Rack assembly units and carrier rack server systems

Abstract

The present disclosure provides a rack assembly unit and a carrier rack server system. The rack assembly unit is used to install a control unit (130) to a carrier rack server system (500), comprising: a rack frame (110), a tray (150) for receiving the control unit. The tray is movably connected to the rack frame at a coupling mechanism, and the coupling mechanism provides movement of the tray between a first open position and a second closed position relative to the rack frame. In the first open position, the tray is separated from the rack frame to facilitate user access to the tray and the control unit that can be received in the tray. In the second closed position, the tray is fully inserted relative to the rack frame and the control unit located in the tray is set in a control unit working position thermally coupled to a cold plate to provide cooling of components of the control unit. A carrier rack server system is also provided, comprising one or more rack assembly units for connecting a controller to a carrier system.

Description

Technical Field

[0001] The present application generally relates to a rack assembly for mounting a control unit in a vehicle system. The rack assembly provides an improved mounting arrangement for mounting a tray for a plug-in automotive type control unit. Background Art

[0002] In one current approach, automotive electronic control units (ECUs) are being replaced by more complex domain control units (DCUs) or, increasingly, multi-domain control units (MDCs). Both types of control units, or controllers for short, are devices designed to support and control various functional domains of a vehicle, such as advanced driver assistance systems (ADAS) or infotainment systems. DCUs are typically less complex devices developed to operate within a single domain, while MDCs control functions from more than one domain. DCU / MDC controllers with different functionalities can be replaced in a vehicle simply by plugging and unplugging the device from the vehicle, similar to replacing blades in a server rack. This physical replacement of the control unit not only provides the vehicle with new / updated functionality, but also new hardware capabilities, such as increased computing power through the use of more efficient logic components, increased system memory capacity through replacement of memory components, improved power distribution systems through the use of next-generation electronic components, and increased hardware capabilities. As computing power increases, the controllers generate additional heat, requiring additional thermal management to account for the increased heat output. Plugging and unplugging devices from the vehicle can damage the devices during insertion and removal. Therefore, there is a need to solve the above-mentioned defects and problems of the current replacement of electronic control units ECU and domain control units DCU or multi-domain control units MDC, and to provide an alternative and improved rack assembly that solves the problems mentioned above, which has an improved mounting arrangement for mounting a tray for plug-in automotive type control units. Summary of the Invention

[0003] The present disclosure aims to provide an improved arrangement for coupling a control unit to a vehicle system in accordance with the embodiments described and claimed.

[0004] According to a first aspect, a rack assembly unit 100, 300 for mounting a control unit 130 to a carrier rack server system 500 is provided, the rack assembly unit 100 comprising:

[0005] Rack frame 110;

[0006] a tray 150 for receiving the control unit 130;

[0007] wherein the tray 150 is movably coupled to the rack frame at a coupling mechanism, the coupling mechanism being configured to provide movement of the tray relative to the rack frame between a first open position and a second closed position;

[0008] In the first open position, the tray 150 is spaced apart from the rack frame 110 to facilitate user access to the tray and the control unit that can be received in the tray, and in the second closed position, the tray 150 is positioned to be fully inserted relative to the rack frame 110, and the control unit 130 located in the tray is disposed in a control unit working position thermally coupled to a cold plate of a cooling system to provide cooling to components of the control unit.

[0009] The rack assembly unit arrangement advantageously provides easy positioning of the control unit within the carrier system while also avoiding any undesirable forces on these components. The rack assembly unit is configured such that, in a first, open position, the tray is vertically lower relative to the rack frame, providing clearance between the control unit located in the tray and the cold plate located on the rack frame. The cold plate is connected to the cooling system. In a second, closed position, the tray is positioned higher relative to the rack frame, and the control unit and the cold plate are thermally coupled. This arrangement forces the heat transfer surfaces of the control unit to engage with those of the cold plate, defining a thermal interface that supports cooling of the electronic components located within the control unit. The rack frame and tray are coupled together to define a housing and support for the control unit. In one configuration, the rack frame includes a first side wall 111 and a second side wall 112 connected by a rear wall 113 and having a front opening 114; the tray 150 includes a first side wall 151 and a second side wall 152 connected by a rear wall 153 and having a front opening 154, and a base 155. The tray is movably coupled to the rack frame such that it is positioned within the rack frame in an upper, closed position and is movable relative to the rack frame to a lower, open position.

[0010] In one arrangement, the rack assembly unit further comprises a securing mechanism for securing the tray in the closed position, the securing mechanism and the rack frame being configured such that when the tray is secured in the closed position at the securing mechanism, the control unit is positioned in contact with the cold plate to define a thermal interface therebetween, and a controlled contact force is applied between the control unit and the cold plate.

[0011] The rack assembly is configured to provide a contact force at a thermal interface between the control unit and the cold plate when the securing mechanism is engaged. The rack assembly unit is generally configured to provide for the application of a controlled force between the control unit and components including the tray, frame, and cold plate, including by virtue of the provision of the securing mechanism. When the securing mechanism is engaged, a controlled force is applied between the control unit and the cold plate. The controlled force is generated by the interaction of the securing mechanism with components of the rack assembly.

[0012] According to one arrangement, the control unit is further electrically and / or communicatively coupled to the carrier rack server system 500 via the rack assembly unit when located in the control unit working position.

[0013] According to another arrangement, the control unit has at least one connector 135 including an electrical and / or communication connector, and the rack assembly unit includes a connector 166 and a corresponding header 165 for coupling the control unit to the backplane 570 of the carrier rack server system 500 .

[0014] In one arrangement, the control unit's connector can include a plug-in connector that can be accommodated at the tray's header when the control unit is inserted into the tray. From a single connection to the header, the control unit is further directly coupled to the carrier system's backplane 570. This electrical and communication connection is provided via the header 165 and connector 166. Given the respective features and forms of the tray and control unit, insertion of the control unit is accomplished as a simple plug-in insertion. Effectively, the rack assembly unit can be considered to act as an adapter between the control unit and the carrier system. The control unit is directly coupled to the backplane via the rack assembly unit.

[0015] In one arrangement, the rack frame 110 includes a cold plate support for receiving and supporting a cold plate 180, and the rack assembly units 100, 300 are configured such that when the tray 150 is in the first open position, which is lower than the second closed position, the control unit located in the tray is spaced apart from the cold plate, and when the tray is in the second closed position, the control unit in the tray is positioned such that a heat transfer surface of the control unit is thermally coupled to a heat transfer surface of the cold plate to form a thermal interface 750 therebetween.

[0016] In one configuration, the cold plate receiving portion is configured such that the cold plate is supported in the upper portion of the rack assembly relative to the tray and control unit. The arrangement and features of the rack frame, tray, and control unit are optimized and configured such that when the rack assembly unit is secured in a high, closed position, the interactions and forces generated between the rack frame, tray, and control unit result in a controlled force at the interface between the control unit and the cold plate. Advantageously, this engagement of the cold plate and control unit defines a thermal interface between the cold plate and control unit, at which the two components are thermally coupled. Heat is transferred from the control unit to the cold plate. The applied controlled force creates a positive engagement and coupling between the cold plate and control unit at the thermal interface and in the overlapping areas of the respective components. For example, the application of force reduces the occurrence of air gaps. Furthermore, a consistent force is maintained at the thermal interface, thereby maintaining a consistent coupling. As will be noted from the description and accompanying drawings, the thermal interface is formed between the portions of the control unit where the electronic components requiring cooling are located.

[0017] In one arrangement, the rack frame 110 has a first side wall 111 and a second side wall 112, wherein the cold plate support portion is defined by a first recess and a second recess formed at a top edge surface 111-3, 112-3 of each of the first side wall and the second side wall, wherein the first recess and the second recess of the cold plate support portion are positioned opposite each other so that in use the cold plate is arranged to extend between the first recess and the second recess and over a portion of the control unit located in the tray.

[0018] In one configuration, when the control unit is in the working position, a thermal interface material TIM 700 is provided between the control unit 130 and the cold plate 180 such that the heat transfer surface of the control unit is thermally coupled to the heat transfer surface of the cold plate via the TIM.

[0019] Advantageously, providing a TIM layer further facilitates heat transfer at the thermal interface and provides improved thermal coupling.

[0020] In one arrangement, the control unit 130 includes a housing 131 including a TIM receiving portion 133 for receiving a TIM 700 in the form of a TIM layer 701, wherein the TIM receiving portion 133 can be defined by a groove 134 formed in an upper surface of the control unit, the groove defining a perimeter of the TIM receiving portion 133 and having a shape generally corresponding to the cold plate, and wherein an O-ring seal 710 surrounding the TIM receiving portion is located in the groove.

[0021] Advantageously, providing a TIM receiver including a seal along with the control unit and cold plate provides a leak-proof TIM receiver at the interface between the cold plate and the control unit. As described above, when the control unit is thermally coupled to the cold plate, forces are applied between the control unit and the cold plate, and the seal engages corresponding surfaces of each of the cold plate and the control unit housing. TIM 700 may also include a phase-change TIM. The use of a phase-change TIM is supported by the sealing arrangement.

[0022] In one arrangement, the coupling mechanism comprises a hinge mechanism 200,

[0023] The tray and the rack frame are coupled at the rear of the rack assembly by means of the hinge mechanism, wherein the hinge mechanism is configured to provide rotational movement of the tray relative to the rack frame.

[0024] In one arrangement, the tray and the rack frame are further coupled at the front of the rack assembly unit by means of a stop mechanism, the stop mechanism being configured to define and limit an angular range of movement of the tray relative to the rack frame between the first open position of the tray and the second closed position of the tray, the first open position being lower than the second closed position.

[0025] In one arrangement, a stop mechanism comprising fixed brackets 210 located on either side of the tray can be received in a corresponding fixed bracket receiving slot 260 of the rack frame. The range of motion of the fixed brackets in the fixed bracket receiving slot defines the angular range of motion of the tray about the tilt axis 201 and relative to the rack frame 110. Each fixed bracket 210 is movable in the fixed bracket receiving slot in a generally vertical direction Z between a lower open position and an upper closed position. In the open position, the front of the tray is located at a distance Z3 relative to the upper edge surface of the side wall of the rack frame, and the tray is tilted at its rear about the tilt axis such that a control unit located in the tray is spaced relative to the cold plate across its entire surface area. Further, in one arrangement, each fixed bracket receiving slot 260 has a generally rectangular form having an upper edge surface 261 and a lower edge surface 262, wherein the fixed bracket 210 is movable between the upper and lower edge surfaces of the fixed bracket receiving slot, with the lower end defining a stop at the maximum angle of tilt of the tray about the tilt axis, and the upper edge defining a stop when the tray is in the closed position.

[0026] Advantageously, the present configurations provide that when the tray is in the open position, the rack assembly unit and control unit are arranged so that there is clearance or separation between the control unit and the cold plate. When the control unit is tilted relative to the cold plate and relative to the rack frame, the separation distance between the front of the control unit and the rack frame or cold plate is greater than the separation distance between the rear of the control unit and the rack frame or cold plate. However, the components are arranged to provide clearance space on the upper surface area of ​​the control unit. This avoids undesirable forces on the control unit or cold plate and allows for easy access.

[0027] Furthermore, as the tray is moved to the closed position, the control unit moves into contact with the cold plate, such that a contact force is exerted between the control unit and the cold plate. The exerted force is generated by the interaction between the rack frame and the tray, and the control unit and the cold plate, including the interaction as the tray is moved to the closed position and when the securing mechanism is engaged.

[0028] In one arrangement, the rack assembly unit further includes a hinge rotation stop 242 defined by a hinge stop slot 270 formed in the rear wall 113 of the rack frame 110 and a hinge stop protrusion 243 attached to the tray 150 and receivable in the hinge stop slot 270, the hinge rotation stop 242 being configured such that when the tray is tilted relative to the rack frame to the open position, the hinge stop protrusion 243 engages an upper edge surface 271 of the hinge stop slot 270 and limits further tilting of the tray relative to the rack frame.

[0029] In one arrangement, the coupling mechanism comprises a guide pin coupling mechanism 400,

[0030] wherein the tray and the frame frame are movably coupled at the first side wall and the second side wall by the guide pin coupling mechanism to provide movement by translation of the tray relative to the frame frame between the first open position and the closed position; and

[0031] Wherein, the tray and the rack frame include corresponding guide pins and guide slots located at the first side wall and the second side wall of each of the tray and the rack frame.

[0032] In one arrangement, movement of the tray relative to the rack frame is controlled by a range of movement of each guide pin in a corresponding guide slot defined by the guide slot, wherein the range of movement provides translation of the tray relative to the rack frame in a horizontal X direction and a vertical Z direction.

[0033] In one arrangement, the rack assembly unit according to any of the preceding arrangements, wherein the tray 150 further comprises beads located on an inner surface of the base of the tray, the beads being configured to generate a controlled contact force between the tray and the control unit located therein.

[0034] In one arrangement, wherein the securing mechanism for securing the rack assembly in the closed position is defined by corresponding features of the rack frame and the tray or the control unit, the rack frame includes one or more securing brackets 117, 210; and the tray or the control unit coupled to the tray includes corresponding one or more securing brackets 137, 265; wherein fixing screws 220, 221 engage with corresponding securing brackets of the rack frame and the tray or control unit, respectively, to secure the position of the tray relative to the rack frame in the closed position.

[0035] In one arrangement, the rack assembly unit includes: first and second securing brackets on each of the side walls of the rack frame and corresponding third and fourth securing brackets on each of the side walls of the tray, wherein, in the closed position, the corresponding securing brackets of the rack frame and the tray are positioned adjacent to each other and are configured to receive set screws 220 to secure the rack frame to the tray in the closed position.

[0036] In another arrangement, a first fixing bracket is disposed on the rack frame, the first fixing bracket extending between the first and second side walls of the rack frame, the first fixing bracket being configured to couple with a second fixing bracket disposed on the control unit housing. In one arrangement, the control unit housing includes first and second guide pins positioned at a front portion thereof to extend outwardly relative to the first and second side walls and configured to engage corresponding front slots 159 located on the first and second side walls of the tray.

[0037] According to another aspect, a carrier rack server system 500 is provided, comprising:

[0038] a rack support 510 for receiving at least one rack assembly unit 100 or 300;

[0039] a backplane 570 comprising one or more backplane connectors for interfacing with the control unit;

[0040] a cold plate 180 coupled to a cooling system 181 , the cold plate 180 being located in the rack support 510 and being receivable on the rack assembly unit 100 , 300 ;

[0041] The carrier rack server system 500 further includes:

[0042] a rack assembly unit 100, 300 located in a housing for mounting a control unit 130 to the carrier rack server system 500, the rack assembly unit 100, 300 including a connector 166 and one or more headers 165 coupled to the backplane, and the cold plate 180 located on the rack assembly unit;

[0043] a control unit 130 located in the rack assembly unit 100, 300;

[0044] The rack assembly unit 100 , 300 is configured such that when the control unit 130 is located in the working position in the rack assembly unit, the control unit 130 is directly thermally coupled to the cold plate 180 to provide heat transfer from the control unit 130 to the cold plate 180 .

[0045] The carrier rack server system may further include two or more rack assembly units 100 , 300 , which are stacked in the housing 520 for mounting a plurality of control units therein.

[0046] In one arrangement, the control unit 130 includes one or more electrical or communication connectors 135 and a TIM layer 701 located on a housing 131 of the control unit; wherein the rack assembly unit 100, 300 is configured such that when the control unit 130 is in a working position in the rack assembly unit, the control unit 130 is directly thermally coupled to the cold plate 180 at the TIM layer 701 to provide heat transfer from the control unit 130 to the cold plate 180, and the control unit is directly electrically and / or communicatively coupled to the backplane via the connector 166 and corresponding header 165 of the rack assembly unit.

[0047] The carrier rack server system arrangement solves the problems associated with previous solutions and, through a combination of features, allows for accurate and relatively simplified access and connection of the control unit to the carrier system. The arrangement also provides improved cooling and a cooling arrangement that provides improved thermal connection for heat transfer. The provision of a TIM layer further facilitates effective and efficient cooling. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] Figure 1AA schematic diagram of a carrier rack server system 500 is provided, which includes a schematic representation of an automotive rack server equipped with a cold plate and an electronic control unit; in the schematic representation, the heat flow paths between these components are marked with arrows, and according to an exemplary arrangement of the present specification, the control unit is positioned in a stack of rack assembly units, each of which supports a control unit for mounting the control unit within the carrier and coupling it to the carrier system and cooling system as required; Figure 1B A perspective view of a rack showing a plurality of rack assembly units 100 - 1 , 100 - 2 , 100 - 3 according to an arrangement of the present specification is shown.

[0049] Figure 2A 、 Figure 2B 、 Figure 2C and Figure 2D Different views of an exemplary arrangement according to the present specification are provided, wherein a control unit is located in a rack assembly unit; Figure 2A shows a perspective view of a rack assembly unit including a tilt tray coupling mechanism according to an exemplary arrangement, and depicts some of the main components of the rack assembly unit; Figure 2B Shown Figure 2A A top view of the setup; Figure 2C A front plan view is provided; and Figure 2D A side view is provided.

[0050] Figures 3A to 3D An exemplary rack assembly unit is shown, along with a rack frame and tray that are coupled together at a coupling mechanism, in this case a hinge mechanism, to form the rack assembly unit; Figure 3A and Figure 3B Each shows a rack-tray assembly in a secured closed position; Figure 3C and Figure 3D A perspective view of a rack frame and a tray are shown respectively.

[0051] Figures 4A to 4D Shown are the successive steps of the assembly process of the control unit of the tray tilt mechanism. Figure 4A depicts a hinged tray mechanism in an open position in general perspective view, wherein the tray is opened in preparation for insertion of a control unit housing; Figure 4B depicts a side plan view of the hinge tray mechanism with an enlarged view of the slot and guide member and securing mechanism; Figure 4C shows a plan view from the rear of the rack assembly unit and an enlarged view of the head of the tray; Figure 4D A partial cross-sectional view of the hinge connecting plate and hinge stop arrangement is shown.

[0052] Figures 5A to 5EAn overall view of a frame section or frame assembly unit equipped with a guide pin coupling mechanism according to the present specification is shown; Figure 5A and Figure 5B shows a perspective view of the guide pin mechanism with the tray closed, ready for insertion of the control unit housing; Figure 5C and Figure 5D Each shows a rack frame with and without side wall covers; Figure 5E A tray is shown wherein the guide pins are attached to the side walls by means of guide pin plates.

[0053] Figure 6A The tray guide pin slide mechanism is shown in the open position. Figure 6A showing a perspective view of the tray in the rack opened with the side cover panels in place; Figure 6B A plan view from the rear is shown, together with an enlarged view of the arrangement of the head; Figure 6C A partial cutaway side view of the tray guide pin slide mechanism is shown in an open position.

[0054] exist Figures 6A to 7C Mounting the control unit into the rack is shown in FIG. 7A to 7C A similar process is shown for guide pin rack design. 7A to 7C The following are the steps for inserting the control unit into a rack equipped with a tray tilt mechanism. Figure 7A A perspective view of the control unit engaged with the tray is provided; Figure 7B A cross-sectional view of the tray and the control unit at the tray in an inclined position relative to the cold plate is provided; Figure 7C A similar view is shown with the tray in the closed position.

[0055] Figures 8A to 8D The control unit is shown mounted in a frame equipped with a guide pin mechanism. Figure 8A showing a perspective view of the control unit in the housing with an enlarged view depicting the insertion of the control unit guide pins into the cutouts in the tray in the open position; Figure 8B A tray loaded with control units is shown being pushed into the rack following guide cutouts in the rack, wherein an enlarged view shows the tray pins being pushed along the rack guide cutouts until the final closed position; Figure 8C shows a front view of the pallet loaded with the control units fixed in their final position, CC shows a section line through the pallet loaded with the control units fixed in their final position; Figure 8D A cross-sectional view of the tray loaded with control units fixed in their final position is shown, and the thermal interface established between the control units and the cold plate is shown.

[0056] Figure 9Ashows a perspective view of a control unit according to the present specification having a TIM layer 701 on its housing; Figure 9B and Figure 9C A front plan view and a cross-section along line DD are provided respectively; Figure 9D for Figure 9C A magnified view of section A showing details of the interface between the cold plate and the control unit housing including the seal and TIM layer.

[0057] 10A to 10C Provides three Figure 1B a further view of the stack of rack assembly units shown; showing the position of the intermediate tray in a tilted open position relative to the rack frame; Figure 10A Provided Figure 1B A front plan view of the setting; Figure 10B A cross-sectional view is provided showing the position of each of the control unit and the tray relative to the rack frame; Figure 10C for Figure 10B FIG. 1 is an enlarged view of section B of FIG. 1 showing an enlarged view of the control unit in the tray in the open position, showing that the TIM layer and the seal are not in contact with the cold plate. FIG. DETAILED DESCRIPTION

[0058] In the example, the control unit 130 is mounted in a tray 150, which is then mounted in a rack. The tray is equipped with a fixing mechanism, also referred to herein as a coupling mechanism, which enables the tray to be fixed or coupled to its position in the rack, and a head 165, which transmits signals from the control unit 130s in the tray to the backplane 570. Figure 1A Carrier rack server system and Figure 2D The main components of the rack assembly unit in the drawings and other figures are the rack frame, control unit, tray, fixing screws, backplane connector and cold plate.

[0059] This specification provides various exemplary configurations, including a rack assembly with an alternative two-blade retainer (also referred to as a two-blade coupling mechanism). The first coupling mechanism described provides a tilting tray mechanism. The second coupling mechanism provides a guided connection mechanism, wherein the tray is guided by a cutout or slot provided in the rack frame. The rack assembly unit of this specification advantageously provides a leak-proof encapsulation of a phase change thermal interface material (TIM) between the control unit housing and the cold plate, and provides control and generation of contact forces in the thermal interface between the control unit housing and the cold plate.

[0060] Throughout this specification, the term "design" is used to refer to both exemplary and alternative exemplary arrangements. A first tray tilting design or coupling mechanism is based on a hinge mechanism, allowing the tray to tilt within the rack to a predetermined angle, which is required for inserting and removing a control unit. In some alternative examples, the coupling mechanism is a guide-based coupling mechanism that provides a rack equipped with cutouts / guides formed in portions of the rack wall, the cutouts / guides being configured to guide the movement of the tray, thereby enabling safe replacement of a control unit mounted on the tray.

[0061] With reference to the exemplary configuration of the accompanying drawings, this specification provides a rack assembly unit 100, 300 comprising a rack frame 110 and a tray 150 configured to support a control unit 130 mounted on a carrier system. The rack frame 110 and tray 150 are configured to be movably coupled together to form the rack assembly unit 100, 300. Throughout this specification, a rack assembly is also referred to as a rack and tray unit, a rack assembly unit, and a rack segment. Each rack assembly unit 100, 300 according to this specification is configured to mount a control unit 130 within a carrier. The carrier includes a carrier rack server system 500, at which a control unit is mounted to the carrier. The carrier rack server system 500 includes a housing for accommodating the control unit, a connector for interfacing the control unit to the overall carrier system as needed, and a connection to a cooling system. The carrier system includes the carrier's internal communications and electrical systems.

[0062] The control unit 130 may include a plug-in vehicle control unit, including, for example, a DCU, ECU, or MDC. In the present configuration, the rack assembly unit 100 is configured to mount the vehicle control unit 130 to a vehicle via connection at the vehicle rack server system 500 .

[0063] Reference Figure 1A and Figure 1B An exemplary configuration of a carrier rack server system 500 is described. Figure 1AIn the configuration, the carrier rack server system 500 includes three control units 130 mounted in a stacked configuration at a rack support 510. The rack support 510 is configured to receive one or more control units mounted in one or more rack assembly units 100, 300. The carrier rack server system 500 also includes a backplane 570 configured to interface the control units 130 with the carrier system. The backplane 570 includes a backplane connector. When installed in their respective use working positions, each control unit 130 within the carrier rack server system 500 is directly coupled to the backplane 570. The coupling of the control unit 130 to the backplane 570 provides electrical and / or communication coupling of the control unit 130 to the backplane 570 and to the external carrier system. In addition, when installed in the working position, each control unit is thermally coupled to the cooling system. The rack assembly units 100 and 300 are configured to provide thermal coupling of a control unit located therein to a cold plate 180 of a cooling system 181, thereby supporting heat transfer between components of the control unit 130 and the cold plate 180 at a thermal interface 750. A thermal interface material (TIM) 700 is disposed between the control unit 130 and the cold plate 180. In this configuration, the TIM 700 is disposed in a layer 701 between the control unit 130 and the cold plate 180, such that the heat transfer surface of the cold plate 180 is thermally coupled to the heat transfer surface of the control unit 130 via the TIM. The rack assembly unit includes a cold plate receiver for supporting the cold plate as needed for coupling to a corresponding control unit 130. This will be described in further detail below.

[0064] The rack support 510 generally defines a housing 520 in which one or more control units 130 may be positioned, with each control unit being mounted in a separate rack assembly unit 100 therein. The housing 520 includes an upper portion 522 and a base 523, a rear portion 524 and sides, and a front portion 526 defining an opening. Access to the one or more rack assembly units 100, 300 and to the tray or control units is provided at the front portion 526. The rack support 510 is arranged so that the individual rack assembly units 100 and control units 130 mounted therein are oriented generally in a horizontal XY plane. The front and rear portions of the housing 520 are oriented vertically in a ZY plane. As such, in an arrangement including two or more control units, the control units 130 are effectively arranged in a vertical stack within the housing 520. In Figure 1A In the exemplary arrangement of FIG. 5 , the back plate 570 is positioned generally adjacent the rear portion 524 of the housing 520 and between the rear portion 523 and the rack assembly unit 100 .

[0065] The exemplary rack and tray unit or rack assembly unit 100, 300 is advantageously configured to allow for control of the position of the control unit 130 located in the tray 150 relative to the rack frame 110 and, therefore, relative to the cold plate 180 and backplane 570 of the carrier rack server system. Furthermore, the rack assembly unit 100, 300 is configured to provide for force control between the control unit 130 and components including the tray 150, rack frame 110, and cold plate 180. The rack assembly unit 100, 300 is configured to facilitate user access to the tray 150 and control unit 130, including, for example, inserting, adjusting, or replacing the control unit. Each rack assembly unit 100 is configured to be stacked with other rack assembly units 100 to provide a modular stacked rack assembly unit 100'. Figure 1B The stacked rack assembly unit 100 ′ is configured to be received in a carrier rack server system 500 .

[0066] Reference Figures 2A to 2D , describes a rack assembly unit 100 according to a first exemplary arrangement. Figures 2A to 2D In FIG, the control unit 130 is located in the rack assembly unit and the rack assembly unit is shown in a closed state.

[0067] The rack assembly unit 100 includes a rack frame 110 for receiving a corresponding tray 150. The tray 150 is movable relative to the rack frame 110 between a first open position, in which the tray is spaced from the rack frame and configured to allow access, such as for inserting a control unit 130 into the tray 150, and a second closed position, in which the tray is fully inserted into the rack frame, and the control unit 130, located in the tray 150, is in a control unit operating position within the rack assembly unit 100. As shown, a cold plate 180 is located on a support or receiving portion of the rack assembly unit 100. The rack assembly unit and the control unit are configured such that, when used in the operating position, the control unit 130 is thermally coupled to the cold plate 180. Furthermore, when in the operating position, the control unit 130 is coupled to the backplane 570 via the rack assembly unit 100. Thus, the control unit is electrically and communicatively coupled to the carrier system.

[0068] The tray 150 includes a front slit 159 for engaging with a corresponding mating feature of the control unit to help position the control unit 130 in the tray. In the drawings, the front slit comprises a tapered opening at the forward-facing end of the side wall and extends generally horizontally in the X direction along a portion of the side wall of the tray (e.g., having a length on the order of 10 to 20 mm).

[0069] The control unit includes a connector 135 connected via headers 165-1 and 165-2 of the tray 150. Header 165 connects to the backplane connector of the backplane 570 via a flat flexible cable (FFC) and connector 166. Connector 135 is located on the rear side of the control unit and is connected to header 165 at the tray's rear wall 153. The tray includes a rear wall aperture 156 formed in rear wall 153 to accommodate header 165 and connector 166. The rack frame 110 includes a cutout or opening 116 that aligns with header 165 when the tray is connected to the rack frame. When the tray is inserted into the rack frame, header 165 provides the necessary connection toward the backplane 570. The rack frame's width (the distance between the side walls) w1 is greater than the tray's width w2. The rack frame's depth (of the side walls) d1 is greater than both the tray's side wall depth d2 and the control unit's depth d3.

[0070] The depth of each rack frame, as defined by the depth of the rack frame walls, is sufficient to accommodate tilting of the tray in the open position relative to the rack frame and to provide that the tilted tray 150 does not contact or cause forces to be applied to the cooling units on the rack assemblies below it, with reference to Figure 10B and Figure 10C , where, as in Figure 1B , the intermediate tray 150 is shown tilted relative to the corresponding rack frame. Figure 10C The gap or separation distance provided by the rack assembly between the control unit and the top edge portion of the rack assembly is shown, as well as the relative positions of the cold plate and the control unit.

[0071] Reference Figure 2C and Figure 2D , provide additional plan views from the front and side. These views show the compact arrangement of the control unit 130 in the rack assembly unit 100 in a closed position, where the control unit 130 is located between the base 155 of the tray and the cold plate 180 on the rack frame.

[0072] The rack assembly unit includes a securing mechanism comprising one or more set screws 220 and securing brackets 210, 265. The set screws 220 extend through the securing brackets 265 of the rack frame and the corresponding securing brackets 210 of the tray to provide a connection between the rack frame and the tray and secure the rack assembly unit in a closed position. In the illustrated arrangement, the first and second brackets are positioned on corresponding sidewalls of the rack frame and the tray, with screws inserted into each set of securing brackets. In use, when the rack assembly unit and the control unit are positioned in a carrier rack server system, the rack assembly unit is secured in a closed position by the set screws.

[0073] The rack assembly unit further comprises a coupling mechanism for movably coupling the tray and the rack frame. The coupling mechanism provides for movement of the tray relative to the rack frame and assembly of the tray and the rack frame to form a unit. Figure 1B 、 Figures 2A to 2D 、 Figures 3A to 3D and Figures 4A to 4D The exemplary coupling mechanism is a hinge mechanism 200 that articulates the tilted tray 150. The hinge mechanism 200 includes corresponding hinges 205, hinge receiving portions 255, and rotation stop features provided on both the tray and the rack frame. The rotation stop features include a fixed bracket 210 and a fixed bracket receiving slot 260. Figures 3A to 4D The tilt tray mechanism is described in further detail.

[0074] Reference Figures 3A to 3C The rack frame 110 includes side walls 111 and 112 connected by a rear wall 113. The side and rear walls include inward-facing surfaces 111-1, 112-1, and 113-1, outward-facing surfaces 111-2, 112-2, and 113-2, and a front opening 114. The side and rear walls have top edge surfaces 111-3, 112-3, and 113-3, and lower edge surfaces 111-4, 112-4, and 113-4. The side walls have forward-facing edge surfaces 111-5 and 112-5, and rearward-facing edge surfaces 111-6 and 112-6. In use, the front of the rack assembly unit faces outward and is the side from which a user accesses the trays and control units. The rearward-facing side faces the back panel. As shown, portions of the side and rear walls include cutouts forming rear wall apertures 156, base apertures 157, or openings 116, and the exterior surfaces of the rack frame walls may define the exterior surfaces of the rack assembly unit 100. In alternative arrangements, cover panels may be applied to the exterior surfaces of the side and / or rear walls.

[0075] The rear wall 113 includes a cutout portion defining a connector cutout or opening 116 to accommodate the head 165 of the tray 150. In use, the head 165 protrudes through the opening 116 of the rack frame to connect to the backplane 570. Each side wall 111, 112 includes a recess 120 having a lower edge surface 121 that is recessed relative to the top edge surface 111-3, 112-3. In use, the two recesses 120 provided at the opposing side walls 111, 112 together define a cold plate receiving portion of the rack frame. Figure 2AAs shown, in use, the cold plate 180 is supported by the rack frame. The recess 120 has a depth d4, corresponding to the distance from the top edge surfaces 111-3, 112-3 of the side walls 111, 112 to the lower edge surface 121 of the recess 120, which is greater than the depth of the cold plate. Note that multiple rack assembly units 100 or 300 can be stacked, with recesses 122 provided at the lower edge of each side wall at positions corresponding to the recess 120, such that, in the stacked configuration, the lower edge surface of a second rack assembly stacked above the first is spaced from the cold plate 180. The rack assembly unit is configured to accommodate the cold plate, protect it from undesirable forces, and allow access.

[0076] The tray 150 is movably coupled to the rack frames 110 of the rack assembly unit 100 , each rack frame including corresponding mating features of the hinge mechanism 200 . Figures 2A to 2D as well as Figure 3A and Figure 3B The tray is shown coupled to a rack frame.

[0077] As in Figure 3C As best shown in FIG, the rack frame 110 includes a hinge receiving portion 255 comprising a plurality of circular holes at a rear end portion of each side wall configured to mate with corresponding hinges 205. The rack frame includes a fixing bracket receiving slot 260 and a fixing bracket 265 at a front end portion of each side wall configured to mate with a corresponding fixing bracket 210 of the tray 150.

[0078] Reference Figure 3D The tray 150 includes a first side wall 151 and a second side wall 152, a rear wall 153, a base 155, and a front opening 154. The side walls and rear wall include inward-facing surfaces 151-1, 152-1, 153-1 and outward-facing surfaces 151-2, 152-2, 153-2. The side walls and rear wall have upper edge surfaces 151-3, 152-3, 153-3 and lower edge surfaces 151-4, 152-4, 153-4. The side walls have front edge surfaces 151-5, 152-5 and rear edge surfaces 151-6, 152-6. In an exemplary arrangement, the base 155 and rear wall 153 include cutouts defining a base aperture 157 and a rear wall aperture 156. The base aperture 157 may be provided to reduce the overall weight of the tray. The rear wall aperture 156 is configured to accommodate one or more headers 165 of the tray 150. The base 155 of the tray also includes ribs 164. The ribs define contact surfaces for contacting and engaging with the control unit.

[0079] Reference Figures 3A to 3D and Figures 4A to 4D , the fixing mechanism, which in this arrangement is a hinge mechanism 200, is described in further detail.

[0080] The tray includes a hinge 205 and a fixing bracket 210 provided on the side walls 151, 152. The hinge 205 is located at the rear of the side walls in the X direction and, when connected to the rack frame at the hinge receiving portion, is located between the rear wall and side walls of the tray and the rear wall and side walls of the rack frame in use. The hinge 205 is located at the hinge connecting plate 240 ( Figure 3C and Figure 4D ) are attached to each side wall, which allows the hinge to be positioned at positions separated in the X direction relative to the rear edge surfaces 151-6 and 152-6 of the side walls 151, 152. The hinge 205 extends outwardly in the Y direction relative to the side wall to connect to the hinge receiving portion 255 of the rack frame. The fixing bracket 210 is located at the front of the side wall and also protrudes outwardly relative to the wall surface in the direction of the rack frame that is located outside the tray during use.

[0081] The hinge 205 and hinge receptacle 255 of the rack frame are positioned and configured to correspond and mate. The hinge 205 can be received in the hinge receptacle 255, which is located in the sidewalls 111 and 112 on each side of the rack frame. The hinge 205 is inserted into the hinge receptacle 255 on either side of the tray, movably coupling the tray to the rack frame and defining a tilt axis 201 for the tray relative to the rack frame. When positioned between the rear wall of the tray and the rear wall of the rack frame, the hinge 205 is offset in the X-direction relative to the rear edge surfaces of the rear wall and each sidewall of the tray, as well as the tilt axis.

[0082] The tray 150 and the rack frame 110 are also coupled together near the front of the rack assembly unit 100. The tray's securing brackets 210 and corresponding securing bracket receiving slots 260 and securing brackets 265 of the rack frame are located at the front of the respective side walls of the tray and the rack frame, respectively. The tray's securing brackets 210 are configured to couple to the rack frame at the corresponding securing bracket receiving slots 260 and securing brackets 265 of the rack frame.

[0083] Reference Figure 4A 、 Figure 4B 、 Figure 4C and Figure 4D, a hinge mechanism 200 for coupling the tray and the rack frame is described in more detail. The fixed bracket receiving slot 260 of the exemplary device includes a rectangular hole having an upper edge surface 261 and a lower edge surface 262, and the fixed bracket 210 of the tray can be received in the fixed bracket receiving slot and can move between its upper edge surface 261 and the lower edge surface 262 in the fixed bracket receiving slot 260, which provides a stop for the range of movement of the fixed bracket. The interaction of the fixed bracket 210 with the fixed bracket receiving slot 260 also defines the range of tilt of the tray relative to the rear tilt axis. The fixed bracket 210 is movable relative to the slot generally in the vertical Z direction. When the fixed bracket 210 of the tray engages with the lower edge surface 262 of the slot, the tray is in the open position and tilted at a maximum angle α of the tilt range of movement of the tray relative to the rack frame. Figure 4A and Figure 4B In the exemplary arrangement of , the lower edge surface 262 of the retaining bracket receiving slot is arranged to be inclined at an angle α relative to the horizontal direction (and the orientation of the upper and lower edge surfaces of the side walls) such that in the open position, the retaining bracket 210 and the lower edge surface 262 are at substantially the same angle and the engagement surface of the retaining bracket is aligned to engage with the lower edge surface 262.

[0084] Although Figures 2A to 2D as well as Figure 3A and Figure 3B In FIG, the tray is shown in the closed position with the fixing pins or screws 220 in place in the fixing brackets 265 and 210, but in Figure 4A and Figure 4B , the tray is shown in an open position. The tray is spaced apart from the rack frame so that a user can access the tray to insert, replace, or remove a control unit.

[0085] Reference Figure 4C , one or more heads 165 of the tray are positioned in the rear wall apertures 156 of the tray and extend through the opening 116 of the rack frame. As described above, the rack frame is configured to provide clearance for movement of the tray relative to the rack frame and other rack assembly units in the stack. Figure 4C As shown, the base of the tray in the tilted position is completely contained within the footprint of the rack frame, and the tilting does not affect the alignment of the tray's head 165 relative to the opening 116 of the rack frame.

[0086] Reference Figure 4D , the hinge 205 is located on the tray by means of a hinge connecting plate 240. The hinge connecting plate 240 can be attached to the outer surface of the side walls 151, 152 by fixing means 241.

[0087] The tray may include a recess 158 for receiving a hinge plate 240. The hinge plate is shaped and sized to attach to a rear end portion of each side wall such that a portion of the hinge plate overlaps a portion of an outer surface of the side wall and a portion of the plate extends rearwardly relative to the side wall to position the hinge 205 at the rear of the tray. In use, when the tray is coupled to the rack frame, the hinge and tilt axis are located between the rear wall of the tray and the rear wall of the rack frame.

[0088] The rack assembly unit 100 may also include a hinge rotation stop 242 defined by corresponding hinge rotation stop features of the rack frame and the tray. The rack frame includes at least one hinge stop slot 270 having an upper edge surface 271 and a lower edge surface 272 formed in its rear wall 113. The tray includes at least one hinge stop protrusion 243 configured to protrude from the rear of the tray and be received in a corresponding hinge stop slot 270. The hinge rotation stop 242 is configured such that when the tray is tilted relative to the rack frame to an open position, the hinge stop protrusion 243 engages the hinge stop slot 270 at the upper edge surface 271 and limits further tilting of the tray relative to the rack frame. The hinge rotation stop 242 advantageously provides additional support and stability to the tray 150 in the open position and allows for controlled movement of the tray relative to the rack frame.

[0089] exist Figure 4D In the embodiment, the tray is in the open position and the hinge stop projection 243 engages the upper edge of the hinge stop slot 270. The hinge rotation stop 242 may be provided on one or both sides of the frame assembly. Figure 4D As shown in the exemplary arrangement of FIG, the hinge stop protrusion 243 can be provided as part of the hinge connecting plate 240. Thus, the hinge 205 and the hinge stop protrusion 243 are directly coupled to the hinge connecting plate 240. The tilt of the hinge controls a configuration that also allows for control of forces between components of the rack assembly unit and components located or supported thereon.

[0090] Reference Figures 5A to 5E as well as Figures 6A to 6C , depicts a rack assembly unit 300 according to an alternative arrangement of these figures. The overall arrangement of the rack assembly unit 300 is similar to that of the rack assembly unit 100, and many features of the trays and rack frames correspond to each of the two arrangements. Similar reference numerals are used where appropriate.

[0091] Reference Figure 5AThe rack assembly unit 300 includes a tray 150 and a rack frame 110, which are movably coupled to form a rack assembly. The tray is configured to receive a control unit. The tray is movable between an open position and a closed position. In the open position, the tray is spaced apart from the rack frame to allow for insertion, removal, or replacement of a control unit. In the closed position, the tray is positioned to be received within the rack frame. The rack assembly and the control unit are configured to correspond so that when the tray is engaged within the rack frame in the closed position, the control unit located within the tray is positioned in its operational position. In the operational position of the control unit, when the rack assembly is positioned within the carrier rack server system 500, the control unit is positioned to be thermally coupled to the cold plate and also to the server's backplane connector to provide electrical and / or communication connectivity. The connector 135 of the control unit 130 is coupled to the backplane connector of the backplane via the tray's header 165. The tray 150 is movably coupled to the rack frame 110.

[0092] Reference Figure 5A , the tray is shown coupled to the rack frame. The rack frame includes a fixing bracket 117 extending in the Y direction between the upper portions of the side walls 111, 112 of the rack frame. The fixing bracket 117 includes an aperture 119. The fixing bracket 117 is arranged to mate with the bracket including the aperture 139 (e.g., see FIG. 1 ) when the control unit is located in the tray in the closed position. Figure 8A and Figure 8C ) are aligned with the fixing bracket 137 and the fixing screw 221 is inserted through the hole 119 and the hole 139 to fix the rack assembly unit and the control unit in the closed position. Figures 5A to 5E The rack frame of the arrangement also includes a side wall cover 118. The side wall cover 118 can be attached to the side walls 111, 112 and provides an outer cover for the guide coupling mechanism. The side wall cover provides additional support at these side walls and protects the guide coupling mechanism.

[0093] The guide pin coupling mechanism 400 of the rack assembly unit 300 is different from the hinge mechanism 200 of the rack assembly unit 100 and will be referred to as Figures 5B to 5E The rack assembly unit 300 includes a guide pin coupling mechanism 400 based on a guide pin and a guide slot arrangement, which define the guide pin coupling mechanism 400. The guide pin coupling mechanism 400 is configured to provide a movable coupling of the tray 150 to the rack frame 110. Figure 5B In FIG, the tray is coupled to the rack frame at a guide pin coupling mechanism 400. The guide pin coupling mechanism 400 includes corresponding mating features of the tray and the rack frame. Figure 5B and Figure 5D As shown, each side wall 111, 112 of the rack frame includes guide slots 410 and 420. Figure 5EAs shown, each side wall 151 and 152 of the tray includes a first guide pin 430 and a second guide pin 440 that can be received in the guide slot 410. Figures 5A to 5E In the arrangement, the tray moves by translation relative to the frame chassis in the general X direction. Throughout the range of movement, the tray 150 remains generally horizontally oriented in the XY plane. The guide pin coupling mechanism is described in further detail below.

[0094] Reference Figure 5C and Figure 5D , guide slits 410 and 420 are described in further detail. The first and second side walls 111 and 112 include an upper guide slit 410 and a lower guide slit 420. Guide slit 410 is formed in the side walls, extending from an opening 411 in the front edge of the wall toward the rear of the tray in the X-direction. The length of guide slit 410 is l1. It is shorter than guide slit 420, for example, approximately 0.1 to 0.2 times the total length of the side walls. Guide slit 410 includes a horizontal straight portion 412 and an inclined portion 413. The guide slit angles upward to its rear end 414. Guide slit 410 is located vertically (in the Z-direction) above guide slit 420. Guide slit 420 has a length l2. It is longer than guide slit 410 and extends generally along the length (X-direction) of the side walls. Guide slit 420 includes a horizontal straight portion 422 and an inclined portion 423. The guide slot is inclined upward at the inclined portion 423 to a rear end portion 424 of the guide slot.

[0095] Reference Figure 5E Each side wall 151, 152 of the tray includes a first guide pin 430 and a second guide pin 440 that are receivable in corresponding guide slots 410, 420 of the frame. The guide pins extend outward, generally at right angles to the outward-facing surface 151-2, 152-2 of each side wall. In this exemplary arrangement, the guide pins have a cylindrical shape and are sized to be receivable in the corresponding guide slots. Guide pins 430, 440 are located on guide pin plates 431, 441, which are attached to the side walls via retaining pins or other suitable means. Each guide pin plate is clamped to at least a portion of the outer side wall of the tray, such that the guide pin plate overlaps a portion of the side wall. Guide pin 430 is generally located near the top edge surfaces 111-3, 112-3 of the side walls, at the front end of the tray. Guide pin 440 is generally located near the bottom edge surfaces 111-4, 112-4 of the side walls, at the rear end of the tray. The tray is coupled to the rack frame by inserting the first guide pin 430 and the second guide pin 440 into the guide slots 410 and 420, respectively. In the illustrated arrangement, the guide pin 440 is positioned offset in the X direction relative to the rear wall 153 of the tray.

[0096] Reference Figures 6A to 6C The tray is shown positioned within the rack frame in the open position. During use, the tray is moved relative to the rack frame by applying a force (push or pull) in the X-direction. As the guide pins 430 and 440 move within the guide slots 410 and 420, the tray moves in translation. As described above, the rear end 414 and 424 of each guide slot are elevated relative to the front opening 411 and 421 and the horizontal straight portions 412 and 422 (Z-direction). In practice, when the tray moves from the open to the closed position, the movement is guided by the guide pins within the guide slots. As the guide pins move along the horizontal straight portions 412 and 422 of the respective guide slots 410 and 420, the tray translates relative to the rack frame to a lower, first, vertical position Z1. As the tray is further inserted and moved toward the closed position, the guide pins move along the inclined portions 413 and 423 of the guide slots, causing the tray's vertical position relative to the rack frame to change, moving to a second, higher vertical position than the first. In the closed position, the tray is in a higher, second, vertical position Z2. This provides a connection between the control unit 130 located in the tray 150 and the cold plate 180 in its operating position. The range of movement of the tray in the X direction relative to the rack frame is effectively limited by the length l1 of the upper guide slot 410. The range of movement of the tray in the vertical direction (Z direction) relative to the rack frame is limited by the height difference between the raised end of the guide slot and the lower straight portion.

[0097] Figures 6A to 6C A view of the rack assembly unit 300 is provided with the tray 150 in the open position. Figure 6A and 6B The relative positions of the tray and the frame are shown when the tray is in the open position and in a first, lower vertical position Z1 relative to the frame.

[0098] Reference Figure 6C , which shows the features of the guide slits and the interaction of the first guide pin 430 and the second guide pin 440 with the guide slits 410 and 420. The upper guide slit 410 includes an opening 411, a horizontal straight portion 412, an inclined portion 413 and a rear end portion 414. The lower guide slit 420 includes an opening 421, a horizontal straight portion 422, an inclined portion 423 and a rear end portion 424. The upper slit supports the first guide pin 430 at different heights relative to the lower edge surfaces 111-4, 112-4 of the side walls 111, 112, including a lower height s1 and an uppermost height s2. The lower slit supports the guide pin 440 at different heights relative to the lower edge surfaces 111-4, 112-4 of the side walls 111, 112, including a lower height s3 and an uppermost height s4. In Figure 6CIn the present embodiment, the first guide pin 430 and the second guide pin 440 are positioned at the frontmost position of their range of motion (X-direction) in the guide slot and at the lower height of their range of motion (Z-direction). That is, the tray is in the open position and positioned within the rack frame at a first, lower vertical position Z1. When the tray is in the closed position, the guide pins are at their end stop positions at the rearmost portion of their range of motion in the X-direction and at the uppermost height of their range of motion in the Z-direction. The tray is then positioned within the rack frame at a second, higher vertical position Z2.

[0099] Reference Figure 7A 、 Figure 7B and Figure 7C The features of the control unit 130 will now be described in greater detail. It should be understood that the rack assembly units 100, 300 and the control unit 130 are configured to correspond to each other. Furthermore, the control unit 130 is configured to be received within and engage with the tray 150. As described above, the exemplary configuration of this specification advantageously provides the necessary coupling to the control unit for carrier operation.

[0100] 7A to 7C and Figures 8A to 8C The control unit and the rack assembly unit 100 are shown respectively. 7A to 7C ) and rack assembly unit 300 ( Figures 8A to 8D ) and some further details of the arrangement for coupling the control unit to the cold plate.

[0101] Reference 7A to 7C , the tray includes a front slot 159 for receiving corresponding guide pins 132 of the control unit 130. The control unit includes a housing 131 of the control unit. The coupling pins are located on opposite side walls of the housing. It will be appreciated that various electronic components may be provided in the control unit housing. The control unit is configured so that in its operating position within the rack assembly the control unit is positioned so that active cooling is provided to components of the control unit that require cooling. The TIM 700 may be provided in a layer 701 on the TIM receiving portion 133 of the housing 131 of the control unit 130. Figure 7A In the embodiment shown, the tray is in an open position, for example to allow insertion of a control unit, and the TIM 700 can be seen positioned atop the control unit. The cold plate 180 is supported on a cold plate receiving portion of the rack frame. The rack assembly and control unit are configured such that when the tray is inserted into the closed position, the TIM 700 is moved into position with and aligned with the cold plate 180 as desired. The interaction of the rack frame, tray, and control unit also provides thermal coupling of the control unit to the cold plate 180 at the TIM layer 701.

[0102] Figure 7BThe rack assembly unit 100 is shown with the tray 150 in an open position, tilted relative to the rack frame 110, and the control unit 130 positioned within the tray. In the open position, the control unit 130 and TIM 700 are positioned below and angled relative to the cold plate 180. Some clearance space may be provided between the cold plate and the control unit so that, in the open position, there is no physical contact between the control unit and TIM layers and the cold plate. The control unit's connector 135 connects to the head 165 of the rack and to a connector 166 at the rear of the rack assembly unit.

[0103] Figure 7C The rack assembly unit 100 is shown after being moved from an open position to a closed position. The control unit 130 relies on a combination of features of the rack assembly and the control unit in an operational position for use within a carrier. The control unit 130 is coupled to a cold plate 180 via a TIM 700 for heat transfer. The connector 135 of the control unit 130 connects to the backplane of the carrier system via the tray's header 165 and connector 166. Figure 7C The detail shows the interaction of the ribs 164 located on the base of the tray 150 with the control unit 130.

[0104] Reference Figure 8A The tray is in an open position of the rack assembly unit 300, which includes a guide pin coupling mechanism 400. The guide pins 132 of the control unit are located in the front slots 159 of the tray. The securing arrangement of the rack assembly unit 300 is also shown. The rack frame includes a securing bracket 117 having a first hole and a second hole. As shown, the securing bracket 137 is coupled to the control unit and to the tray.

[0105] The control unit 130 includes a TIM 700 disposed in a TIM layer 701 in a TIM receiving portion 133 of its housing. Figure 8B and Figure 8C As shown, when the tray 150 of the rack assembly unit 300 moves to the closed position, it translates toward the rear of the rack frame and also translates to a second, higher vertical height within the rack frame. As described above, each guide slot 410, 420 comprises two heights (in the Z direction). Thus, the control unit in the tray moves upward within the rack frame and is coupled to the cold plate via the TIM 700 in the tray's closed position.

[0106] When the tray moves to the closed position, as Figure 8B As shown, the fixing brackets 137 and 117 are brought into contact and joined together at the holes 119 and 139. The rack assembly unit 300 is fixed in the closed position using the fixing screws 221. This fixing is also Figure 8D Shown in cross-section.

[0107] Reference Figures 9A to 9C , depicts an exemplary arrangement of a control unit 130, wherein a TIM 700 is included in a TIM layer 701. The control unit in the exemplary figures is located in a rack assembly unit 300. The control unit 130 includes a TIM receiving portion 133 located on an upper outer surface of its housing 131. A recess 134 is formed in the upper surface, which, in the exemplary arrangement, defines a rectangular TIM receiving portion. The recess 134 defines the perimeter of the TIM receiving portion 133. Figure 9C As shown, the groove is recessed relative to the surface and a seal 710, such as an O-ring, is located in this groove 134. The TIM 700 is arranged in a layer 701 on the housing in a receiving portion defined by the groove. In the closed position of the tray and the operating position of the control unit, as shown Figure 9B and Figure 9C As shown, the control unit is coupled to the lower surface of the cold plate 180 via a TIM 700. A seal 710 engages respective heat transfer surfaces of both the control unit housing and the cold plate.

[0108] Reference Figure 9B and Figure 9C And combined Figure 1A , describing in more detail the heat transfer provided. Figure 1A The carrier rack server system 500 is shown equipped with a cold plate 180 and an electronic control unit 130. The respective heat transfer surfaces of the cold plate and the control unit are thermally coupled at a thermal interface 750, with a heat flow path 760 schematically indicated by arrows. To allow heat to flow from the electrical / electronic components 138 within the control unit 130 to the cold plate 180, an effective heat flow path 760 is established. In the illustrated arrangement, heat flow path 760 is based on the use of a thermal interface material (TIM) 700 disposed between the cold plate and the control unit. This TIM 700 material is used to reduce the so-called thermal contact resistance between the mating heat transfer surfaces, thereby allowing for improved heat flow through the thermal interface (TI) 750. The TIM 700 can be provided in the form of a gel, grease, soft, compliant pad, or phase change material. Other TIM types are also possible. To allow for efficient heat transfer through the TIM layer 701, it is positioned between the heat source (e.g., the control unit housing) and the cold plate while the two components are firmly pressed against each other. Contact pressure plays an important role in improving the thermal conductivity of the thermal joint because it reduces the interface thickness and allows the micron-scale cavities to be filled by the TIM. Both effects increase the thermal conductivity of the thermal interface 750.

[0109] Reference Figure 10A 、 Figure 10B and Figure 10C , showing Figure 1BReferring to the accompanying drawings, the features and control of the relative positions of the control unit 130, TIM 700 and cold plate 180 located in the tilt tray of the rack assembly unit 100 are described. Figure 1B and Figure 10A 、 Figure 10B and Figure 10C The middle tray is shown in the open position and tilted relative to the rack frame. The control unit includes a TIM 700, as shown in FIG. 9A to 9D As depicted, the TIM 700 is disposed on the upper surface of a TIM receiving portion 133, which is surrounded by a groove 134. A seal 710, such as an O-ring, is located in the groove 134. In the open position, the control unit and the TIM are not in contact, wherein the control unit is located adjacent to the cold plate and angled relative to its lower surface and aligned to couple to the cold plate as the tray moves to the closed position. Figure 10B , the control unit 130 located in the upper and lower trays in the closed position is shown coupled to the cold plate 180 via the TIM 700. Also shown is the coupling of the connector 135 of the control unit to the header 165 of the tray.

[0110] Furthermore, the exemplary rack assembly units 100 and 300 are configured to create a leak-proof encapsulation of a phase change thermal interface material (TIM) 700 between the housing 131 of the control unit 130 and the cold plate 180. The rack assembly units 100 and 300 are also configured to generate a contact force at a thermal interface (TI) 750 between the control unit and the cold plate 180.

[0111] An advantage of the exemplary rack assembly arrangement of the present disclosure and a target problem solved by the exemplary rack assembly unit is protecting the TIM 700, which is a layer 701 on the housing 131 of the control unit 130, from damage when the control unit is replaced following the replacement procedure. Furthermore, the exemplary rack assembly unit is configured to overcome the problem of generating the necessary contact pressure at the TIM between the control unit and the cold plate 180 secured to the rack frame 110.

[0112] For example, automotive electronic control units (ECUs) are being replaced by more complex domain control units (DCUs) or, increasingly, multi-domain control units (MDCs). Both types of control units, or controllers for short, are devices designed to support and control various functional domains of a vehicle, such as advanced driver assistance systems (ADAS) or infotainment systems. DCUs are typically less complex devices developed to operate within a single domain, while MDCs control functions from more than one domain.

[0113] In the case of a high-performance control unit 130 (e.g., dedicated to ADAS functionality), where power dissipation reaches over 150 W, forced liquid cooling is often the only possible solution for keeping the temperature of delicate electronics within safety and lifetime limits. This is due to the high maximum ambient temperatures typically encountered in automotive applications when the vehicle is operating under operating conditions (above 50°C), as well as the limited thermal robustness of logic components such as system-on-chips or memory modules. A cooling system 181 circulates liquid coolant within a cold plate 180, which is used to dissipate thermal energy from hot areas. Such a cold plate 180 can be integrated into the vehicle rack server system 500 and cannot be replaced along with the control unit 130. Figure 1A A schematic diagram of a carrier rack server system 500 is shown equipped with a cold plate 180 and an electronic control unit 130. In the schematic diagram, the heat flow path 760 between these components is marked by arrows.

[0114] To allow heat to flow from the electrical / electronic components within the control unit 130 to the cold plate 180, an efficient heat flow path is established between these components. One possible method for achieving this heat flow path is to use a thermal interface material (TIM) 700. TIM 700 is used to reduce the so-called thermal contact resistance between mating surfaces, thereby allowing improved heat flow across the interface. To allow efficient heat transfer through the TIM layer 701, the TIM layer 701 is applied between the heat source (e.g., the control unit's housing 131) and the cold plate 180 while firmly pressing the two components against each other. This contact pressure plays an important role in improving the thermal conductivity of the thermal joint by reducing the interface thickness and allowing the microcavities to be filled by the TIM 700. Both effects increase the thermal conductivity of the interface.

[0115] In the case of a carrier rack server system and control unit and rack assembly units 100, 300 in an automobile, a number of technical problems may arise, examples of which are presented below:

[0116] 1. Create a thermally efficient heat flow path between the control unit housing 131 and the cold plate 180 for electronics cooling.

[0117] 2. Method for assembling the housing 131 and TIM layer 701 of a control unit into a rack assembly unit 100, 300 while protecting the TIM layer from damage during insertion of the control unit.

[0118] 3. Apply appropriate contact pressure to the thermal interface filled with the TIM layer 701 without damaging delicate electronic or mechanical components (connectors).

[0119] 4. In the case of utilizing phase change thermal interface material 700, develop leak proof TIM receiving portion 133, groove 134, seal 710 which will prevent leakage / dripping of liquid TIM.

[0120] 5. Apply appropriate contact force on the thin layer 701 of the TIM 700 within the frame geometry tolerances caused by the manufacturing process.

[0121] 6. Provide a universal, cost-effective and compact rack assembly unit 100, 300 that is suitable for all vehicle categories from economy vehicles to luxury vehicles.

[0122] 7. Provide a modular rack assembly unit 100, 300 that can be easily scaled depending on the number of insertion slots required.

[0123] 8. Provide a rack that allows quick and easy replacement of control units with only limited access to these devices (due to the rack being installed in the motor vehicle), in particular from the front (with Figure 1A on the opposite side of the back panel in the printer).

[0124] The first problem addressed by the exemplary arrangement of the present description and the advantages of the arrangement relate to "creating a thermally efficient heat flow path 760 between the control unit housing 131 and the cold plate 180 for electronics cooling," which is addressed by the exemplary design using a layer 701 of thermal interface material 700 between the control unit housing 131 and the cold plate 180. To maintain the required cleanliness of the device, it is assumed that a solid-state TIM 700 will be used between the control unit housing 131 and the cold plate 180, which can be easier to replace, less "messy," and more stable than thermal grease or gel. However, it will be appreciated that alternative solutions for applying phase change materials are possible.

[0125] The second problem addressed and advantage of the exemplary arrangement of the present disclosure relates to "assembling a control unit (e.g., a control unit) housing and a TIM layer into a rack assembly unit while protecting the TIM layer from damage during insertion of the control unit." This problem is addressed by the exemplary design of applying a TIM 700 to the housing 131 of the control unit 130 before inserting the control unit into the tray 150. Subsequently, the control unit is inserted into the opened tray. In the next step, the tray is closed by rotating it about the tilt axis 201 (hinge mechanism 200) or by pushing it through guide slots 410, 420 (alternatively, guide coupling mechanism 400). In the final step, the position of the control unit is secured, and the required contact force is applied to the thermal interface 750 by the fixing screws 220, which are available at the front of the rack assembly unit 100. During this process, when the TIM reaches its final position in the assembly, it is already in contact engagement with the cold plate 180, thus preventing any physical interaction between the TIM and the rack components during assembly. Consequently, the risk of potential damage to the TIM layer is limited.

[0126] Another problem addressed and advantage of the exemplary arrangements of the specification relates to "applying appropriate contact pressure to the thermal interface filled with the TIM layer without damaging delicate electronic or mechanical components (connectors). This problem is addressed by the exemplary arrangements by eliminating any delicate components from the load transfer path. In both exemplary arrangements, contact force is transferred between the set screw 220, the control unit housing 131, the tray 150, and the rack mechanical components (hinge 205, hinge receptacle 255, or guide slots 410, 420, or first guide pins 430, 440). The backplane connector is isolated from the load path by using a flat flexible cable (FFC) that connects the backplane 570 to the connector 166 secured to the tray. Therefore, any force generated by pushing the tray against the cold plate during assembly is compensated by the deflection of the FFC strap. Consequently, no damaging force is applied to the connector. Instead of using an FFC strap and connector 166, another possible implementation of the electrical connection between the control unit 130 and the backplane 570 is to use a so-called floating board-to-board connector. These electrical connectors are able to compensate for translational and angular misalignment and therefore do not generate undesirable forces on the PCB to which they are connected.Another advantage of using floating connectors is higher signal integrity due to lower electrical noise injected into the system when the FFC strip is eliminated and the number of physical interconnects is minimized.

[0127] Another problem addressed and advantage of the exemplary configurations of this specification relates to "developing a leak-proof TIM application area that prevents leakage / dripping of liquid TIM when utilizing a phase-change thermal interface material." This problem is addressed by the exemplary design of a sealed application area or TIM receiving portion 133 for phase-change thermal interface material 700, located on the top of control unit 130. This area is surrounded by a groove 134 within which an O-ring seal 710 is disposed. During assembly, when the control unit housing is pushed against the cold plate, this O-ring seal 710 is also pressed against the cold plate surface and seals the area defined by it. Phase-change TIM 700 can be applied in this area.

[0128] Another problem addressed and advantage of the exemplary arrangement of the present disclosure relates to "applying an appropriate contact force on thin layer 701 of TIM 700 within the geometric tolerances of the housing resulting from the manufacturing process." This problem is addressed by the exemplary invention through the introduction of set screws 220 that allow adjustment and simultaneous limitation of the contact force and the position of tray 150 (loaded with control unit 130) in housing 170. Furthermore, specially designed ribs 164 in base 155 of tray 150 improve the distribution of contact force on housing 131 of the control unit.

[0129] Another problem addressed and advantage of the exemplary arrangement of the specification relates to "providing a versatile, cost-effective, and compact rack suitable for all vehicle categories, from economy vehicles to luxury vehicles," which is addressed by using a simple sheet metal structure for the rack, comprising a rack frame and tray components that can be screwed, riveted, or welded into the final product. The sheet metal components of the exemplary rack are cut or stamped from sheet metal and bent into the desired shape, allowing for a cost-effective design suitable for all types of vehicles. Furthermore, the exemplary design is based on simple geometric features (hinges or guide cutouts) that allow for the replacement and securing of the control unit 130 without the need for complex or cumbersome mechanisms.

[0130] An additional problem solved by the exemplary arrangement of the specification and an advantage of the arrangement relates to "providing a modular rack design that can be easily scaled depending on the number of insertion slots required", which is solved by the exemplary invention by designing a section or rack component unit 100, 300 that can be replicated in a final rack structure, which includes rack component units stacked as many times as needed to accommodate the required number of control units 130, such as DCU / MDCs.

[0131] Another problem addressed by the exemplary arrangement of the present specification, as well as an advantage of the arrangement, relates to "providing a rack design that allows for quick and easy replacement of control units 130 with only limited access to these devices (caused by the rack being mounted in the vehicle), particularly from the front (with Figures 2A to 2D This problem is solved by the present invention by designing the rack assembly units 100, 300 in such a way that only front access is required for inserting, extracting, and securing the control units 130 in position in the rack. In addition, if the cold plate 180 needs to be cleaned of excess TIM, this can be done after removing the control units 130 from the tray 150.

[0132] The exemplary rack assembly units 100 and 300 according to the present disclosure can, for example, be constructed from assembled sheet metal components. This can be achieved by riveting (as exemplified in the figure below) or other suitable methods such as welding, screwing, or other methods. This approach has the advantage of low mass production costs. The components are initially cut from large sheets of metal (aluminum alloy or steel, but possibly other materials such as magnesium alloy), bent into the desired shape, assembled, and secured to the final rack configuration. Other advantages of this assembly are low weight and high compactness, as, in the exemplary arrangement, the component wall thickness is low, on the order of approximately 1 mm. Furthermore, both rack assembly alternatives based on the hinge mechanism 200 and the guide pin coupling mechanism 400 can be constructed using relatively simple, inexpensive components, such as hinges and guide pins.

[0133] Figures 2A to 4D Shown is a hinge mechanism and a guide pin mechanism ( Figures 5A to 6C ) provides an overall view of a rack component unit 100 or section.

[0134] The components listed in the accompanying drawings have the following functions:

[0135] Chassis frame 110 - serves as a support for all other components and allows the entire assembly to be installed in a motor vehicle.

[0136] Tray 150 serves as a support for the control unit's housing 131. It also transmits thermal interface forces between the chassis frame 110 and the cold plate 180, limiting undesirable loads on fragile components such as PCBs and connectors. The complete chain of force-transmitting components is as follows: cold plate 180 -> thermal interface material 700 -> control unit's housing 131 -> tray 150 -> hinge 205 / first and second guide pins 430 and 440 and fixing screws 220 and 221 -> chassis frame 110.

[0137] Fixing screws 220, 221 - used to secure the tray in position within the rack frame. These screws also generate and limit the securing force within the mechanism (both within the hinge mechanism 200 and the guide pin coupling mechanism 400), thereby allowing for the required contact pressure within the thermal interface material 700 between the control unit housing 131 and the cold plate 180.

[0138] Flat Flexible Cable (FFC) with connector 166 - Compensates for angular and linear displacement of the tray due to opening the tray with the fixing screws and adjusting the position of the tray. The FFC connects the head 165 fixed to the tray with the connector inserted into the backplane 570.

[0139] Header 165 in tray - used to connect connector 135 on the rear of control unit 130 to backplane 570 (via FFC strap and connector 166).

[0140] Fixing screws 220, fixing brackets 265 and 117, 137 - In both alternative arrangements, the fixing brackets 265 or, in the alternative arrangement, the fixing brackets 117 are available on the rack frame 110, and corresponding fixing brackets 210 are located on the tray 150 or provided as fixing brackets 137 coupled to the control unit 130 and the tray 150. In either case, they allow the use of the fixing screws 220, 221 to secure the position of the tray in the rack.

[0141] Control unit housing contact ribs—ribs 164 stamped into the tray's base 155—are used to compensate for geometric inaccuracies caused by the manufacturing and assembly processes. When formed on the bottom of the tray, ribs 164 create line contact between the control unit housing 131 and the tray 150. Because they are separated (raised above) from the rest of the tray's base 155, ribs 164 ensure contact regardless of tray tolerances. Additionally, two set screws 220 generate a force that pushes the tray 150 against the control unit housing 131. This force deflects the tray's thin-walled structure, improving contact between ribs 164 and the control unit housing 131.

[0142] Hinge 205 (hinge mechanism 200 )—connects the tray to the rack frame at the hinge 205 and hinge receptacle 255 , allowing rotational movement (tilt) of the tray 150 .

[0143] Pin Guide Cutouts (Guide Pin Coupling Mechanism 400) - Cutouts or guide slots 410, 420 provided in the side walls 111, 112 of the rack frame 110 that guide first and second guide pins 430, 440 located on the side walls 151, 152 of the tray 150. The shape of the cutouts or guide slots 410, 420 provides for two types of movement of the tray relative to the rack frame:

[0144] First, the linear motion of the tray is generated by the horizontal linear portions 412, 422 of the cutouts / guide slots 410, 420, allowing the tray to slide parallel to the bottom surface of the cold plate 180.

[0145] Secondly, the non-linear trajectory motion generated by the inclined portions 413 , 423 of the cutouts / guide slots 410 , 420 forces the tray 150 (loaded with the control units 130 ) to be pushed against the cold plate 180 , thereby ensuring a thermal interface 750 between the control units 130 and the cold plate 180 .

[0146] Guide cutout cover or side wall cover 118 (guide pin coupling mechanism 400) - a plate that covers the cutouts / guide slots 410, 420 in the side walls 111, 112, protecting the mechanism and adding rigidity to the structure.

[0147] First guide pin 430 and second guide pin 440 —cylindrical pins attached to tray 150 , an arrangement for sliding through cutouts / guide slots 410 , 420 in rack frame 110 .

[0148] Figures 4A to 4D The design details of the tray tilt mechanism are shown with the tray open, ready for insertion of the control unit housing. The tilt angle is defined in the example solution by two design features: the fixing bracket receiving slots 260 in the side walls of the frame prevent the fixing brackets 210 ( Figure 4C and Figure 4D ); The hinge stopper slit 270 in the rear wall 153 (back panel side) prevents the hinge from rotating the stopper 242 ( Figure 4D ).

[0149] Another possible implementation of a rack equipped with a tray tilt mechanism described in this article is based on the use of floating connectors to connect the control units installed in the tray to the backplane. Floating connectors can replace FFC strips, allowing small-scale compensation of angular and planar misalignments. Typical misalignments that can be compensated by floating connectors amount to translational positioning inaccuracies of less than 1 mm in the X and Y plane directions, and angular misalignments of less than 3 degrees. Therefore, the use of this type of device requires a higher rack manufacturing and assembly accuracy compared to solutions based on FFC strips. The advantage is that the electrical noise generated in the connection is reduced, which is very desirable from a signal integrity point of view.

[0150] 7A to 7CThe following steps are shown for inserting a control unit into a rack equipped with a tray tilt mechanism. To do this, the following steps are performed: The guide pins 132 on the control unit's housing 131 are inserted into the front slots 159 in the tray's side walls 151, 152, while the tray is tilted at an angle relative to the rack frame into an open position. The control unit 130 is pushed into the open tray 150 until it reaches its final installation position, in which the connector 135 on the rear of the control unit is fully inserted into the tray's head 165. The tray, loaded with the control unit 130, is rotated into its final position until the TIM 700 on top of the control unit's housing 131 contacts the cold plate 180. By tightening the set screws 220 in the fixing brackets 265 and 210, the ribs 164 in the tray's base 155 push against the control unit's housing 131, securing the tray's final position and generating force in the thermal interface between the control unit and the cold plate. Figure 7C The tray loaded with control units is shown secured in its final position, establishing a thermal interface 750 between the control units 130 and the cold plate 180, with an enlarged view detailing the ribs 164 in the bottom wall of the tray pushing against the DCU / MDC housing / control unit housing 131.

[0151] Figures 8A to 8D The following steps are shown to sequentially insert the control unit into a rack equipped with a guide pin mechanism:

[0152] - while the tray is in the open position, insert the guide pins 132 of the control unit 130 into the front slots 159 in the side walls 151, 152 of the tray,

[0153] - Push the control unit into the opened tray until it reaches its final installation position, in which the connector 135 at the rear of the control unit is fully inserted into the head 165 of the tray,

[0154] - push the tray loaded with the control units to its final position until the TIM 700 on top of the housing 131 of the control unit comes into contact with the cold plate 180 (the tray slides through the non-straight portion of the guide cutout, resulting in a simultaneous movement towards the back plate and the cold plate),

[0155] - By tightening the fixing screws 221 at the fixing brackets 117 and 137, the ribs 164 in the bottom of the tray push against the control unit housing, fixing the final position of the tray and generating a force in the thermal interface between the control unit and the cold plate.

[0156] The proposed vehicle-server-like carrier rack server system 500 allows for an enhanced thermal interface 750 between the DCU / MDC and the cold plate 180, achieved through the use of a phase-change thermal interface material 700. Typically, phase-change thermal interface materials (TIMs) used in electronics cooling systems are solid materials at room / ambient temperatures that become liquid when the system's temperature rises. In the liquid state, the phase-change material (PCM) 703 flows into surface irregularities, filling air gaps in the thermal interface and improving its thermal conductivity. Typical phase-change temperatures for PCMs used in electronics cooling applications reach 50°C to 70°C. Above this temperature, the solid PCM becomes liquid until the temperature drops to the same or similar value.

[0157] A problem associated with using PCMs in automotive applications is the need to ensure leak-proofing of the PCM application area, which prevents molten material from leaking / dripping under normal vehicle operating conditions (vibration, shock, etc.). To meet this requirement, the two design options proposed in this document can be modified. This modification is applied to the control unit housing by forming a groove around the TIM 700 on the surface of the control unit housing, allowing the control unit to interface with the cold plate.

[0158] like 9A to 9D As shown, the groove is filled with an O-ring, which is pressed against the cold plate, sealing the application area of ​​the PCM. 9A to 9D The grooves and O-rings used in a tray tilt rack design are shown; however, the same modifications can be applied to racks equipped with a guide pin mechanism. Figure 9A An overall view on the housing 131 of the control unit with the groove 134 , the O-ring seal 710 and the phase change TIM layer 701 is shown. Figure 9B depicts a front view of the rack assembly unit, wherein DD shows a section line through the rack assembly and a section through the rack assembly unit, and Figure 9D An enlarged detail view of the O-ring sealing the TIM receiving portion 133 against the cold plate is shown.

[0159] 10A to 10C A stack of three sections, or rack assembly units 100, of a tray tilt rack type is shown, with the middle tray in an open position. It can be seen that these sections can be replicated and stacked one on top of the other to create a larger capacity rack, thus operating with a larger number of control units. Due to this feature, the example rack design is a scalable solution. Figure 10CAn enlarged, detailed view of the gap between the O-ring and the cold plate is shown when the tray is in the open position. This gap allows for easy replacement of inserts without risking damage to the TIM layer on the top surface of the control unit. With the tray open, the gap between the TIM, O-ring, and cold plate is visible, allowing for safe insertion / removal of the control unit 130 covered with layer 701 of TIM 700.

[0160] This specification claims priority to U.S. provisional application US63 / 242,138, filed on September 9, 2021, the contents of which are incorporated herein by reference.

Claims

1. A rack assembly unit, the rack assembly unit (100, 300) being used to mount a control unit (130) to a carrier rack server system (500), wherein: The rack assembly unit (100, 300) comprises: Rack frame (110); a tray (150) for receiving the control unit (130); wherein the tray (150) is movably coupled to the housing frame at a coupling mechanism, the coupling mechanism being configured to provide for movement of the tray relative to the housing frame between a first open position and a second closed position; wherein, in the first open position, the tray (150) is spaced apart from the rack frame (110) to facilitate user access to the tray and the control unit receivable therein, and in the second closed position, the tray (150) is positioned to be fully inserted relative to the rack frame (110) and such that the control unit (130) located therein is disposed in a control unit operating position thermally coupled to a cold plate of a cooling system to provide cooling to components of the control unit, wherein the control unit (130) comprises a housing (131), the housing (131) comprising a thermal interface material receiving portion (133) for receiving a thermal interface material (700) in the form of a thermal interface material layer (701), wherein the thermal interface material receiving portion (133) is defined by a groove (134) formed in an upper surface of the control unit, the groove defining a periphery of the thermal interface material receiving portion (133) and having a shape corresponding to the cold plate, and wherein a seal (710) surrounding the thermal interface material receiving portion is located in the groove.

2. The rack assembly unit according to claim 1, wherein: The rack assembly unit further includes a securing mechanism for securing the tray in the second closed position, the securing mechanism and the rack frame being configured such that when the tray is secured in the second closed position at the securing mechanism, the control unit is positioned in contact with the cold plate to define a thermal interface therebetween, and a controlled contact force is applied between the control unit and the cold plate.

3. The rack assembly unit according to claim 1 or claim 2, wherein: The control unit is also electrically and / or communicatively coupled to the carrier rack server system (500) via the rack assembly unit when located in the control unit working position, the control unit (130) having at least one connector (135) including an electrical and / or communication connector, and the rack assembly unit (100, 300) including a connector (166) and a corresponding header (165) for coupling the control unit to a backplane (570) of the carrier rack server system (500).

4. The rack assembly unit according to claim 1, wherein: The rack frame (110) includes a cold plate support portion for receiving and supporting a cold plate (180), and the rack assembly unit (100, 300) is configured such that when the tray (150) is in the first open position lower than the second closed position, the control unit located in the tray is spaced apart from the cold plate, and when the tray is in the second closed position, the control unit in the tray is positioned such that a heat transfer surface of the control unit is thermally coupled to a heat transfer surface of the cold plate to form a thermal interface (750) therebetween.

5. The rack assembly unit according to claim 4, wherein: The rack frame (110) has a first side wall (111) and a second side wall (112), wherein the cold plate support portion is defined by a first recess and a second recess formed at a top edge surface (111-3, 112-3) of each of the first and second side walls, wherein the first recess and the second recess of the cold plate support portion are positioned opposite each other so that in use the cold plate is arranged to extend between the first recess and the second recess and over a portion of the control unit located in the tray.

6. The rack assembly unit according to claim 1, wherein: When the control unit is located at the control unit working position, a thermal interface material (700) is provided between the control unit (130) and the cold plate (180), so that the heat transfer surface of the control unit and the heat transfer surface of the cold plate are thermally coupled via the thermal interface material.

7. The rack assembly unit according to claim 1, wherein: The coupling mechanism includes a hinge mechanism (200), wherein the tray and the rack frame are coupled at a rear portion of the rack assembly unit by means of the hinge mechanism, the hinge mechanism being configured to provide rotational movement of the tray relative to the rack frame.

8. The rack assembly unit according to claim 7, wherein: The tray and the rack frame are further coupled at the front of the rack assembly unit by means of a stop mechanism, the stop mechanism being configured to define and limit an angular range of movement of the tray relative to the rack frame between a first open position of the tray and a second closed position of the tray, the first open position being lower than the second closed position.

9. The rack assembly unit according to claim 7 or 8, wherein: The rack assembly unit further includes a hinge rotation stop (242) defined by a hinge stop slot (270) formed in a rear wall (113) of the rack frame (110) and a hinge stop protrusion (243) attached to the tray (150) and capable of being received in the hinge stop slot (270), the hinge rotation stop (242) being configured such that when the tray is tilted relative to the rack frame to the first open position, the hinge stop protrusion (243) engages with an upper edge surface (271) of the hinge stop slot (270) and limits further tilting of the tray relative to the rack frame.

10. The rack assembly unit according to claim 5, wherein: The coupling mechanism includes a guide pin coupling mechanism (400), wherein the tray and the frame frame are movably coupled at the first side wall and the second side wall by the guide pin coupling mechanism to provide movement by translation of the tray relative to the frame frame between the first open position and the second closed position; and Wherein, the tray and the rack frame include corresponding guide pins and guide slots located at the first side wall and the second side wall of each of the tray and the rack frame.

11. The rack assembly unit according to claim 10, wherein: The movement of the tray relative to the rack frame is controlled by a range of movement of each guide pin in a corresponding guide slot defined by the guide slot, wherein the range of movement provides for horizontal and vertical translation of the tray relative to the rack frame.

12. The rack assembly unit according to claim 2, wherein: the securing mechanism being defined by corresponding features of the rack frame and the tray or the control unit, The rack frame includes one or more fixing brackets (117, 210); and The tray or the control unit coupled to the tray comprises corresponding one or more fixing brackets (137, 265); The fixing screws (220, 221) are engaged with the corresponding fixing brackets of the rack frame and the tray or the control unit to fix the position of the tray relative to the rack frame in the second closed position.

13. A carrier rack server system, wherein: The carrier rack server system (500) comprises: a rack support (510) for receiving at least one rack assembly unit (100, 300) according to any one of claims 1 to 12; a backplane (570) comprising one or more backplane connectors for interfacing with the control unit; a cold plate (180) coupled to a cooling system (181), the cold plate (180) being located in the rack support (510) and capable of being received on the rack assembly unit (100, 300); The carrier rack server system (500) further includes: a rack assembly unit (100, 300) located in a housing for mounting a control unit (130) to the carrier rack server system (500), the rack assembly unit (100, 300) including a connector (166) coupled to the backplane and one or more headers (165), and the cold plate (180) located on the rack assembly unit; a control unit (130) located in the rack assembly unit (100, 300); wherein the rack assembly unit (100, 300) is configured such that when the control unit (130) is in an operating position in the rack assembly unit, the control unit (130) is directly thermally coupled to the cold plate (180) to provide heat transfer from the control unit (130) to the cold plate (180), wherein the control unit (130) includes one or more electrical or communication connectors (135) and a thermal interface material layer (701) located on a housing (131) of the control unit; wherein the rack assembly unit (100, 300) is configured such that when the control unit (130) is located in a working position in the rack assembly unit, the control unit (130) is directly thermally coupled to the cold plate (180) at the thermal interface material layer (701) to provide heat transfer from the control unit (130) to the cold plate (180), and the control unit is directly electrically and / or communicatively coupled to the backplane via a connector (166) and a corresponding header (165) of the rack assembly unit.

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