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- For The Best Receiver Testing, Record And Play Back RealWorld Signals The internet Home of Electronic News, EDN, Electronic Business. Skip navigation ... Novel measurement circuit eases batterystackcell design 1 System Cooling Enhances Electronic Circuit Reliability

Sam Davis | ED Online ID #16766 | September 27, 2007

Effective thermal management must be employed at the component level and the system level (see "Shrewd Thermal Management Helps Defeat The Heat," ED Online 16767). The system may employ good circuit design practices and reliable components, but system reliability will suffer if appropriate temperature controls aren't properly implemented. Available devices, techniques, and software that provide thermal management at the system level include fans, liquid cooling, thermally enhanced circuit boards, and thermal analysis software.

Fans for electronic systems are usually attached directly to a motor's output, without gears or belts. Motors for acpowered fans usually use mains voltage, while motors for dcpowered fans use low voltage, typically 24, 12, or 5 V. Fans for electronic systems usually use brushless dc motors to minimize electromagnetic interference (EMI). Table 1 lists the characteristics of fans employed in electronic systems.

A fan inside an electronic system draws cooler air into the case from the outside, expels warm air from inside, or moves air across a heatsink to cool a particular component. The use of fans and/or other hardware to cool a system is called active cooling. The width and height of these usually square fans are measured in millimeters, with common sizes including 60, 80, 92, and 120 mm. Round fans are also available.

Airflow ratings are in cubicfeet per minute (CFM) for a rotation speed in revolutions per minute (RPM). Fans with a higher CFM rating may produce less noise (in decibels, or dB). Some fans come with an adjustable RPM so they can produce less noise if the system does not need as much airflow. The type of bearing used in a fan affects performance and noise output (Table 2).

System packaging is important when employing fans for cooling. That is, components mounted on the pc board should not restrict air flow, particularly higherpower devices. Heatsink fins should be in line with the flow of air. In addition, if the cooling system uses air filters, they should be accessible for cleaning.

Liquid Cooling
A liquid cooling system usually consists of a cold plate, pump, heat exchanger, and pipes or hoses (Fig. 1). This thermal management system employs a pump to move a continuously flowing liquid in a loop that cools a pc board. In operation, the system's pc board generates heat that transfers to a thermally conductive cold plate, heating the liquid coolant flowing through it.

This heated liquid coolant is then pumped through the heat exchanger, which moves the heat from the liquid coolant to either the ambient air or, in the case of a liquidtoliquid heat exchanger, to another liquid coolant. The cooled liquid coolant then flows through the pipes or hoses back to the cold plate. Most liquid coolants also use a small amount of additives to inhibit corrosion and lubricate the pump.

Cold plates come in different forms. One approach consists of copper or stainless steel tubes pressed into a channeled aluminum extrusion. A second technique uses flat aluminum or copper tubes with an internal fin that increases their performance. A third type consists of two aluminum or copper plates metallurgically bonded together with an internal fin.

Coolant compatibility with a wetted surface is a factor in selecting a specific coldplate technology. A copper cold plate is compatible with water and most common coolants. Aluminum performs well with an ethylene glycol/water mixture, oils, and other fluids, but is not compatible with untreated water. Stainless steel is necessary when using deionized water or other corrosive fluids. Table 3 lists the possible problems that can occur with liquid cooling systems and the appropriate corrective measures.

Another liquidbased approach to combat heat is spray cooling with pinholesized openings that shower a semiconductor with droplets of a special liquid that won't damage electronic circuits. Cooling occurs in two ways. Heat is thought to disperse most efficiently when bubbles of vapor form as the coolant evaporates from the surface in a process known as boiling. The coolant also removes heat by simply warming as it flows over the semiconductor toward a drain. The liquid and vapor are then collected and recycled, and a heat exchanger with a slowmoving fan dissipates the heat they carry.

Thermally Enhanced Circuit Boards
Some electronic systems, such as power modules, exhibit high power and small size where it's not convenient to use a heatsink. These modules usually carry high current and need a high voltageisolation rating. In some applications, they may have to operate over a temperature range that reaches up to 200¡(ãà
°C.

One type of thermally enhanced circuit board is the directbond copper (DBC) substrate commonly used in power modules. It consists of a ceramic base with a sheet of copper bonded to one or both sides of the ceramic material. In the manufacturing process, a copperoxygen eutectic bonds to the copper and ceramic base. The top copper layer can be chemically etched in a manner similar to conventional printedcircuit technology. The bottom layer is usually soldered to a heat spreader.

One type of DBC uses alumina (Al2O3) as the ceramic base because of its relatively low cost, though it isn't a good thermal conductor and is relatively brittle. The aluminumnitride (AlN) DBC is more expensive than alumina, but has better thermal performance. Beryllium oxide (BeO) can also be used for the ceramic base, but is usually avoided because of its toxicity.

A major advantage of DBC substrates is their low coefficient of thermal expansion (CTE), which is close to that of silicon. This ensures relatively good thermal cycling performance for semiconductors mounted on the substrate.

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Written by Philip Buonpastore
Monday, 10 December 2007

SAN JOSE, CA Nuvation announced today that it has opened a design center in Shanghai, China. The company reports that the new design center will increase the company¡(¯s offshore capabilities, localize design for manufacturing, and allow access to the Chinese marketplace.

"Nuvation has always been recognized by our customers for engineering excellence in new product development from concept to production," stated Michael Worry, CEO. ¡(°à
h,We are thrilled with the talent joining our Shanghai team and are looking forward to rapid growth in this facility."Medical System Integrator
System Assembly Mfg Services Long Life Cycle ISO9000
www.corvalentmedical.com
Electronic Manufacturing
PCA COB BoxBuild Custom Displays Design & NPI, ISO9001 TS16949 RoHS
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ZhuHai Southern Software Park Development Co.,Ltd
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Beijing Huada Test Co.,Ltd(BHTC)

China Electronics Corporation
State Development & Investment Corporation
National Development and Reform Commission
Ministry of information Industry
China Semiconductor Industry Association
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Electronic City
ChinaICIP
Shanghai National Integrated Circuit Design Industrial Center

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Arc flash calculator, short circuit analysis. Power distribution system balanced symmetrical and unbalanced short circuit analysis needed for arc flash protection boundary, incident energy calculation, selection of electrical equipment, circuit protection devices. Bolted 3phase, line to earth, double phase to ground, phase to phase, single phase open faults through zero and above zero impedance can be resolved.
Bender Inc. Industrial protection for measuring voltage, current, phase loss, phase reversal, frequency and other conditions in AC and DC systems up to 690V.
Bill Switchgear Manufactures circuit breakers, circuit protection and control.
BONEGA Velkoobchod spol. s.r.o. Development, production and distribution of electrical installation devices, miniature circuit breakers, residual current devices, and switches.
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Dianxing Electrical Appliance Industry Co., Ltd. AC voltage regulator manufacturer and exporter in China that supplies AC voltage regulators.
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Ferraz Shawmut, Inc. Develops and manufactures fuses, blocks and switches. Product specifications, news, and details of employment opportunities.
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Fusetek Canadian fuse manufacturer.
Gamma Fuses Distributor based in Florida USA, Gamma is a specialist fuse supplier of industrial fuses, and accessories.
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Hinode Electric co., Ltd. Manufacturer of semiconductor fuses.
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Jaker Electric Co., Ltd. Manufacturer of load break switch, power fuse mounting base. From Taiwan.
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Lexor Electronic Laboratories Ltd. Delay line and filter network manufacturers.
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MD Semiconductor, Inc. High current surge, transient voltage suppression device manufacturer.
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MEM Low Voltage Products Manufacturers of circuit breakers, switchgear, fusegear, low voltage switchboards, capacitors, TVSS and motor control gear.
Merlin Gerin The electrical distribution information website for Merlin Gerin brand of Schneider Electric.
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Orion Italia Manufacturer of electrical measure and protection relays.
Poco Sales Inc. US distributor of circuit breakers by Airpax, CBI, Eaton, ETA, Carlingswitch, Heinemann, Schurter. Featuring circuit breaker specifications, engineering drawings and design guides.
Portex. Manufacturers and exporters of thermal and current controls of electrical equipment.
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Rebeck Enterprise Co., Ltd. Manufacturer of motor, circuit breaker, contactor, transformer, electrical/ HVAC components, relay, motor starter.
Reuter Hanney, Inc. Provider of electrical testing, power quality studies, system design and coordination services to commercial, industrial and institutional facilities throughout the midAtlantic region.
Rowe Hankins Components Ltd Distributor of circuit protection devices, switches,hydraulic,magnetic circuit breakers, switchgear, traction components and measuring systems.
Safe Line S.L. Manufactures protection devices for overvoltage, low voltage, surge arrester and lightning. From Spain.
Safety Design, Inc. US supplier of a lockout system that can be retrofitted to any electrical panel or circuit breaker.
Sankosha USA Manufacturer of gas tube surge arresters and gas discharge tubes for over voltage surge protection from lightning and other transient voltages.
Schurter, Inc. Manufacturer of circuit protection devices including fuses, holders, circuit breakers for equipment, connectors, power entry modules, cordsets and switches.