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The collaboration between European Thermodynamics Limited and the military sector underscores ETL’s commitment to providing innovative thermoelectric solutions that cater to the evolving challenges of modern warfare. By working closely with the military and leveraging ETL’s expertise in thermal engineering and bespoke component manufacturing, the armed forces can confidently meet their demanding operational requirements while staying at the forefront of technological advancement. This collaboration ensures that ETL is a valued ally in the pursuit of excellence by our armed forces.
In an era marked by rapid technological advancement, European Thermodynamics Limited (ETL) has worked closely with the military sector, offering cutting-edge thermoelectric engineering solutions and bespoke components. As the military faces an ever-increasing demand for innovative technology to address complex challenges, ETL has become a go-to resource, providing thermal engineering expertise and tailored thermoelectric solutions.
Mobile Telecommunications Equipment
European Thermodynamics (ETL) was approached by a leading global provider of 3G/4G LTE and backhaul mobile telecommunications equipment with a critical challenge: enhancing the thermal performance of their equipment chassis. The complexity of the task was evident as the equipment generated up to 60W of power, and conventional embedded fan cooling was not a viable option. The solution required efficient heat dissipation through natural convection and conduction cooling. This prompted ETL to reevaluate the material initially proposed by the client and explore alternative materials that could better serve the purpose.
The client’s requirements extended beyond a mere redesign; they needed a comprehensive thermal analysis, prototype development, and a supply-ready component for their system. The existing design had untapped potential and inefficient heat distribution.
The Solution:
To achieve cost-effectiveness and significantly enhance heat dissipation, ETL proposed transitioning to an alternative material with excellent die-casting capabilities and superior heat transfer performance. A356 die-cast material, boasting a remarkable thermal conductivity of 160W/m·K, emerged as the ideal choice. ETL’s computational fluid dynamics (CFD) modelling team worked on optimizing the enclosure’s geometry, considering both vertical and horizontal orientations. Collaborating with a die-casting partner, a meticulous design for manufacture (DFM) study followed the CFD modelling, ensuring the assembly was tailored for high-pressure die-casting.
Early challenges, including issues with anodization application, were effectively addressed. A fine electro-plated coating was applied to darken the enclosure, maximizing radiative heat exchange. Minor tooling amendments (T1, T2) were made, and the product was successfully launched. It set a new industry benchmark by significantly increasing output power while relying solely on passive cooling through chassis contact points. This innovation resulted in an impressive mean time between failures (MTBF), elevating the overall system assembly to a new standard in die-cast material product design.
Ongoing Advancements:
ETL’s materials science engineering team is actively engaged in research to further enhance the capabilities of A356 material, pushing its thermal conductivity toward an impressive 180W/m·K.
The Result:
The final prototype, ready for production tooling, represents a remarkable achievement in the optimization of telecommunications equipment chassis. ETL’s innovative approach, coupled with a shift in material composition and meticulous design enhancements, not only met the client’s expectations but also raised industry standards for heat management and performance. This case study showcases ETL’s expertise in tackling complex thermal challenges and underscores its commitment to pushing the boundaries of material science and engineering in telecommunications.
“We worked with European Thermodynamics on the Innovteg project. We would recommend them because they have very high competence in thermoelectric materials, they have highly skilled personnel, and are a flexible organisation to undertake complicated development tasks with.” – Lars Hälldahl, CEO, K-Analys
ETL’s collaboration with the military sector is underpinned by several key factors:
