Cooling plate with uniform airflow

Abstract

A cooling plate assembly includes: a wall surrounding an effective volume adjacent to an inlet air chamber; the wall includes an inlet opening at one end on the top side of the inlet air chamber and an air chamber opening between the inlet air chamber and the effective volume. It also includes a baffle that partially separates the inlet air chamber from the effective volume. The baffle is structurally configured to preferentially redirect flow from the inlet air chamber to the effective volume.

Description

Background Technology

[0001] This invention relates to the fields of electrical, electronic, thermal, mechanical and computer science, and more specifically, to an apparatus for cooling computer components.

[0002] One device for cooling computer components is a "cooling plate," which is a conductive heat sink that comes into direct contact with the component or through an intermediate thermal interface material (TIM). The cooling plate can be a solid metal block, typically with fins for enhanced air cooling; or it can be a hollow structure through which coolant (e.g., water) flows from an inlet to an outlet.

[0003] Typically, in heat exchangers, it is desirable to provide air chambers on each side of the effective (e.g., plate) volume of the heat exchanger; these chambers are wide and thick enough to establish uniform pressure (isobaric) conditions that produce substantially uniform flow through the effective region. However, in typical cooling plate applications, the size of the air chambers is limited by the size and spacing of the components to be cooled. Often, the cooling plate air chambers are not large enough to establish conditions close enough to isobaric to produce the desired flow uniformity. Summary of the Invention

[0004] The principle of this invention provides a technique for adjusting the transition section of the cooling plate air chamber.

[0005] According to one aspect, an exemplary cooling plate assembly includes a wall surrounding an effective volume of an inlet air chamber, and a baffle partially separating the inlet air chamber from the effective volume. The wall includes an inlet opening at one end of the inlet air chamber and an air chamber opening between the inlet air chamber and the effective volume. The baffle is structurally configured to preferentially redirect flow from the inlet air chamber to the effective volume.

[0006] According to another aspect, an exemplary cooling plate assembly includes: a top portion having an inlet opening extending through the top portion; a bottom portion surrounding an effective volume and an inlet chamber on one side of the effective volume, wherein the inlet chamber overlaps with the inlet opening; and a deflector protruding from the outer wall of the inlet chamber toward the effective volume. In some cases, the deflector near the bottom surface of the inlet chamber may protrude closer to the inlet opening than the deflector near the top surface of the inlet chamber.

[0007] According to another aspect, an exemplary cooling plate assembly includes: a top plate having an inlet opening through the top plate; a bottom plate; and a stack of N intermediate plates sandwiched between the top plate and the bottom plate and attached to each other and to the top and bottom plates, each intermediate plate having a central opening, the central openings of the stack of intermediate plates overlapping to define an internal volume surrounded by the top plate, the bottom plate, and the intermediate plates. The internal volume includes an effective volume, an inlet chamber on one side of the effective volume, and an inlet opening overlapping the inlet chamber. This aspect also includes deflectors projecting from the outer wall of the inlet chamber toward the effective volume. The deflectors near the bottom plate project further toward the effective volume than the deflectors near the top plate, such that at the lowest intermediate plate, the deflector projectes a distance P from the outer wall of the inlet chamber, and at the highest intermediate plate, the deflector projectes a second distance P / N from the outer wall of the inlet chamber, and at each intermediate plate rising from the lowest plate to the highest plate, the deflector projectes less than P.

[0008] According to another aspect, a cooling plate device is constructed via an exemplary process comprising: obtaining an initial cooling plate design including: an effective volume; an inlet chamber adjacent to the effective volume and connected to the effective volume through an opening in the chamber; and an inlet opening overlapping the inlet chamber; performing a computational fluid dynamics analysis of the initial cooling plate design; identifying simulated flow in a first portion of the effective volume near the inlet opening, the simulated flow being greater than simulated flow in a second portion of the effective volume away from the inlet opening; and generating an improved cooling plate design by introducing a blocking member that partially separates the inlet chamber from the effective volume into the initial cooling plate design. The blocking member blocks the entire height or a portion of the height of the chamber opening adjacent to the inlet opening, and blocks a decreasing portion of the height of the chamber opening as it extends away from the inlet opening along the chamber opening. The blocking member blocks the chamber opening more near its bottom side than near its top side. Further steps include performing computational fluid dynamics analysis on the improved cooling plate design; identifying the simulated flow in the first part and the simulated flow in the second part within ten percent of the average flow rate across the air chamber opening; and manufacturing the cooling plate assembly according to the improved cooling plate design.

[0009] According to another aspect, a method for enhancing the flow uniformity through an effective volume of a cooling plate device includes: introducing coolant into an inlet chamber of the cooling plate device through an inlet opening; blocking a portion of the coolant from flowing into a first portion of the effective volume from the inlet chamber, wherein the first portion is close to the inlet opening; and deflecting a portion of the coolant to flow into a second portion of the effective volume from the inlet chamber, wherein the second portion is downstream of the first portion from the inlet chamber.

[0010] In view of the above, the technology of the present invention can provide substantially beneficial technical effects. For example, one or more embodiments provide one or more of the following:

[0011] Enhanced flow profile through the effective volume of the cooling plate.

[0012] Enhanced heat transfer within the effective volume of the cooling plate.

[0013] Improved flow uniformity through the effective volume of the cooling plate.

[0014] These and other features and advantages of the invention will become apparent from the following detailed description of illustrative embodiments of the invention, which are read in conjunction with the accompanying drawings. Attached Figure Description

[0015] Figure 1 A cross-sectional view of a cooling plate according to the prior art is shown.

[0016] Figure 2 A first cross-sectional view of a cooling plate with an adjustable air chamber according to an exemplary embodiment is depicted.

[0017] Figure 3 Depicting Figure 2 The second cross-sectional view of the cooling plate shown.

[0018] Figure 4 Depicting Figure 3 Some dimensions of the flow barrier shown.

[0019] Figure 5 Depicting Figure 2 and Figure 3 The third cross-sectional view of the cooling plate shown.

[0020] Figure 6 Described Figure 5 Some dimensions of the flow deflector shown.

[0021] Figure 7 Depicting Figure 5 Some dimensions of the flow deflector shown. Detailed Implementation

[0022] Figure 1A cross-sectional view of a prior art cooling plate 100 is shown, comprising a top portion 102 and a bottom portion 104, with an inlet nozzle 106 and an outlet nozzle (not shown to avoid confusion) connected at the top to the top and bottom portions 102 and 104. The top and bottom portions 102 and 104 surround an inlet chamber 108, an effective volume 110, and an outlet chamber 112. Note the smooth, continuous planar outer walls 116, 118 of the inlet and outlet chambers 108 and 112. Also note the opening of the effective volume 110 along the entire length of the inlet and outlet chambers 112. Individual features such as plates, pins, or sieves exist within the effective volume 110, but are not shown to avoid confusion; as those skilled in the art will understand, these individual features of the effective volume define the path of fluid flow from the inlet chamber 108 to the outlet chamber 112 and generally provide extended surfaces to enhance heat transfer.

[0023] In conventional cooling plates, the flow from the cooling plate inlet typically enters the top surface of the inlet chamber at a considerable angle (e.g., greater than 70°) to the length of the inlet chamber. This flow impacts the bottom surface of the inlet chamber and "splashes," causing the coolant flow across the effective volume of the cooling plate to become uneven. For example, in a conventional cooling plate, the coolant flow rushes into a first portion of the effective volume near the inlet opening, partially bypasses a second portion of the effective volume downstream of the first portion, and then enters a third portion of the effective volume downstream of the second portion.

[0024] Embodiments of the invention advantageously remedy at least some of such flow nonuniformity by providing the following to improve the flow uniformity through the effective volume: (i) a flow deflector near the inlet opening to reduce excessive flow through the first portion of the effective volume; and (ii) a flow deflector adjacent to the second portion of the effective volume (slightly upstream in some embodiments) to enhance the flow through the second portion.

[0025] Figure 2 A first cross-sectional view is depicted of a cooling plate 200 having walls including a top portion 202 and a bottom portion 204, which surrounds an inlet chamber 208 leading to an effective volume 210, which in turn leads to an outlet chamber 212. Individual features such as plates, pins, or sieves are not shown within the effective volume 210 to avoid confusion; as those skilled in the art will understand, such features define the path of fluid flow from the inlet chamber 208 to the outlet chamber 212 and generally provide extended surfaces to enhance heat transfer. The top portion 202 may be a single plate or blank segment or multiple stacked plates, while the bottom portion 204 may be a single plate or blank segment or multiple stacked plates 230 (see reference). Figure 5(Further description). The inlet nozzle 206 is connected to the inlet chamber 208 via the top portion 202. In one or more embodiments, the outlet chamber 212 is symmetrical to the inlet chamber 208, such that the flow through the cooling plate 200 can be easily reversed without diminishing the effectiveness of the exemplary cooling plate. In one or more embodiments, the baffle 220 (further reference) Figure 3 (Description) The air chamber opening 221 is located between a portion of the inlet air chamber 208 and a portion of the effective volume 210 (see description). Figure 3 The inlet air chamber 208 includes a first region 234, a second region 236, and a third region 238. Under normal operation, the third region is downstream of the second region, and the second region is downstream of the first region.

[0026] Also refer to Figure 3 It depicts a second cross-sectional view of the cooling plate 200, with an inlet opening 209 formed in the top portion 202 for receiving an inlet nozzle (206, in Figure 2 (As shown in the diagram). The baffle 220 partially separates the inlet air chamber 208 from the effective volume 210. The baffle 220 is disposed adjacent to the inlet transition portion 207, and the inlet nozzle (206, Figure 2 (As shown in the diagram) It is typically attached to the inlet transition via inlet opening 209. The baffle is structurally configured to preferentially redirect flow from the inlet chamber into the effective volume such that the flow “splashing” from the inlet opening onto the bottom surface of the inlet chamber does not enter too much of the effective volume in the first portion near the inlet opening and not too little in the second portion of the effective volume away from the inlet opening. For example, in one or more embodiments, the baffle 220 is structurally configured to preferentially redirect flow because it includes a plurality of fingers 222 of varying lengths, wherein the fingers on the top portion 202 or near the top surface of the inlet chamber 208 are shorter than the fingers on the bottom plate 204 or near the bottom surface of the inlet chamber 208 (extending less far from the inlet transition 207). For example, in one or more embodiments (as shown in the diagram) Figure 4As shown in the diagram, the length of the lowest finger is L, and the length from each lower finger to the next higher finger decreases (L / number of fingers N), such that for three fingers, each higher finger is 1 / 3 shorter than the longest / lowest finger, and the length of the highest finger is L / N, or 1 / 3 of the length of the lowest finger. One effect of the different finger lengths is that the obstruction 220 near the top portion 202 restricts the flow into the effective volume 210 less than it does near the bottom portion 204. In operation of the cooling plate 200, the coolant flow near the bottom portion 204 has a higher velocity toward the effective volume 210 than the coolant flow near the top portion 202, because the impact of the flow from the nozzle onto the bottom surface of the inlet chamber can generate a high-speed flow along that surface. This flow forces more coolant into the effective area near the nozzle than desired, particularly near the bottom surface of the inlet chamber. Typically, the baffle 220 helps guide the high-speed coolant flow away from the first region of the effective volume 210 closest to the inlet transition 207, and downstream along the inlet air chamber 208 toward regions 236 and 238 of the effective volume 210, which could otherwise result in "insufficient flow".

[0027] In one or more embodiments, the size of the baffle 220 is obtained by performing a CFD analysis on the flow from the inlet chamber 208 into the effective volume 210 using computational fluid dynamics (CFD) software starting with a predetermined initial sieve density (e.g., at least 100 elements spanning the chamber opening 221 in a finite element computational sieve). In one or more embodiments, the sieve size is reduced (i.e., more, smaller elements) until the maximum and minimum velocity values ​​obtained with the smaller sieve size remain within 5% of the values ​​obtained with the next larger sieve size. The size of the baffle is varied until the CFD analysis produces a uniformity across the chamber opening 221 for the flow at a predetermined percentage (e.g., 10%) of the average flow rate through the chamber opening 221. Suitable CFD software is familiar to those skilled in the art; for example, ANSYS FLENT or ANSYS CFX software, available by way of example and not limitation, from Ansys, Inc., Canonsburg, Pennsylvania, USA. Those skilled in the art are familiar with constructing suitable sieves for finite element analysis, with appropriate types of cells and sieve fineness, including more sieve detail in regions of higher flow gradients, and iteratively achieving a suitable sieve size.

[0028] Still referencing Figure 3 The outer wall 216 of the inlet chamber 208 includes a deflector 224 projecting from the outer wall toward the effective volume 210, which is typically aligned near a second region of the effective volume. See also... Figure 5In one or more embodiments, the outer wall 217 of the outlet chamber 212 includes a deflector 225. This outlet deflector 225 guides air from the effective volume 210 (see [link to relevant documentation]). Figure 2 and 3 The flow enters the outlet transition section 227, which leads to the outlet nozzle 228 via the outlet opening 229.

[0029] Refer again Figure 3 In one or more embodiments, the deflector 224 further protrudes toward the effective volume 210 near the bottom plate 204 or bottom surface of the inlet air chamber, and not far toward the effective volume near the top plate 202 or top surface of the inlet air chamber. For example, in one or more embodiments (such as...) Figure 6 As shown, the protruding distance varies linearly with the height of deflector 224, with the lowest point protruding at a distance P and the highest point protruding at a distance (P / N), where N is the distance from the bottom to the top of the deflector, expressed in layers or dimensions. Therefore, in one or more embodiments, deflector 224 has an inclined surface toward the effective volume 210. This is again related to the higher velocity flow located near the bottom surface. However, in one or more embodiments, deflector 224 protrudes the same distance toward the effective volume over its entire height, and therefore it is not inclined. In one or more embodiments, the maximum protrusion of deflector 224 may be separated from the inlet transition 207 proportionally to the size of the protrusion, such that a larger portion of the deflector protrudes further from the inlet transition. That is, (as shown...) Figure 7 As shown, the deflector 224 at each layer i can protrude a distance xi from the centerline of the inlet opening 209, where xi is proportional to Pi. However, in one or more embodiments, the maximum protrusion of the deflector 224 is at the same distance from the inlet transition 207 at each height, regardless of the size of the maximum protrusion. Therefore, in one or more embodiments, the maximum protrusion of the deflector 224 is at the same distance from the inlet transition 207 near the top portion 202 as it is near the bottom portion 204.

[0030] In one or more embodiments, as the deflector 224 protrudes further toward the effective volume 210, the deflector begins to protrude closer to the inlet transition 207. Therefore, the deflector 224 extends closer to the inlet transition 207 of the bottom portion 204 compared to its protrusion toward the top portion 202. For example, in one or more embodiments, at each layer i of the deflector, the distance Yi from the centerline of the inlet opening 209 to the starting point of the deflector 224 varies proportionally with (P-Pi / P), where Pi is the distance the deflector 224 protrudes at layer i, and P is the maximum distance protruding from the outer wall of the inlet chamber 208.

[0031] Refer again Figure 5In one or more embodiments, the cooling plate 200 between the top plate 202 and the bottom plate 204 is composed of intermediate layers 230, each intermediate layer having a thickness between 0.25 mm and 0.5 mm (e.g., approximately 0.3 mm). In one or more embodiments, there are six intermediate layers 230, such that the internal height of the cooling plate 200 is between 1.5 mm and 3.0 mm (e.g., approximately 1.8 mm) deep, and the thickness of the cooling plate 200 is between 2.0 mm and 4.0 mm (e.g., approximately 2.5 mm). In one or more embodiments, the cooling plate 200 includes an extended surface (e.g., a pin, sheet, or sieve) within the effective volume 210. For example, in one or more embodiments, the cooling plate 200 has vertical sheets in the effective volume 210, formed by cuts in the intermediate layers 230 or by machining or forming as an extension of the bottom plate 204. Any suitable extended surface can be used; to avoid confusion, the sheet is omitted in the accompanying drawings, but the sheet typically extends from the top and bottom plates (usually vertically) and defines flow channels between the air chambers.

[0032] Based on the discussion so far, it will be understood that, generally speaking, an exemplary cooling plate device according to one aspect of the invention includes a top plate 202 having an inlet opening 209 therethrough; a bottom plate 204; and a stack of intermediate plates 230 sandwiched between and connected to each other and to the top and bottom plates. Each intermediate plate has a cutout defining an inlet air chamber 208 and an outlet air chamber 212 surrounded by the top plate, bottom plate, and intermediate plates. An internal volume 205 includes an effective volume 210, an inlet air chamber 208 on one side of the effective volume, and an inlet transition 207 overlapping the inlet opening. The exemplary device 200 also includes a baffle 220 separating the inlet air chamber 208 from the effective volume 210, wherein the baffle includes a plurality of fingers 222 at different heights of the stack, and the higher fingers in the stack provide smaller spacing than the lower fingers in the stack. In addition to the stacking of plates, other methods, such as machining, 3D printing technology, etc., can be used, in which case the “steps” mentioned in the plates can be “smoothed”. “

[0033] In one or more embodiments, the exemplary device further includes a deflector 224 projecting from the outer wall 216 of the inlet chamber 208 toward the effective volume 210. In one or more embodiments, the deflector near the base plate 204 projects closer to the inlet transition 207 than the deflector near the top plate 202. In one or more embodiments, the deflector near the base plate projects further toward the effective volume 210 than the deflector near the top plate.

[0034] In one or more embodiments, the inlet chamber in normal operation surrounds a first region 234 immediately adjacent to the inlet transition, a second region 236 downstream of the first region, and a third region 238 downstream of the second region. A deflector 224 is located in the second region 236, where it facilitates the flow of coolant toward the effective volume 210.

[0035] In one or more embodiments, the thickness of each intermediate plate 230 is between 0.2 mm and 0.5 mm, and the depth of the internal volume 205 is between 1.5 mm and 3.0 mm.

[0036] According to another aspect, an exemplary cooling plate assembly 200 includes a top plate having an inlet opening 209 therethrough; a bottom plate 204; and a stack of intermediate plates 230 sandwiched between and connected to each other and to the top and bottom plates. Each intermediate plate has a central opening. The central openings of the stack of intermediate plates overlap to define an internal volume 205 surrounded by the top plate, bottom plate, and intermediate plates. The internal volume 205 includes an effective volume 210, an inlet chamber 208 on one side of the effective volume, and an inlet transition 207 overlapping the inlet opening. A deflector 224 protrudes from the outer wall 216 of the inlet chamber 208 toward the effective volume 210. The deflector 224 near the bottom plate 204 protrudes closer to the inlet transition 207 than the deflector near the top plate 202. In one or more embodiments, the deflector near the bottom plate protrudes further toward the effective volume than the deflector near the top plate. In one or more embodiments, the device further includes a barrier 220 that separates the inlet air chamber 208 from the effective volume 210. The barrier includes a plurality of fingers 222 at different heights in the stack, with the higher fingers in the stack restricting the flow less than the lower fingers in the stack.

[0037] According to another aspect, an exemplary cooling plate assembly includes a top portion and a bottom portion, the top portion having an inlet opening therethrough, and the bottom portion surrounding an internal volume enclosed by the top portion. In some embodiments, the top and bottom may be integrally manufactured, for example, by 3D printing or other additive manufacturing. In other embodiments, the bottom portion may include a plurality of stacked plates, i.e., a base plate and one or more intermediate plates. The internal volume includes an effective volume, an inlet chamber on one side of the effective volume, and an inlet transition overlapping the inlet opening. The inlet chamber includes a deflector projecting from the outer wall of the inlet chamber toward the effective volume, wherein the deflector projects further toward the effective volume near the bottom of the internal volume than it does near the top plate. The inlet chamber, in normal operation, surrounds a first region immediately adjacent to the inlet transition, a second region downstream of the first region, and a third region downstream of the second region.

[0038] In one or more embodiments, the deflector protrudes closer to the inlet transition near the bottom of the internal volume than near the top plate. In one or more embodiments, the internal volume is 1.5 to 3.0 millimeters (mm) deep.

[0039] In one or more embodiments, the "top" plate should be understood as the plate into which the nozzles enter for a given air chamber region. In some cases, however, two nozzles may enter the same plate, which is not necessary. In fact, the nozzles may also enter the ends of the cooling plate, or they may enter opposite plates.

[0040] According to another aspect, an exemplary cooling plate assembly surrounds an internal volume. The internal volume includes an effective volume, an inlet chamber on one side of the effective volume, and an inlet opening overlapping the inlet chamber. A baffle restricts the flow from the inlet chamber into the effective volume. The portion of the baffle near the top plate restricts the flow less than the portion of the baffle away from the top plate.

[0041] In one or more embodiments, the exemplary device further includes a deflector that protrudes from the outer wall of the inner chamber toward the effective volume. The deflector protrudes further toward the effective volume near the bottom of the inner volume than it does near the top plate. In one or more embodiments, the deflector protrudes closer to the inlet transition near the bottom of the inner volume than it does near the top plate.

[0042] According to another aspect, an exemplary cooling plate device includes a wall surrounding an effective volume adjacent to an inlet air chamber, and a baffle partially separating the inlet air chamber from the effective volume. The wall includes an inlet opening at one end of the inlet air chamber and an air chamber opening between the inlet air chamber and the effective volume. The baffle is structurally configured to preferentially redirect flow from the inlet air chamber into the effective volume. In one or more embodiments, the baffle obstructs the air chamber opening more near the bottom side than near the top side, and / or obstructs the air chamber opening more at an end of the inlet air chamber near the inlet opening than at a location further away from the inlet opening, or the baffle obstructs the air chamber opening more near the inlet opening than at a location further away from the inlet opening, and obstructs the air chamber opening more near the bottom side than near the top side.

[0043] In one or more embodiments, the barrier includes N fingers extending from the inlet opening along the inlet air chamber, with the lowest finger being the longest and the highest finger being the shortest. In one or more embodiments, the length of the lowest finger is L, the length of the highest finger is L / N, and each finger rising from the lowest to the highest finger is L / N shorter than the next lower finger.

[0044] In one or more embodiments, the blocking member includes a plurality of fingers extending from the bottom side of the air chamber opening toward the top side of the air chamber opening, with the longest finger closest to the inlet opening and the shortest finger furthest from the inlet opening. In one or more embodiments, each finger is separated from its adjacent finger by a certain gap.

[0045] In one or more embodiments, the barrier separates the inlet air chamber from at least 10 percent of the effective volume of the portion spanning the air chamber opening, wherein this portion is at least 10 percent of the area of ​​the air chamber opening. In one or more embodiments, the barrier separates the inlet air chamber from the effective volume of at least 30 percent of the portion of the air chamber opening.

[0046] The blocking element can be continuous. The blocking element can be divided into sections. The blocking element may include perforations.

[0047] One or more embodiments further include a deflector projecting from the outer wall of the inlet chamber toward the effective volume. In one or more embodiments, the deflector near the bottom surface of the inlet chamber projects closer to the inlet opening than the deflector near the top surface of the inlet chamber. In one or more embodiments, the deflector near the bottom surface of the inlet chamber projects further toward the effective volume than the deflector near the top surface of the inlet chamber. In one or more embodiments, the deflector adjacent to the bottom surface projects a distance P, and the deflector adjacent to the top surface projects a distance P / N, where N is a measure of the height of the inlet chamber. In one or more embodiments, the inlet chamber, in normal operation, surrounds a first region immediately adjacent to the inlet opening, a second region downstream of the first region, and a third region downstream of the second region, and the deflector is located in the second region.

[0048] In one or more embodiments, the wall comprises a stack of a top plate, a bottom plate, and intermediate plates between the top and bottom plates, wherein the thickness of each intermediate plate is between 0.2 mm and 0.5 mm, and the depth of the internal volume is between 1.5 mm and 3.0 mm. As discussed and illustrated, the "top" plate includes an inlet opening in some embodiments.

[0049] According to another aspect, an exemplary cooling plate assembly includes: a top portion having an inlet opening therethrough; and a bottom portion surrounding an effective volume and an inlet chamber on one side of the effective volume. The inlet chamber overlaps with the inlet opening. A deflector protruding from the outer wall of the inlet chamber toward the effective volume is also included. In some cases, the deflector near the bottom surface of the inlet chamber protrudes closer to the inlet opening than the deflector near the top surface of the inlet chamber. Typically, the deflector and the deflector are configured as a function of coolant characteristics and operating conditions (e.g., using computational fluid dynamics as described herein).

[0050] In one or more embodiments, the deflector near the bottom surface protrudes further toward the effective volume than the deflector near the top surface (this feature can typically be provided separately from or together with the feature that the deflector near the bottom surface of the inlet chamber protrudes closer to the inlet opening than the deflector near the top surface of the inlet chamber).

[0051] In one or more embodiments, the inlet chamber, during normal operation, surrounds a first region immediately adjacent to the inlet opening, a second region downstream of the first region, and a third region downstream of the second region, with the deflector located in the second region.

[0052] One or more embodiments further include a baffle that partially separates the inlet chamber from the effective volume. The baffle blocks the entire height of the chamber adjacent to the inlet opening and blocks a decreasing portion of the chamber's height advancing away from the inlet opening along the chamber opening, and the baffle blocks the chamber opening more near the bottom side than near the top side. In one or more embodiments, the baffle separates the inlet chamber from at least 10 percent of the effective volume across the chamber opening, wherein this portion is at least 10 percent of the area of ​​the chamber opening.

[0053] In one or more embodiments, the bottom portion includes a base plate opposite to the top portion and at least one intermediate plate attached between the base plate and the top portion, wherein the thickness of each intermediate plate is between 0.2 mm and 0.5 mm, and the depth of the internal volume is between 1.5 mm and 3.0 mm.

[0054] According to another aspect, an exemplary cooling plate assembly includes: a top plate having an inlet opening therethrough; a bottom plate; and a stack of N intermediate plates sandwiched between and attached to each other and to both the top and bottom plates. Each intermediate plate has a central opening. The central openings of the stack of intermediate plates overlap to define an internal volume surrounded by the top plate, bottom plate, and intermediate plates. The internal volume includes an effective volume, an inlet chamber on one side of the effective volume, and an inlet opening overlapping the inlet chamber. This aspect also includes deflectors projecting from the outer wall of the inlet chamber toward the effective volume. The deflectors closer to the bottom plate project further toward the effective volume than the deflectors closer to the top plate, such that at the lowest intermediate plate, the deflector projects a distance P from the outer wall of the inlet chamber, while at the highest intermediate plate, the deflector projects a second distance P / N from the outer wall of the inlet chamber, and at each intermediate plate rising from the lowest to the highest plate, the deflector projects less than P.

[0055] According to another aspect, a cooling plate device is constructed through an exemplary process comprising: obtaining an initial cooling plate design including an effective volume, an inlet chamber adjacent to and connected to the effective volume via a chamber opening; and an inlet opening overlapping the inlet chamber; performing a computational fluid dynamics analysis of the initial cooling plate design; identifying simulated flow in a first portion of the effective volume near the inlet opening, the simulated flow being greater than simulated flow in a second portion of the effective volume away from the inlet opening; and generating an improved cooling plate design by introducing a blocking member that partially separates the inlet chamber from the effective volume into the initial cooling plate design. The blocking member blocks the entire height of the chamber opening adjacent to the inlet opening and blocks a decreasing portion of the height of the chamber opening extending away from the inlet opening along the chamber opening. The blocking member blocks the chamber opening more near its bottom side than near its top side. Further steps include performing computational fluid dynamics analysis on the improved cooling plate design; identifying the simulated flows in the first and second portions within ten percent of the average flow rate across the air chamber opening; and manufacturing the cooling plate assembly according to the improved cooling plate design. In one or more embodiments, manufacturing the cooling plate assembly includes constructing an intermediate layer on top of a base plate using additive manufacturing. In one or more embodiments, manufacturing the cooling plate assembly includes bonding an intermediate plate to the base plate.

[0056] According to another aspect, a method for enhancing the flow uniformity through an effective volume of a cooling plate assembly includes: introducing coolant into an inlet chamber of the cooling plate assembly through an inlet opening; blocking a portion of the coolant from flowing into a first portion of the effective volume from the inlet chamber, wherein the first portion is near the inlet opening; and deflecting a portion of the coolant to flow into a second portion of the effective volume from the inlet chamber, wherein the second portion is downstream of the first portion from the inlet chamber. In one or more embodiments, the coolant is blocked and deflected more near the bottom surface of the inlet chamber than near the top surface of the inlet chamber.

[0057] Various embodiments of the invention have been described for illustrative purposes, but are not intended to be exhaustive or limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein has been chosen to best explain the principles of the embodiments, their practical application, or improvements to existing technologies on the market, or to enable others skilled in the art to understand the embodiments disclosed herein.

Claims

1. A cold plate apparatus comprising: a wall surrounding an active volume adjacent to an inlet plenum, wherein the wall includes an inlet opening at one end of a top side of the inlet plenum and a plenum opening between the inlet plenum and the active volume, wherein the wall includes a stack of a top plate, a bottom plate, and at least three intermediate plates between the top plate and the bottom plate; and a blocker partially separating the inlet plenum from the active volume, wherein the blocker is structurally configured to preferentially redirect flow from the inlet plenum into the active volume, the blocker blocking the plenum opening more near a bottom side of the plenum opening opposite the inlet opening than near a top side of the plenum opening adjacent the inlet opening; wherein portions of the at least three intermediate plates form a deflector that protrudes from an outer wall of the inlet plenum toward the active volume, and wherein a bottommost of the at least three intermediate plates protrudes farther toward the active volume than a topmost of the at least three intermediate plates.

2. The apparatus of claim 1, wherein, the blocker includes N fingers extending from the inlet opening along the inlet plenum, a lowest finger being longest and a highest finger being shortest.

3. The apparatus of claim 2, wherein, a length of the lowest finger is L, a length of the highest finger is L / N, and each finger rising from lowest to highest is shorter than a next lower finger by L / N.

4. The apparatus of claim 1, wherein, at least ten percent of the blocker separates the inlet plenum from the active volume across a portion of the plenum opening, wherein the portion is at least ten percent of an area of the plenum opening.

5. The apparatus of claim 1, wherein: the inlet plenum, under normal operation, encloses a first region immediately adjacent to an inlet transition, a second region downstream of the first region, and a third region downstream of the second region, and the deflector is in the second region.

6. The apparatus of claim 1, wherein, a thickness of each intermediate plate is between 0.2 millimeters (mm) and 0.5 millimeters (mm), and a depth of the inner volume is between 1.5 mm and 3.0 mm.

7. A cold plate apparatus comprising: a wall surrounding an active volume adjacent to an inlet plenum, wherein the wall includes an inlet opening at one end of a top side of the inlet plenum and a plenum opening between the inlet plenum and the active volume, wherein the wall includes a stack of a top plate, a bottom plate, and at least three intermediate plates between the top plate and the bottom plate; and a blocker partially separating the inlet plenum from the active volume, wherein the blocker is structurally configured to preferentially redirect flow from the inlet plenum into the active volume, the blocker blocking the plenum opening more near the one end of the inlet plenum than along the inlet plenum away from the inlet opening; wherein portions of the at least three intermediate plates form a deflector that protrudes from an outer wall of the inlet plenum toward the active volume, and wherein a bottommost of the at least three intermediate plates protrudes farther toward the active volume than a topmost of the at least three intermediate plates.

8. The apparatus of claim 7, wherein, The barrier blocks the plenum opening more near a bottom side of the plenum opening opposite the inlet opening than near a top side of the plenum opening proximate the inlet opening.

9. The apparatus of claim 7, wherein, The barrier includes a plurality of fingers extending from the bottom side of the plenum opening toward the top side of the plenum opening, the fingers nearest the inlet opening being longest and the fingers farthest from the inlet opening being shortest.

10. The apparatus of claim 9, wherein, Each finger is separated from an adjacent finger by a gap.

11. A cold plate apparatus comprising: a top portion having an inlet opening therethrough; a bottom portion surrounding an active volume and an inlet plenum at a side of the active volume, wherein the inlet plenum overlaps the inlet opening, there being a plenum opening between the inlet plenum and the active volume; a barrier partially separating the inlet plenum from the active volume, wherein the barrier blocks the plenum opening more near a bottom side of the plenum opening opposite the inlet opening than near a top side of the plenum opening proximate the inlet opening; and a deflector projecting from an outer wall of the inlet plenum toward the active volume, wherein a portion of the deflector near a bottom surface of the inlet plenum projects farther toward the active volume than a portion near a top surface of the inlet plenum.

12. The apparatus of claim 11, wherein, The portion of the deflector near the bottom surface projects farther toward the inlet opening than the portion near the top surface.

13. The apparatus of claim 11, wherein: the inlet plenum, under normal operation, encloses a first region immediately proximate an inlet transition, a second region downstream of the first region, and a third region downstream of the second region, and the deflector is in the second region.

14. The apparatus of claim 11, wherein, The bottom portion includes a bottom plate opposite the top portion and at least one intermediate plate attached between the bottom plate and the top portion, wherein a thickness of each intermediate plate is between 0.2 millimeters (mm) and 0.5 millimeters (mm) and a depth of the interior volume is between 1.5 mm and 3.0 mm.

15. A cold plate apparatus comprising: a top portion having an inlet opening therethrough; a bottom portion surrounding an active volume and an inlet plenum at a side of the active volume, wherein the inlet plenum overlaps the inlet opening, there being a plenum opening between the inlet plenum and the active volume; a barrier partially separating the inlet plenum from the active volume, wherein the barrier blocks a decreasing portion of a height of the plenum opening progressing away from the inlet opening; and a deflector projecting from an outer wall of the inlet plenum toward the active volume, wherein a portion of the deflector near a bottom surface of the inlet plenum projects farther toward the active volume than a portion near a top surface of the inlet plenum.

16. A cold plate apparatus comprising: a top plate having an inlet opening therethrough; a bottom plate; a stack of N intermediate plates sandwiched between and attached to the top plate and the bottom plate, each intermediate plate having a central opening, the central openings of the stack of intermediate plates overlapping to define an internal volume enclosed by the top plate, the bottom plate, and the intermediate plates, wherein the internal volume includes an active volume, an inlet plenum on a side of the active volume, and an inlet opening overlapping the inlet plenum, there being a plenum opening between the inlet plenum and the active volume; a barrier partially separating the inlet plenum from the active volume, wherein the barrier is structurally configured to preferentially redirect flow from the inlet plenum into the active volume, the barrier blocking the plenum opening more near a bottom side of the plenum opening opposite the inlet opening than near a top side of the plenum opening adjacent the inlet opening; and a deflector protruding from an outer wall of the inlet plenum toward the active volume, wherein a portion of the deflector near the bottom plate protrudes farther toward the active volume than a portion of the deflector near the top plate, wherein at a lowest intermediate plate the deflector protrudes a distance P from the outer wall of the inlet plenum, and at a highest intermediate plate the deflector protrudes a second distance P / N from the outer wall of the inlet plenum, wherein at each intermediate plate rising from the lowest intermediate plate to the highest intermediate plate the deflector protrudes less than P.

17. A cold plate apparatus comprised of a process comprising: An initial cooling plate design is obtained, the initial cooling plate design comprising: an active volume; an inlet plenum adjacent the active volume and connected to the active volume through a plenum opening; and an inlet opening overlapping the inlet plenum; performing a computational fluid dynamics analysis of the initial cold plate design; identifying simulated flow in a first portion of the active volume proximate the inlet opening that is greater than simulated flow in a second portion of the active volume distal the inlet opening; generating an improved cold plate design by introducing a barrier partially separating the inlet plenum from the active volume into the initial cold plate design, wherein the barrier blocks an entire height of the plenum opening adjacent the inlet opening and blocks a decreasing portion of the height of the plenum opening progressing away from the inlet opening along the plenum opening, wherein the barrier blocks the plenum opening more near a bottom side of the plenum opening than near a top side of the plenum opening; performing a computational fluid dynamics analysis of the improved cold plate design; identifying that the simulated flow in the first portion and the simulated flow in the second portion are within ten percent of an average flow across the plenum opening; and manufacturing a cold plate apparatus according to the improved cold plate design.

18. The apparatus of claim 17, wherein, manufacturing the cold plate apparatus includes building the intermediate layer on top of a bottom plate by additive manufacturing.

19. The apparatus of claim 17, wherein, manufacturing the cold plate apparatus includes bonding the intermediate plates to the bottom plate.

20. A method of enhancing flow uniformity through an active volume of a cold plate apparatus, the method comprising: introducing coolant into an inlet plenum of the cooling plate arrangement through an inlet opening of the cooling plate arrangement; blocking a portion of the coolant from flowing from the inlet plenum into a first portion of an active volume, wherein the first portion is proximate to the inlet opening; and deflecting a portion of the coolant to flow from the inlet plenum into a second portion of the active volume, wherein the second portion is downstream of the first portion along the inlet plenum, wherein the coolant is blocked and deflected more near a bottom surface of the inlet plenum than near a top surface of the inlet plenum.

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