view taken along the direction of arrow A in
FIG. 19.
[0103] FIG. 21A is a plan view showing the refrigerant bath
section.
[0104] FIG. 21B is a view taken along the direction of arrow B in
FIG. 21A.
[0105] FIG. 22 is a plan view showing an intermediate plate
120A.
[0106] FIG. 23A is a plan view showing an intermediate plate
120B.
[0107] FIG. 23B is a plan view showing an intermediate plate
120C.
[0108] FIG. 23C is a plan view showing an intermediate plate
120D.
[0109] FIG. 24A is a plan view showing an intermediate plate
130A.
[0110] FIG. 24B is a plan view showing an intermediate plate
130B.
[0111] FIG. 24C is a plan view showing an upper plate 130C.
[0112] FIG. 25 is a front view showing the external appearance of a
cooling apparatus boiling and condensing a refrigerant according to
an eighth embodiment of the invention.
[0113] FIG. 26A is a plan view showing a refrigerant diffusion
section.
[0114] FIG. 26B is a view taken in the direction of arrow C in FIG.
26A.
[0115] FIG. 27A is a plan view showing an intermediate plate
120D.
[0116] FIG. 27B is a plan view showing an intermediate plate
120G.
[0117] FIG. 27C is a plan view showing an intermediate plate
120F.
[0118] FIG. 28A is a plan view showing an intermediate plate
120E.
[0119] FIG. 28B is a plan view showing an intermediate plate
120C.
[0120] FIG. 28C is a plan view showing an intermediate plate
120B.
[0121] FIG. 29A is a plan view showing an intermediate plate
120A.
[0122] FIG. 29B is a plan view showing a refrigerant bath
section.
[0123] FIG. 30 is a front view showing the partial external
appearance of a cooling apparatus boiling and condensing a
refrigerant according to a ninth embodiment of the invention.
[0124] FIG. 31A is a plan view showing a refrigerant bath section
according to a tenth embodiment of the invention.
[0125] FIG. 31B is a view taken in the direction of arrow D in FIG.
31A.
[0126] FIG. 32 is a front view showing the partial external view of
a cooling apparatus boiling and condensing a refrigerant according
to the tenth embodiment of the invention.
[0127] FIG. 33 is a plan view showing a refrigerant bath section
according to an 11th embodiment of the invention.
[0128] FIG. 34 is a sectional view taken in line E-E in FIG.
33.
[0129] FIG. 35 is a sectional view taken in line F-F in FIG.
33.
[0130] FIG. 36 is a plan view showing a modification of the
refrigerant bath section according to the 11th embodiment of the
invention.
[0131] FIG. 37 is a sectional view showing the cooling apparatus
boiling and condensing a refrigerant according to a modification of
the 11th embodiment of the invention.
[0132] FIG. 38 is a perspective view showing the cooling apparatus
boiling and condensing a refrigerant according to a 12th embodiment
of the invention.
[0133] FIG. 39 is a plan view showing a refrigerant diffusion
section according to the 12th embodiment of the invention.
[0134] FIG. 40A is a sectional view showing the process of
fabricating the refrigerant diffusion section in FIG. 39.
[0135] FIG. 40B is a sectional view showing the process of
fabricating the refrigerant diffusion section in FIG. 39.
[0136] FIG. 40C is a sectional view showing the process of
fabricating the refrigerant diffusion section in FIG. 39.
[0137] FIG. 41 is a perspective view showing a modification of a
sacrificial member according to the 12th embodiment of the
invention.
[0138] FIG. 42 is a plan view showing a first modification of the
refrigerant diffusion section according to the 12th embodiment of
the invention.
[0139] FIG. 43 is a plan view showing a second modification of the
refrigerant diffusion section according to the 12th embodiment of
the invention.
[0140] FIG. 44 is a perspective view showing a sacrificial member
arranged in the refrigerant bath section according to the 12th
embodiment of the invention.
[0141] FIG. 45 is a sectional view showing a refrigerant bath
section having the sacrificial member shown in FIG. 44.
[0142] FIG. 46 is a sectional view showing a conventional cooling
apparatus boiling and condensing a refrigerant.
[0143] FIG. 47 is a front view showing the external appearance of a
conventional cooling apparatus boiling and condensing a
refrigerant.
[0144] FIG. 48 is a partially sectional elevation showing a cooling
apparatus according to a 13th embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0145] (First Embodiment)
[0146] A cooling apparatus boiling and condensing a refrigerant
(hereinafter, referred to as the cooling apparatus) according to a
first embodiment of the invention is explained with reference to
FIGS. 1 to 7. A cooling apparatus 100 operates in such a manner
that a refrigerant sealed therein is boiled and gasified by the
heat of heat-generating members 10 such as a semiconductor device
(IGBT), and the refrigerant thus gasified is condensed into liquid
phase by an external cooling fluid supplied from an external
source, while at the same time discharging the latent heat of
condensation into the external cooling fluid thereby to cool the
heat-generating members 10.
[0147] The whole system is shown in FIG. 1, in which a radiator 1
and the cooling apparatus 100 (an inlet pipe 160 and an outlet pipe
170) are connected by pipes 3 to each other. Also, a pump 2 driven
by a motor 21 is interposed between the radiator 1 and the cooling
apparatus 100, so that the cooling water of the radiator 1
circulates through the interior of the cooling apparatus 100. The
cooling apparatus 100 according to this invention is of water
cooled type in which the cooling water of the radiator 1
corresponds to the external cooling fluid.
[0148] Of the drawings used for the description that follows, FIG.
2 is a front view of the cooling apparatus 100, FIG. 3 a plan view
of the cooling apparatus 100, FIG. 4 a sectional view taken in line
A-A in FIG. 3, and FIGS. 5 to 7 plan views showing plates 110, 130A
to 130E and 120.
[0149] The cooling apparatus 100, as shown in FIG. 2, comprises a
multilayer structure including an upper plate 110, a lower plate
120 arranged under the upper plate 110, and a plurality of
intermediate plates 130A to 130E having a plurality of apertures
131 to 134 (FIGS. 5 to 7) interposed between the upper plate 110
and the lower plate 120, an inlet pipe 160, an outlet pipe 170 and
a refrigerant filling pipe 180. These component members are formed
of aluminum or an aluminum alloy high in heat conductivity and
integrally brazed to form the cooling apparatus 100.
[0150] The upper plate 110, as shown in FIG. 5A, is a substantially
square tabular member formed with an inlet pipe hole 111 at the
lower right corner, an outlet pipe hole 112 at the upper left
corner and a refrigerant pipe hole 113 at the lower left portion,
as viewed in FIG. 5A. The holes 111, 112 and 113, as shown in FIGS.
2 to 4, are connected with the inlet pipe 160, the outlet pipe 170
and the refrigerant filling pipe 180, respectively.
[0151] The intermediate plates 130A, 130B and 130C, as shown in
FIGS. 5B, 5C and 6A, respectively, are each a tabular member having
the same contour as the upper plate 110 and have a plurality of
refrigerant apertures 131. The refrigerant apertures 131 are each
an elliptic hole vertically long in the drawings. A plurality of
the refrigerant apertures 131 are arranged in both vertically and
horizontally, and when the intermediate plates 130A, 130B and 130C
are stacked, adapted to be superposed one on another (the apertures
131 communicate with each other).
[0152] The intermediate plates 130A, 130B are formed with a
plurality of cooling water apertures 132 in addition to the
refrigerant apertures 131. The cooling water apertures 132 include
a plurality of comb-shaped inlet-side apertures 132a and a
plurality of comb-shaped outlet-side apertures 132b extending
horizontally, and a plurality of elliptic intermediate apertures
132c extending in vertical direction in the drawings. The
intermediate apertures 132c are arranged in columns between the
columns of the refrigerant apertures 131 in the drawing. The
portions of the inlet-side apertures 132a and the outlet-side
apertures 132b corresponding to the teeth of the comb correspond to
the positions of the intermediate apertures 132c. The cooling water
apertures 132 (132a, 132b, 132c) of the intermediate plates 130A,
130B are staggered from each other so that all the cooling water
apertures 132 (132a, 132b, 132c) communicate with each other when
the intermediate plates 130A, 130B are stacked alternately with
each other.
[0153] The intermediate plates 130D, 130E, as shown in FIGS. 6B and
6C, are rectangular tabular members having a contour corresponding
to an area of such a size as to cover the refrigerant apertures 131
of the intermediate plates 130A to 130C. The intermediate plates
130D and 130E have a plurality of vertically long refrigerant
apertures 133 and a plurality of horizontally long refrigerant
apertures 134 as shown in the drawings, respectively. The
refrigerant apertures 133 are formed in positions corresponding to
the horizontal positions of the columns of the refrigerant
apertures 131.
[0154] The holes 111, 112, 113 and the apertures 131 to 134 of the
plates 110, 130A to 130E are formed by cutting, pressing or
etching.
[0155] The lower plate 120, as shown in FIG. 7, is a rectangular
tabular member having the same contour as the intermediate plates
130D, 130E.
[0156] As shown in FIG. 4, the intermediate plates 130A to 130E are
stacked between the upper plate 110 and the lower plate 120.
Specifically, a plurality of the intermediate plates 130A and 130B
are stacked alternately with each other under the upper plate 110,
and the intermediate plate 130C is laid under the multilayer
structure of the intermediate plates 130A and 130B. Further, the
intermediate plates 130D and 130E are stacked under the
intermediate plate 130C. According to this embodiment, two
intermediate plates 130D, 130E, one of each, are used.
Nevertheless, a set of three or more plates 130D, 130E may be used
to form a multilayer structure.
[0157] Between the intermediate plates 130A to 130C, the
refrigerant apertures 131 communicate in the direction of stacking
thereby to form a plurality of refrigerant paths 141 as a plurality
of first small spaces. Between the intermediate plates 130D and
130E, on the other hand, the refrigerant apertures 133, 134
communicate with each other at points where they cross each other
to thereby form a refrigerant bath section 101. The refrigerant
flow paths 141 and the refrigerant bath section 101 further
communicate with each other thereby to form a refrigerant space 140
as a first space.
[0158] A predetermined amount of refrigerant is injected by way of
the refrigerant filling pipe 180 communicating with the refrigerant
space 140, and the refrigerant is mainly stored to fill up the
refrigerant bath section 101. Flon (HFC 134a) is used as the
refrigerant in this embodiment. Other refrigerants such as water,
alcohol, fluorocarbon, etc. may be used as an alternative
refrigerant. Incidentally, the open side of the refrigerant filling
pipe 180 is sealed by welding or the like means after injecting the
refrigerant.
[0159] Further, between the plurality of the intermediate plates
130A and 130B alternately stacked, the cooling water apertures 132,
i.e. the inlet-side apertures 132a, the outlet-side apertures 132b
and the intermediate apertures 132c communicate along both the
direction of stacking and the direction of the plate surface
thereby to form a cooling water space 150 as a second space. The
portion of the cooling water space 150 which is formed by the
intermediate apertures 132c, for example, makes up the cooling
water paths 151 as second small spaces. Incidentally, the cooling
water space 150 communicates with the inlet pipe 160 and the outlet
pipe 170.
[0160] As described above, the feature of this invention is the
cooling water apertures 132 formed in the intermediate plates 130A,
130B immediately below the upper plate 110. Thus, the upper
portions 150A of the cooling water space 150 (cooling water paths
151) are formed in proximity to the inner surface of the upper
plate 110. Also, the cooling water paths 151 alternately coexist
with the refrigerant paths 141 due to the arrangement of the
intermediate apertures 132c and the refrigerant apertures 131.
[0161] The heat-generating member 10 is arranged on the outer
surface of the upper plate 110 as well as on the outer surface of
the lower plate 120, and is fastened fixedly with a bolt or the
like not shown. In the description that follows, the lower
heat-generating member and the upper heat-generating member are
discriminated from each other by being designated by reference
numerals 10a and 10b, respectively. In order to reduce the contact
thermal resistance between the heat-generating members 10a, 10b and
the plates 110, 120, a heat conductive grease may be applied
between them.
[0162] Next, the operation and the effects of this embodiment are
explained. The refrigerant in the refrigerant bath section 101 is
boiled and gasified by the heat of the heat-generating member 10a,
and rises along each refrigerant path 141. The refrigerant gasified
is thus cooled by the cooling water flowing in the cooling water
path 151, and after being condensed into liquid state mainly on the
wall surface, refluxes to the refrigerant bath section 101 by its
own weight. In this way, the cooling apparatus 100 transports the
heat of the heat-generating member 10a by boiling and gasification,
and discharges the latent heat of condensation at the time of
condensation into a liquid state, to the cooling water, thereby to
cool the heat-generating member 10a.
[0163] The heat of the heat-generating member 10b, on the other
hand, is discharged into the cooling water in the cooling water
path 151 in proximity through the upper plate 10 thereby to cool
the heat-generating member 10b.
[0164] As described above, according to this invention, the
heat-generating member 10 mounted on the outer surface of the upper
plate 110 to improve the mounting density and effectively utilize
the space can be cooled by the cooling water in the nearby cooling
water path 151.
[0165] Also, as the refrigerant paths 141 and the cooling water
paths 151 are arranged alternately to coexist, the area where the
cooling water and the refrigerant boiled and gasified by the
heat-generating member 10a are in proximity to each other is
increased for an improved heat exchange efficiency.
[0166] (Second Embodiment)
[0167] A second embodiment of the invention is shown in FIG. 8.
According to the second embodiment, unlike in the first embodiment
described above, the area where the upper portions 150A of the
cooling water spaces 150 (cooling water paths 151) are in proximity
to the inner surface of the upper plate 110 corresponds to the area
of the heat-generating member 10b.
[0168] As a result, the heat-generating member 10b can be cooled
effectively in accordance with the mounting position and size
thereof. Also, the area where the upper portions 150A of the
cooling water spaces 150 are not in proximity to the upper plate
110 is formed with the refrigerant diffusion section 103, and
therefore the reflux of the refrigerant boiled and gasified by the
heat-generating member 10a is promoted for an improved cooling
performance of the heat-generating member 10a.
[0169] (Third Embodiment)
[0170] A third embodiment of the invention is shown in FIG. 9.
According to the third embodiment, as compared with the first
embodiment described above, the lower portions 150B of the cooling
water spaces 150 are also arranged in proximity to the inner
surface of the lower plate 120. Also, a plurality of device chips
11 constituting a plurality of heat sources of the heat-generating
member 10a therein are arranged in positions corresponding to the
positions of the refrigerant paths 141.
[0171] As a result, the heat-generating member 10a is cooled also
by the cooling water in the cooling water spaces 150 (cooling water
paths 151), and therefore the amount of the refrigerant sealed in
the refrigerant spaces 140 can be reduced.
[0172] Also, the refrigerant in the refrigerant spaces 140 is
easily boiled and gasified, and the heat exchange is promoted with
the cooling water in the cooling water spaces 150 thereby to
improve the cooling performance.
[0173] In the above second and third embodiments, the
heat-generating member 10b mounted on the upper surface of the
cooling apparatus 100 may be an inverter for compressing gas such
as a refrigerant and the heat-generating member 10a mounted on the
lower surface of the cooling apparatus 100 may be an inverter for
propulsion.
[0174] (Other Embodiments)
[0175] As compared with the first embodiment, the device chips 11
in the heat-generating member 10b are preferably arranged in a
position corresponding to the positions of the cooling water paths
151, respectively, as shown in FIG. 10, whereby the thermal
resistance between the device chips 11 and the cooling water can be
reduced for an improved cooling performance.
[0176] The cooling apparatus 100 according to this invention is
equal to the conventional one disclosed in prior art even in the
case where the heat-generating member 10a is arranged only on the
lower plate 120 without any heat-generating member 10b on the upper
plate 110.
[0177] (Fourth Embodiment)
[0178] FIG. 11 is a side view showing the whole of the cooling
apparatus 100 according to this embodiment, FIG. 12 an enlarged
view of the portion A in FIG. 11, and FIGS. 13 to 15 plan views of
the plates 110, 130A to 130F and 120, respectively.
[0179] The cooling apparatus 100 according to this embodiment
comprises a refrigerant bath section 101 for storing the
refrigerant, a heat exchange section 102 for exchanging heat
between the boiling refrigerant heated by the heat-generating
member 10 in the refrigerant bath section 101 and the cooling water
providing a heat receiving medium, and a refrigerant diffusion
section 103 for diffusing in horizontal direction the refrigerant
vapor flowing in from the refrigerant bath section 101 through the
heat exchange section 102 (FIG. 12).
[0180] The cooling apparatus 100 operates in such a manner that the
refrigerant sealed therein is boiled and gasified by the heat of
the heat-generating member 10 such as a semiconductor device
(IGBT), and when the refrigerant vapor is condensed into liquid
state by the cooling water supplied from an external source, the
latent heat of condensation is discharged into the cooling water
thereby to cool the heat-generating member 10. The cooling
apparatus 100 is what is called the water-cooled cooling apparatus
of high cooling efficiency utilizing the latent heat transfer of
the refrigerant.
[0181] The cooling apparatus 100 comprises, as shown in FIG. 12: a
multilayer structure including an upper plate 110, a lower plate
120 arranged under the upper plate 110, and a plurality of
intermediate plates 130 (intermediate plates 130A to 130F) stacked
between the upper plate 110 and the lower plate 120 and having a
plurality of apertures 131A to 131F, 132C, 132D (FIGS. 13 to 15);
an inlet pipe 160 and an outlet pipe 170 constituting pipe members;
and a connecting plate 180 constituting a connecting member. These
component parts are formed of aluminum or an aluminum alloy high in
heat conductivity, and are integrally brazed to form the cooling
apparatus 100.
[0182] As shown in FIG. 13A, the upper plate 110 is a substantially
rectangular tabular member and has two notches 114 on the right
side thereof as shown in the drawing.
[0183] The intermediate plates 130A to 130F, as shown in FIGS. 13B,
13C, 14A, 14B, 14C and 15A, respectively, have the same contour as
the upper plate 110, and each have notches 134 in the same shape
and at the same positions as the notches 114 of the upper plate
110.
[0184] Also, the intermediate plates 130A to 130F have a plurality
of elliptic refrigerant apertures 131A to 131F. A plurality of the
refrigerant apertures 131A to 131F are arranged in vertical or
horizontal direction, and when the intermediate plates 130A to 130F
are stacked, are superposed one on another (communicate with each
other) thereby to form a single hermetically sealed space.
[0185] Also, as shown in FIGS. 14A and 14B, the intermediate plates
130C, 130D are formed with cooling water apertures 132C, 132D in
addition to the refrigerant apertures 131C, 131D described above.
The cooling water apertures 132C, 132D, except for some of them,
are comb-shaped and have a portion corresponding to the comb teeth
extending between the refrigerant apertures 131C, 131D.
[0186] In the cooling water apertures 132C, 132D, the end portions
corresponding to the forward ends of the comb teeth are arranged in
staggered positions. In the case where the intermediate plates
130C, 130D are stacked on one another, the whole of the cooling
water apertures 132C, 132D communicate with each other thereby to
form the cooling water paths 105 providing fluid paths for a heat
receiving medium.
[0187] Between the notches 134 and the cooling water apertures
132C, 132D to the extreme right side at the upper and lower parts,
in the drawing, of the intermediate plates 130C, 130D, two notches
133C, 133D are formed, respectively, to establish communication.
The notches 133C, 133D are formed in the same shape and at the same
position of the intermediate plates 130C, 130D. When the
intermediate plates 130A to 130F are stacked, therefore, the
rectangular inlet 106 and the rectangular outlet 107 described
later are formed.
[0188] The lower plate 120, as shown in FIG. 15B, is a tabular
member having the same contour as the upper plate 110. The lower
plate 120 is formed with notches 124 at the same positions as and
deeper (horizontally longer in the drawing) than the notches 114 of
the upper plate 110.
[0189] As shown in FIG. 12, the intermediate plates 130A to 130F
are stacked between the upper plate 110 and the lower plate 120.
Specifically, between the upper plate 110 and the lower plate 120,
there are stacked, from the upper plate 120 side down, two
intermediate plates 130A, one intermediate plate 130B, six
intermediate plates including three intermediate plates 130C and
three intermediate plates 130D alternating with each other, one
intermediate plate 130B, one intermediate plate 130E and two
intermediate plates 130F.
[0190] With this multilayer configuration, a space for storing the
refrigerant is formed by the refrigerant apertures 131E, 131F in
the refrigerant bath section 101 including the four lowest plate
members.
[0191] In the heat exchange section 102 formed of eight plate
members thereabove, refrigerant paths communicating with the
refrigerant storage space of the refrigerant bath section 101 are
formed of the refrigerant apertures 131B, 131C, 131D. At the same
time, the cooling water paths 105 (FIG. 14, not shown in FIG. 12)
having the inlet 106 and the outlet 107 providing communication
ports with the exterior, at the both ends of the cooling water
paths are formed by the cooling water apertures 132C, 132D.
[0192] Further, refrigerant paths communicating with the
refrigerant paths of the heat exchange section 102 for diffusing
the refrigerant vapor in horizontal direction are formed by the
refrigerant apertures 131A in the refrigerant diffusion section 103
formed of the three uppermost plate members.
[0193] Once the plates 110, 130, 120 are stacked, as described
above, and, as shown in FIG. 16, a recess 104 corresponding to the
shape of the connecting plate 180 described later is formed by the
notches 114, 134, 124 at the end surface of the multilayer
structure of the plates 110, 130, 120.
[0194] The connecting plate 180 is a metal plate member formed by
bending a flat plate member into an L shape in a press or the like,
and includes a flat surface portion 181 and a projected portion 182
projected in the direction perpendicular to the flat surface
portion 181. As shown in FIG. 16, the flat surface portion 181 of
the connecting plate 180 is formed with a circular through hole 183
into which the pipe members including the inlet pipe 160 and the
outlet pipe 170 (the outlet pipe 170 is not shown in FIG. 16) are
to be inserted.
[0195] The connecting plate 180 is arranged in the recess 104 at
the end surface of the multilayer structure of the plates 110, 130,
120. Then, the flat surface portion 181 covers the inlet 106 or the
outlet 107 (the outlet 107 is not shown in FIG. 16) in the recess
104 while, at the same time, the whole area of the through hole 183
is laid inside of the outer periphery of the inlet 106 or the
outlet 107, as the case may be. In FIG. 16, the internal
configuration of the inlet 106 is not shown.
[0196] Incidentally, the notches 124 of the lower plate 120 are
deeper than the notches 114, 134 of the other plates 110, 130 and
are formed in the lowest layer of the recess 104, thereby forming a
fitting recess 104 for fitting the projected portion 182 of the
connecting plate 180.
[0197] The inlet pipe 160 and the outlet pipe 170 have the same
shape and make up substantially cylindrical piping members of an
aluminum alloy material for connecting to the external pipe.
[0198] The upper plate 110 and the lower plate 120 are formed of an
aluminum material for its heat conduction characteristics, while
the intermediate plates 130 are formed of a clad material with a
brazing material layer formed on the surface of a base metal of an
aluminum alloy material. A brazing material is cladded also on the
inner surface of the connecting plate 180 made of an aluminum alloy
material.
[0199] In forming the cooling apparatus 100, as shown in FIG. 16,
the upper plate 110, the intermediate plates 130 (130A to 130F) and
the outer plate 120 are stacked and the connecting plate 180 is
inserted in the recess 104 of the multilayer structure. Then, the
end portions of the inlet pipe 160 and the outlet pipe 170 (not
shown) are inserted in the through hole 183 of the connecting plate
180.
[0200] In the process, a brazing material 190 is supplied between
the connecting plate 180 and the inlet pipe 160 and the outlet pipe
170. This assembly, once complete, is held with a jig or the like
and integrally brazed by heat.
[0201] Though not shown, the cooling apparatus 100 formed this way
has a filling pipe communicating with the internal refrigerant
storage space. A predetermined amount of refrigerant is injected
into the internal spaces through the filling pipe, and after
injection, the forward end of the filling pipe is hermetically
sealed off. Flon (HFC 134a) is used as the refrigerant.
[0202] With reference to the configuration described above, the
operation of the cooling apparatus 100 according to this embodiment
is briefly explained. The refrigerant in the refrigerant bath
section 101 is boiled and gasified by the heat of the
heat-generating members 10, and rises along the refrigerant paths
in the heat exchange section 102. The refrigerant is cooled by the
cooling water flowing in the cooling water paths 105 and, after
thus being condensed into liquid state mainly on the wall surface
of the refrigerant paths, refluxes to the refrigerant bath section
101 by its own weight.
[0203] The refrigerant vapor that has failed to be condensed while
rising along the refrigerant paths in the heat exchange section 102
is diffused by the refrigerant paths in the refrigerant diffusion
section 103, and falls down mainly along the refrigerant paths
smaller in upward pressure in the heat exchange section 105. The
refrigerant then is cooled and condensed into liquid state by the
cooling water flowing in the cooling water paths 105 and refluxes
to the refrigerant bath section 101.
[0204] With the configuration and operation described above, the
inlet 106 and the outlet 107 are formed in the surface of the end
portion of the plates 110, 120, 130 along the direction of
extension thereof (the direction perpendicular to the direction of
stacking), and the inlet pipe 160 and the outlet pipe 170 are
projected outward from the inlet 106 and the outlet 107,
respectively. Therefore, the substantial height along the direction
of stacking of the plate members 110, 120, 130 is not
increased.
[0205] Also, in the case where an electronic part is required to be
mounted on the upper surface of the cooling apparatus 100 (the
surface of the upper plate 110), the inlet pipe 160 and the outlet
pipe 170 do not interfere and, therefore, a sufficient mounting
space can be secured.
[0206] The intermediate plates 130C, 130D making up the main parts
of the heat exchange section 102 have notches 133C, 133D,
respectively, of the same size and at the same positions, at the
end portions thereof thereby to form the inlet 106 and the outlet
107 rectangular in shape. As compared with the inlet 106 and the
outlet 107 substantially circular in shape, therefore, the number
of geometric patterns of the intermediate plates can be
reduced.
[0207] In spite of the rectangular shape of the inlet 106 and the
outlet 107, the employment of the connecting plate 180 covering
them and having a circular through hole 183 for insertion of the
inlet pipe 160 and the outlet pipe 170 cylindrical in shape can
securely and readily connect the inlet pipe 160 and the outlet pipe
170 to the inlet 106 and the outlet 107, respectively.
[0208] In forming the cooling apparatus 100, the connecting plate
180 is inserted in the recess 104, and the projected portion 182 of
the connecting plate 180 is fitted by being inserted in the fitting
recess 104a. Before brazing, therefore, the positioning and the
tacking (temporary fixing) process can be easily executed while at
the same time securing a connecting area positively.
[0209] Further, after brazing, the connecting plate 180 is embedded
in the multilayer structure of the plates 110, 120, 130 and,
therefore, the size in the horizontal direction (the direction in
which the plates extend) of the cooling apparatus 100 can be
suppressed.
[0210] (Fifth Embodiment)
[0211] Next, a fifth embodiment of the invention is explained with
reference to FIG. 17. The fifth embodiment, as compared with the
fourth embodiment, is different in the configuration of the
connecting portion of the inlet pipe 160 and the outlet pipe 170.
In FIG. 17, the component parts identical or similar to those of
the fourth embodiment are designated by the same reference
numerals, respectively, and are not described again.
[0212] As shown in FIG. 17, an L-shaped connecting plate 185
according to the fifth embodiment is projected between the upper
and lower intermediate plates 130B (heat exchange section 102) at
the end surface of the multilayer structure of the plates 110, 120,
130. Unlike in the first embodiment, therefore, the plates 110,
120, 130 are not formed with the notches 114, 124, 134 except for
the intermediate plate 130B arranged as the fifth layer from the
bottom. The notch 134 formed in the intermediate plate 130B laid as
the fifth layer from the bottom makes up a fitting recess according
to this embodiment. The projected portion 187 of the connecting
plate 185 is connected by being inserted and fitted in the recess
134.
[0213] With the configuration described above, as in the fourth
embodiment, the substantial height along the direction of stacking
of the plates 110, 120, 130 is not increased. Also, as the
projected portion 187 of the connecting plate 185 fitted by being
inserted in the recess 134 is held between the intermediate plates
130D and 130E on the upper and lower sides thereof, the positioning
and the tacking process can be positively and easily carried out
before brazing.
[0214] (Sixth Embodiment)
[0215] A sixth embodiment of the invention is explained below with
reference to FIG. 18. According to the sixth embodiment, unlike the
fourth embodiment, no connecting plate is used at the connecting
portion between the inlet pipe 160 and the outlet pipe 170. In FIG.
18, the component parts identical or similar to those of the fourth
embodiment are designated by the same reference numerals,
respectively, and are not described again.
[0216] FIG. 18 shows only the inlet 106 side. The inlet pipe 165
making up a pipe member projected from the inlet 106 according to
the third embodiment has an end portion thereof nearer to the
multilayer structure of the plates 110, 120, 130 expanded or
reduced to a rectangular shape corresponding to the shape of the
inlet 106.
[0217] Also, the multilayer structure of the plates 110, 120, 130
and the inlet pipe 165 are connected to each other by a brazing
material 190 supplied therebetween without using the connecting
plate. In FIG. 18, the internal configuration of the inlet 106 is
not shown. The outlet 107 side not shown also has the same
configuration.
[0218] With this configuration, like the configuration of the
fourth embodiment, the substantial height along the direction of
stacking of the plate members 110, 120, 130 is not increased. Also,
the number of parts is reduced due to the lack of the connecting
plate.
[0219] (Other Embodiments)
[0220] According to each of the embodiments described above, the
number of the plate members stacked is 15 and not limited to this
figure. Also, the aperture pattern of the refrigerant apertures and
the cooling water apertures of the plate members is not limited to
the shown ones.
[0221] According to the fourth embodiment, the connecting plate 180
is inserted in the recess 104 formed over the entire area along the
direction of stacking of the multilayer structure. In the fifth
embodiment, on the other hand, the connecting plate 185 is
projected only from the end portion of the heat exchange section
102. Nevertheless, a recess may alternatively be formed only at the
end portion of the heat exchange section 102, and the connecting
plate 180 may be inserted in this recess.
[0222] With this configuration, as compared with the fourth
embodiment, the positioning and tacking process can be much more
easily and securely carried out before brazing.
[0223] Also, instead of flon used in each of the embodiments
described above, water, alcohol or fluorocarbon, or the like, may
alternatively be employed as the refrigerant.
[0224] Also, in each of the embodiments described above, the
cooling apparatus 100 is of a type boiling and condensing
refrigerant. As an alternative, the invention is applicable also to
a cooling apparatus of such a type that the heat of a
heat-generating member is discharged directly to a heat receiving
medium but not by the latent heat transfer through the
refrigerant.
[0225] (Seventh Embodiment)
[0226] A cooling apparatus boiling and condensing a refrigerant
(hereinafter, referred to as the cooling apparatus) according to a
seventh embodiment of the invention is explained with reference to
FIGS. 19 to 24. The cooling apparatus 100 is of water cooled type,
in which the refrigerant sealed therein is boiled and gasified by
the heat of heat-generating members 10 such as a semiconductor
device (IGBT), and when the gasified refrigerant is condensed into
liquid state by the cooling water (external cooling fluid) supplied
from an external source, the latent heat of condensation is
discharged into the external cooling fluid thereby to cool the
heat-generating members 10.
[0227] Of the drawings referred to below, FIG. 19 is a front view
of the cooling apparatus 100, FIG. 20 a plan view of the cooling
apparatus 100, FIG. 21 a plan view and a front view of the
refrigerant bath section 210, and FIGS. 22 to 24 plan views of the
plates 120A to 120D, 230A to 230C.
[0228] The cooling apparatus 100, as shown in FIGS. 19 and 20,
comprises, from the bottom up, the refrigerant bath section 210, a
heat exchange section 120 and a refrigerant diffusion section 230
stacked in that order, an inlet pipe 140 and an outlet pipe 150
arranged on the upper surface (intermediate plate 120D) of the heat
exchange section 120, and a refrigerant filling pipe 160 on the
upper surface (upper plate 230C) of the refrigerant diffusion
section 230. These component parts are formed of aluminum or an
aluminum alloy high in heat conductivity and integrally brazed
thereby to form the cooling apparatus 100.
[0229] The refrigerant bath section 210 constitutes a first feature
of this invention and, unlike the heat exchange section 120 and the
refrigerant diffusion section 230 described later, is integrally
formed by cold forging (or casting) as shown in FIGS. 19 and
21.
[0230] Specifically, the refrigerant bath section 210 is a
container-like portion so formed that a side wall 212 is arranged
on the outer periphery of a rectangular bottom surface portion 211
with a space formed inside. On the left and right sides of FIG. 3,
a plurality of (12 in this case) thick cylindrical potions 213 are
expanded into the inner space from the side wall 212 and projected
in the direction away from the bottom surface area. The thick
portions 213 are formed with a plurality (12 in this case) of screw
portions 214 from the lower side of the bottom surface portion 211.
The cylindrical projections of the thick portions 213 are
accommodated in the cooling water apertures 122 (the inlet aperture
122a and the outlet aperture 122b), described later, of the heat
exchange section 120.
[0231] Further, a plurality of ribs (corresponding to the first
ribs according to this invention) 215 are integrally formed and
projected from the bottom surface portion 211 toward the aperture
side in horizontal direction in FIG. 21. The projected end portion
of each rib 214 is located at the same position as the
aperture-side end portion of the side wall 212, and a gap is formed
between the longitudinal end of the rib 215 and the side wall
212.
[0232] A heat-generating member (corresponding to the first
heat-generating member according to the invention) 10 is arranged
and fastened fixedly by bolts 11 on the lower surface of the
refrigerant bath section 210. In order to reduce the contact heat
resistance between the heat-generating member 10 and the
refrigerant bath section 210, a heat conductive grease may be
interposed between them.
[0233] The heat exchange section 120 constitutes a second feature
of the invention, and as shown in FIGS. 19, 22 and 23, is formed of
a plurality of intermediate plates 120A to 120D in stack.
Specifically, the intermediate plate 120A is arranged on the upper
surface of the refrigerant bath section 210. The intermediate
plates 120B and the intermediate plates 120C are arranged
alternately with each other on the upper surface of the
intermediate plate 120A, and the intermediate plate 120D is
arranged on the multilayer structure of the intermediate plates
120B and 120C. The intermediate plate 120A is coupled in contact
with the end portion far from the bottom surface portion of the
ribs 215 and the side wall 212 of the refrigerant bath section 210.
The end portion far from the bottom surface of the ribs 215 is
coupled at a position between the refrigerant apertures 121
(described later) of the intermediate plate 120A.
[0234] The intermediate plates 230A to 230D are each a rectangular
tabular member having the same contour as the refrigerant bath
section 210 and have a plurality of refrigerant apertures 121. The
refrigerant apertures 121 are elliptic holes extending in
horizontal direction in the drawing. A plurality of the refrigerant
apertures 121 are arranged both horizontally and vertically in such
a manner as to be superposed one on another (communicate with each
other) when the intermediate plates 230A to 230D are stacked one on
another.
[0235] The intermediate plate 120A is formed with a plurality of
(12 in this case) thread bypass holes 123 are formed through the
cylindrical thick portions 213 of the refrigerant bath section
210.
[0236] In addition to the refrigerant apertures 121, cooling water
apertures 122 are formed in the intermediate plates 230B and 230C.
The cooling water apertures 122 include an inlet-side aperture 122a
and an outlet-side aperture 122b extending in comb-like form
vertically in the drawing and elliptic intermediate apertures 122c
extending horizontally in the drawing. The intermediate apertures
122c are interposed between the refrigerant apertures 121
vertically in the drawing. The portions of the inlet-side aperture
122a and the outlet-side aperture 122b corresponding to the comb
teeth are located at positions corresponding to the intermediate
apertures 122c. The end portions of the cooling water apertures 122
(122a, 122b, 122c) of the intermediate plates 230B, 230C are
staggered.
[0237] Further, the intermediate plate 120D is formed with an inlet
pipe hole 124 at the upper right part and an outlet pipe hole 125
at the lower left part in the drawing. The pipe holes 124 and 125
are coupled with the inlet pipe 140 and the outlet pipe 150,
respectively, as shown in FIGS. 19 and 20.
[0238] In the heat exchange section 120, the refrigerant apertures
121 communicate with each other along the direction of stack
thereby to form a plurality of first spaces 121A. The first spaces
121A communicate with the internal spaces of the refrigerant bath
section 210 and the refrigerant diffusion section 230 described
later. In the plurality of the intermediate plates 120B, 120C
stacked alternately with each other between the intermediate plates
120A and 120D, the cooling water apertures 122 including the
inlet-side apertures 122a, the outlet-side apertures 122b and the
intermediate apertures 122c communicate with each other in the
directions both along the stack and along the plate surface thereby
to form second spaces 122A. The second spaces 122A communicate with
the inlet pipe 140 and the outlet pipe 150.
[0239] The refrigerant diffusion section 230, like the heat
exchange section 120, is formed of a plurality of the plates 230A
to 230C by stacking as shown in FIGS. 19 and 24. Specifically, the
intermediate plates 230A and the intermediate plates 230B are
stacked alternately with each other, and an upper plate 230C is
arranged on the multilayer structure of the intermediate plates
230A and 230B.
[0240] The intermediate plates 230A, 230B are rectangular tabular
members having a contour corresponding to the area surrounding the
refrigerant apertures 121 of the intermediate plates 120A to 120D
of the heat exchange section 120. The intermediate plates 230A,
230B each have a plurality of refrigerant apertures 231, 232 formed
as elongate horizontal or vertical holes in the drawing. The
refrigerant apertures 231 are formed in positions corresponding to
the vertical arrangement of refrigerant apertures 121 of the heat
exchange section 120.
[0241] The upper plate 230C has the same contour as the
intermediate plates 230A, 230B. A refrigerant pipe hole 233
communicating with the refrigerant apertures 231 or 232 is formed
in the lower right part of the drawing. The refrigerant pipe hole
233 is connected with a refrigerant pipe 160, as shown in FIGS. 19
and 20.
[0242] In the refrigerant diffusion section 230, an internal space
is formed at each portion where the refrigerant apertures 231, 232
cross and communicate with each other. These internal spaces
communicate with the refrigerant pipe 160.
[0243] The apertures 121, 122, 231, 232 and the holes 123 to 125,
233 of the plates 120A to 120D, 230A to 230C are formed by cutting,
pressing, etching or the like.
[0244] A predetermined amount of refrigerant is injected from the
refrigerant filling pipe 160. The refrigerant is passed from the
refrigerant diffusion section 230 through the first space 121A of
the heat exchange section 120 and stored mainly in the refrigerant
bath section 210 to the full. Flon (HFC 234a) is used as the
refrigerant. Any other alternative refrigerant such as water,
alcohol and fluorocarbon may be used. The open side of the
refrigerant filling pipe 160 is sealed by welding or the like means
after injection of the refrigerant.
[0245] Next, the operation and effects of this embodiment are
explained. The refrigerant in the refrigerant bath section 210 is
boiled and gasified by the heat of the heat-generating members 10,
rises in the first space 121A and flows into the refrigerant
diffusion section 230 where it is diffused. The diffused
refrigerant flows down the first space 121A and, in the process, is
cooled and condensed into liquid phase by the cooling water flowing
in the second space 122A. The liquefied refrigerant refluxes into
the refrigerant bath section 210 by its own weight. As described
above, in the cooling apparatus 100, the heat of the
heat-generating member 10 is transported by boiling and
gasification, and the latent heat of condensation and liquefaction
is discharged into the cooling water thereby to cool the
heat-generating members 10.
[0246] According to this invention, the heat exchange section 120
having a complicated internal structure including the first space
121A and the second space 122A is easily formed by a multilayer
structure of the intermediate plates 120A to 120D. The refrigerant
bath section 210 where only the refrigerant flows is integrally
formed by cold forging, thereby eliminating the multilayer
structure of the plates (120A to 120D). Therefore, the assembly
cost is reduced. Also, as the wasteful material corresponding to
the refrigerant apertures 121 and the cooling water apertures 122
is eliminated, the material cost is reduced.
[0247] By forming the refrigerant bath section 210 integrally, the
screw portions 214 for mounting the heat-generating members 10 are
easily formed. In the prior art, in contrast, the refrigerant bath
section 210 is formed of a multilayer structure of plates, in which
case the screw portions 214 are required to be formed only after
integrally forming the whole of the cooling apparatus 100, a
machining process very difficult to carry out.
[0248] The ribs 215 are formed integrally in the internal space of
the refrigerant bath section 210. Therefore, the area of heat
transfer with the refrigerant is easily increased and the boiling
of the refrigerant is promoted (i.e. the heat exchange performance
is improved). Further, as the end portion of the ribs 215 far from
the bottom surface thereof is connected with the intermediate plate
120A of the heat exchange section 120, the pressure strength of the
refrigerant bath section 210 is improved.
[0249] (Eighth Embodiment)
[0250] An eighth embodiment of the invention is shown in FIGS. 25
to 29. According to the eighth embodiment, as compared with the
seventh embodiment described above, a heat-generating member
(corresponding to the second heat-generating member of the
invention) 10a is arranged also on the upper surface of the
refrigerant diffusion section 230. By way of explanation, the
component members of the cooling apparatus 100 are arranged top
down sequentially in drawings (FIGS. 26 to 29).
[0251] Like the refrigerant bath section 210, the refrigerant
diffusion section 230, as shown in FIGS. 25 and 26, is formed
integrally by cold forging. Specifically, the refrigerant diffusion
section 210 is a container-like component having an inner space
defined by the side wall 235 formed on the outer periphery of the
elliptic upper surface portion 234.
[0252] A plurality (a total of seven in this case, including three
at the central area and four on the wall sides) of thick portions
236 are projected cylindrically from the transverse center of the
upper surface 234 and the side walls 235 toward the side far from
the upper surface. The thick portions 236 are formed with a
plurality of (seven) screw portions 237 from the upper side of the
upper surface 234. Further, a plurality of ribs (corresponding to
the second ribs according to the invention) 238 are integrally
formed in the inner space by being projected from the upper surface
234 toward the opening of the inner space and extend in horizontal
direction in FIG. 26. Specifically, the ribs 238 extend from the
heat-generating member 10a toward the second space 122A of the heat
exchange section 120, and the projected end of each of the ribs 238
is located at the same position as the end portion of the side wall
235 nearer to the opening. The projected end of each of the ribs
238 is connected at a position between the refrigerant apertures
121 of the intermediate plate 120D. Also, a gap is formed at the
central portion and between the longitudinal end and the side wall
212 of each of the ribs 238 to facilitate the diffusion of the
refrigerant.
[0253] Also, an inlet pipe hole 230a is formed at the upper right
position, an outlet pipe hole 230b at the lower left position, and
a refrigerant pipe hole 233 at the lower right position, in FIG.
26, of the refrigerant diffusion section 230. As shown in FIG. 25,
the pipe holes 230a, 230b, 233 are connected with the inlet pipe
140, the outlet pipe 150 and the refrigerant filling pipe 160,
respectively.
[0254] The heat-generating member 10a is arranged and fixedly
fastened by bolts 11 on the upper surface of the refrigerant
diffusion section 230.
[0255] The intermediate plate 120D in contact with the refrigerant
diffusion section 230 of the heat exchange section 120 is formed
with a plurality of thread bypass holes 123 through which the thick
portions 236 of the refrigerant diffusion section 230 are inserted,
respectively. Unlike in the seventh embodiment, neither the inlet
pipe hole 124 nor the outlet pipe hole 125 is formed. Also,
intermediate plates 120G, 120F, 120E are added between the
intermediate plate 120D and the the multilayer structure of the
intermediate plats 120B and 120C alternating with each other. The
intermediate plates 120G, 120F, as compared with the intermediate
plates 120C, 120B, have added thereto thread bypass holes 123
through which the thick portions 236 are passed at the transversely
central portion. The intermediate plate 120E, as compared with the
intermediate plate 120C, is formed with thick portions 126 for
closing the thread bypass holes 123 communicating with the
refrigerant diffusion section 230 at the transversely central
portion thereof.
[0256] Further, harness holes 230c, 127, 117 for accommodating the
harnesses (not shown) of the heat-generating members 10 arranged
above and below the cooling apparatus 100 are formed at the lower
right part, in the drawing, of the refrigerant diffusion section
230, the intermediate plates 120A to 120G and the refrigerant bath
section 210.
[0257] As a result, as in the seventh embodiment, the refrigerant
diffusion section 230 can be formed inexpensively. The screw
portions 237 formed in the refrigerant diffusion section 230 are
accommodated in the spaces formed by the thick portions 126 and the
thread bypass holes 123 formed in the intermediate plates 120D,
120G, 120F, 120E, in such a manner as to prevent the leakage of the
refrigerant and the cooling water.
[0258] The heat-generating member 10a mounted on the refrigerant
diffusion section 230 is cooled by the cooling water of the heat
exchange section 120 (second space 122A). The provision of the ribs
238 in contact with the intermediate plate 120D of the heat
exchange section 120 in the internal space of the refrigerant
diffusion section 230, however, transfers the heat of the
heat-generating members 10 to the cooling water efficiently for an
improved cooling performance.
[0259] (Ninth Embodiment)
[0260] A ninth embodiment of the invention is shown in FIG. 30.
According to the ninth embodiment, as compared with the eighth
embodiment, the refrigerant diffusion section 230 is integrally
formed with a mounting portion 139 for mounting a predetermined
mating member.
[0261] The mounting portion 139 is formed as an expansion having a
mounting hole 139a. The mounting portion 139 is used, for example,
to fix the harnesses or the pipes of the vehicle or to mount the
cooling apparatus 100 on the vehicle body.
[0262] As described above, in the case where the refrigerant
diffusion section 230 is formed as a multilayer structure of
plates, another member is required to be connected to form the
mounting portion 139. According to this embodiment, in contrast,
the mounting portion can be integrally formed inexpensively. The
mounting portion 139 may be arranged on the refrigerant bath
section 210 instead of on the refrigerant diffusion section
230.
[0263] (Tenth Embodiment)
[0264] A tenth embodiment of the invention is explained with
reference to FIGS. 31 and 32. According to the tenth embodiment, as
compared with the seventh to ninth embodiments, a plurality of
depressions (corresponding to the first depression of the
invention) 116 are formed in the bottom surface portion 211 of the
refrigerant bath section 210. The depressions 116 are each formed
as a spherical dimple 116a.
[0265] As a result, even in the case where the cooling apparatus
100 mounted on a vehicle is tilted, for example, in accordance with
the position of the vehicle while running, as shown in FIG. 32, all
the refrigerant is not concentrated at a lower place but held by
the dimples 116a. Thus, the boiling action of the refrigerant is
prevented from being reduced. Unlike in the multilayer structure,
the dimples 116a can be formed easily when forming the refrigerant
bath section 210.
[0266] (11th Embodiment)
[0267] An 11th embodiment of the invention is shown in FIGS. 33 to
35. The feature of the 11th embodiment, as compared with the tenth
embodiment described above, is the combination of the ribs 215 and
the depressions 116.
[0268] In the refrigerant bath section 210 (the FIG. 33 shows the
refrigerant bath section 210 turned by 90 degrees from the state
shown in FIG. 31), a plurality of the depressions 116 are formed
elliptically, and the ribs 215 are arranged in the depressions 116,
respectively.
[0269] As a result, as explained with reference to the tenth
embodiment, in the case where the cooling apparatus 100 is tilted,
the area of heat transfer from the heat-generating member 10 to the
refrigerant held in the depressions 116 is increased by the ribs
215 and the boiling of the refrigerant is thus promoted.
[0270] The ribs 215 may be each formed as concavities, i.e. in the
shape of U or crescent aperture open to the outer periphery from
the center of the refrigerant bath section 210, as shown in FIGS.
36 and 37. Of course, the depressions 116 are each so shaped as to
be able to accommodate a concave rib 215.
[0271] As a result, in the case where the cooling apparatus 100 is
tilted, the depressions 116 and the concave ribs 215 combine to
hold a greater amount of refrigerant. Thus, the boiling action of
the refrigerant is prevented from being reduced.
[0272] As shown in FIG. 37, the ribs 238 in the refrigerant
diffusion section 230 may be formed similarly as concavities (as
shown in FIG. 36) in such a manner as to open to the outer
periphery from the center in the case where the refrigerant
diffusion section 230 is formed integrally by forging and the
heat-generating member 10a is mounted on the refrigerant diffusion
section 230.
[0273] As a result, in the case where the cooling apparatus 100 is
tilted, the refrigerant in the refrigerant diffusion section 230
can be held in the concave depressions of the ribs 238. Thus, the
heat of the heat-generating member 10a can be transferred to the
refrigerant held by the ribs 238 (the refrigerant can be boiled),
thereby making it possible to cool the heat-generating member 10a
efficiently.
[0274] Further, the intermediate plate 120D of the heat exchange
section 120 may be formed with depressions 128 (corresponding to
the second depressions according to the invention) to increase the
amount of the refrigerant held in a manner similar to the
refrigerant bath section 210 when the cooling apparatus 100 is
tilted.
[0275] (12th Embodiment)
[0276] A 12th embodiment of the invention is explained with
reference to FIGS. 38 to 41. According to the 12th embodiment, as
compared with the eighth embodiment, taking anticorrosiveness
against the cooling water into account, the cooling water is
rendered to flow also through the refrigerant diffusion section
230.
[0277] With the cooling apparatus 100 according to this embodiment,
the inlet pipe 140 and the outlet pipe 150 through which the
cooling water flows in and out are arranged on one side of the heat
exchange section 120 so that the cooling water flows by making a U
turn in the heat exchange section 120. Also, a thin plate having a
sacrificial member on at least one of the surfaces thereof is
arranged between the intermediate plates 120A to 120G making up the
heat exchange section 120 (as proposed in prior art).
[0278] In the refrigerant diffusion section 230, on the other hand,
a rectangular partitioning wall 230d is formed thereby to define a
third space 233A (outside the partitioning wall 230d) through which
the cooling water flows from the second space 122A of the heat
exchange section 120. The second space 122A (cooling water aperture
122) of the heat exchange section 120 is formed at a position
corresponding to the third space 233A, and the cooling water
apertures 122 are formed also in the intermediate plate 120D. In
this way, the second space 122A and the third space 233A
communicate with each other. In the third space 233A, on the other
hand, a partitioning wall 230e is formed to prevent the cooling
water from shorting between the inlet pipe 140 side and the outlet
pipe 150 side.
[0279] Also, a space through which the original refrigerant flows
is formed as the refrigerant diffusion section 230 inside the
partitioning wall 230d. This space corresponds to the first space
121A (refrigerant apertures 121) of the heat exchange section 120,
so that communication is established between the two spaces.
[0280] A sacrificial member 270 for the cooling water is arranged
on the inner surface of the refrigerant diffusion section 230. The
sacrificial member 270 acts as an anode of a metal electrode
against the refrigerant diffusion section 230, as well known, and
is consumed (corroded as a sacrifice) by the electrochemical
reaction thereby to lengthen the anticorrosive life of the mating
refrigerant diffusion section 230. The sacrificial member 270 is
formed of an aluminum material containing a predetermined amount of
zinc to reduce the voltage potential against the aluminum material
forming the refrigerant diffusion section 230.
[0281] The sacrificial member 270 is formed on the refrigerant
diffusion section 230 in the manner shown in FIG. 40. Specifically,
first, the sacrificial member 270 is clad in advance on one surface
of the forging material 280 for the refrigerant diffusion section
230 (FIG. 40A). Next, the assembly is formed forging in such a
manner that the side of the assembly cladded with the sacrificial
member 270 is the inner surface of the refrigerant diffusion
section 230 (FIG. 40B). Further, the end portions of the
sacrificial member 270 to be connected with the heat exchange
section 120 are cut off (FIG. 40C). This is to prevent the
refrigerant or the cooling water from leaking with the progress of
corrosion (sacrificial corrosion) of the connecting portion with
the heat exchange section 120.
[0282] Incidentally, in order to eliminate the step of FIG. 40C,
the sacrificial member 270 may be used in which holes 271 are
punched in press beforehand at positions corresponding to the end
portions of the sacrificial member 270 to be connected with the
heat exchange section 120, as shown in FIG. 41.
[0283] With the cooling apparatus 100 having the refrigerant
diffusion section 230 formed in this way, the heat-generating
member 10a arranged on the refrigerant diffusion section 230 can be
cooled by both the refrigerant (heat transfer to the refrigerant)
and the cooling water flowing in the third space 233A.
[0284] Also, the provision of the sacrificial member 270 in the
refrigerant diffusion section 230 through which the cooling water
flows assures the prior corrosion of the sacrificial member 270
over the entire surface. As a result, the thickness of the
refrigerant container is not required to be increased more than
necessary by taking the local corrosion due to the cooling water
into consideration and the corrosion resistance of the refrigerant
diffusion section 230 against the cooling water is improved.
[0285] The third space 233A in the refrigerant diffusion section
230 can be variously arranged, as shown in FIGS. 42 and 43, in
accordance with the size and position of the heat-generating member
10a mounted on the refrigerant diffusion section 230. FIG. 42 shows
an example in which the third space 233A is arranged on one
longitudinal side of the refrigerant diffusion section 230, and
FIG. 43 shows an example in which the third space 233A is formed
over the entire internal part of the refrigerant diffusion section
230.
[0286] Also, as shown in FIG. 44, the third space may be formed in
the refrigerant bath section 210, in which case the heat-generating
member 10 mounted on the refrigerant bath section 210 can be cooled
by both the refrigerant (heat transfer to the refrigerant) and the
cooling water flowing in the third space in the refrigerant bath
section 210.
[0287] The sacrificial member 270 is preferably arranged over the
entire internal part of the refrigerant bath section 210 as a
porous structure having a plurality of pores 272. In the third
space in the refrigerant bath section 210, therefore, the corrosion
resistance is improved by the sacrificial member 270 while at the
same time promoting the boiling of the refrigerant by increasing
the internal heat transfer area of the refrigerant bath section 210
as shown in FIG. 45.
[0288] Incidentally, the porous structure of the sacrificial member
270 is not limited to the structure having the pores 272 but may be
formed of fiber or meshed material.
[0289] (13th Embodiment)
[0290] A 13th embodiment of the invention is shown in FIG. 48. A
cooling apparatus (boiling and condensing a refrigerant) 100
according to the 13th embodiment has respective features of the
first, the fourth and the seventh embodiments. The cooling
apparatus 100 has a similar construction as those of the
above-mentioned embodiments and, therefore, a detailed explanation
of the construction thereof is not given here. In the cooling
apparatus 100, a cooling water path 150 extends to an upper surface
of the cooling apparatus 100, so that heat-generating members 10
are mounted on a lower surface thereof and the upper surface,
respectively, and can be cooled. Also, communication ports of the
cooling apparatus 100 communicating with outside piping are
provided on side surfaces of a multiplayer structure. Further, a
refrigerant bath section 210 of the cooling apparatus 100 is
manufactured by casting.
[0291] While the invention has been described by reference to
specific embodiments chosen for the purposes of illustration, it
should be apparent that numerous modifications could be made
thereto by those skilled in the art without departing from the
basic concept and scope of the invention.
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