Liquid Flow-Over Line Replaceable Modules in a Retrofit, Hybrid Integrated Avionics Rack

Foster-Miller proposes a retrofit ingerated avionics rack (IAR) to interchangeably accept conventional line replaceable modules (LRMs), liquid flow through (LFT) modules, and the novel 500 Watt conformal microchannel liquid flow-over (LFO) module. To allow retrofitting the most advanced avionics conceivable, Foster-Miller also proposes conformal microchannel LFO avionics cards, an innovative card-cooling technique allowing 500 Watts heat rejection per LRM without the weight or liquid inventory of direct immersion cooling. The conformal microchannel covering will direct a flow of liquid coolant over the LRM and each electronic component on it. Space needed for the conformal microchannel at the card surface will come from space saved at the card core -- the central aluminum heat sink (or LFT channels) will be eliminated, leaving only a thin, much lighter composite stiffener. The new IAR and the LFO cards will work together to allow densely-packaged electronics upgrades to existing suites of aircraft with minimal impact on the aircraft environmental control system. A successful Phase I will demonstrate feasibility of the proposed IAR and the conformal microchannel LFO LCM. In Phase II we plan to fabricate and test a working prototype with help from Litton-Amecom and Aeroquip.