Cold plate device, method of manufacturing a cold plate device, and method of improving flow uniformity through the effective volume of a cold plate device - Patents.com

Abstract

To provide a cold plate apparatus for tuning cold plate plenum transitions, and a method of enhancing the flow uniformity through an active volume of the cold plate apparatus.SOLUTION: A cold plate 200 includes walls 216 that surround an active volume 210 adjacent to an inlet plenum 208. The walls include an inlet opening 209 at one end of a top side of the inlet plenum, a plenum opening between the inlet plenum and the active volume, and a blocker 220 that partially separates the inlet plenum from the active volume. The blocker is structurally configured to preferentially redirect the flow from the inlet plenum into the active volume.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to the electrical, electronic, thermal, mechanical, and computer arts, and more particularly to devices for cooling computer components. [Background technology]

[0002] One type of device for cooling computer components is a "cold plate," which is a conductive heat sink placed in direct contact with the component or in contact with a thermally conductive material (TIM). A cold plate may be a solid block of metal, often with fins to facilitate air cooling, or it may be a hollow structure through which a coolant (e.g., water) flows from an inlet to an outlet.

[0003] It is generally desirable in a heat exchanger to provide a plenum on each side of the heat exchanger's active (e.g., finned) volume. This plenum is wide and thick enough to establish a uniform pressure (isobaric) condition that creates substantially uniform flow through the active area. However, in typical cold plate applications, the size and spacing of the components to be cooled limits the size of the plenum. Often, the cold plate plenum is not large enough to establish a condition close enough to isobaric to achieve the desired flow uniformity. Summary of the Invention [Problem to be solved by the invention]

[0004] The principles of the present invention provide a technique for adjusting the transitions in the cold plate plenum. [Means for solving the problem]

[0005] According to one aspect, an exemplary cold plate apparatus includes a wall surrounding an effective volume adjacent an inlet plenum and a blocker partially separating the inlet plenum from the effective volume. The wall includes an inlet opening at one end of the inlet plenum and a plenum opening between the inlet plenum and the effective volume. The blocker is structurally configured to preferentially redirect flow from the inlet plenum toward the effective volume.

[0006] According to another aspect, an exemplary cold plate apparatus includes an upper portion having an inlet opening therethrough, a lower portion surrounding an effective volume and an inlet plenum on one side of the effective volume, where the inlet plenum overlies the inlet opening, and a deflector projecting from an outer wall of the inlet plenum toward the effective volume. Optionally, the deflector near a lower surface of the inlet plenum may project closer to the inlet opening than the deflector near an upper surface of the inlet plenum.

[0007] According to another embodiment, an exemplary cold plate apparatus includes an upper plate having an inlet opening therethrough, a lower plate, and a stack of N intermediate plates sandwiched between and attached to each other and to the upper and lower plates, each intermediate plate having a central opening, the central openings of the stack of intermediate plates overlapping to define an interior volume bounded by the upper, lower, and intermediate plates. The interior volume includes an effective volume, an inlet plenum on one side of the effective volume, and an inlet opening overlapping the inlet plenum. This embodiment also includes a deflector projecting from an outer wall of the inlet plenum toward the effective volume. The deflection portions near the bottom plates protrude more into the effective volume than the deflection portions near the top plates, so that at the bottom intermediate plate, the deflection portions protrude a distance P from the outer wall of the inlet plenum, and at the top intermediate plate, the deflection portions protrude a second distance P / N from the outer wall of the inlet plenum, with each intermediate plate ascending from the bottom plate to the top plate having a shorter protrusion of the deflection portions by P / N.

[0008] According to another aspect, a cold plate apparatus is constructed by an exemplary process including: obtaining an initial cold plate design including an effective volume, an inlet plenum adjacent to the effective volume and connected to the effective volume through a plenum opening, and an inlet opening overlapping the inlet plenum; conducting a computational fluid dynamics analysis of the initial cold plate design; identifying a simulated flow in a first section of the effective volume proximal to the inlet opening that is greater than a simulated flow in a second section of the effective volume distal to the inlet opening; and creating a modified cold plate design by incorporating a shielding portion into the initial cold plate design that partially separates the inlet plenum from the effective volume. The shielding portion shields the entire height, or a portion of the entire height, of the plenum opening adjacent to the inlet opening and a portion of the height of the plenum opening that decreases as one moves along the plenum opening away from the inlet opening. The shielding portion shields the plenum opening to a greater extent near a lower side of the plenum opening than near an upper side of the plenum opening. Further steps include performing a computational fluid dynamics analysis of the modified cold plate design, determining that the simulated flow in the first section and the simulated flow in the second section are within 10 percent of the average flow rate across the plenum opening, and fabricating a cold plate apparatus according to the modified cold plate design.

[0009] According to another aspect, a method of improving flow uniformity through an effective volume of a cold plate device includes introducing coolant into an inlet plenum of the cold plate device through an inlet opening of the cold plate device; shielding a portion of the coolant from entering from the inlet plenum into a first section of the effective volume, the first section being proximate to the inlet opening; and deflecting a portion of the coolant from the inlet plenum to enter a second section of the effective volume, the second section being downstream of the first section along the inlet plenum.

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

[0011] Improved flow profile through the effective volume of the cold plate

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

[0013] Improving flow uniformity through the effective volume of a cooling plate

[0014] These and other features and advantages of the present invention will become apparent from the following detailed description of illustrative embodiments thereof, which is to be read in connection with the accompanying drawings. [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 is a cutaway view of a prior art cooling plate. [Figure 2] FIG. 1 is a first cutaway view of a cooling plate with a regulated plenum in accordance with an exemplary embodiment; [Figure 3] 3 is a second cutaway view of the cooling plate shown in FIG. 2. [Figure 4] FIG. 4 illustrates certain dimensions of the flow shield shown in FIG. 3. [Figure 5] 4 is a third cutaway view of the cooling plate shown in FIGS. 2 and 3. FIG. [Figure 6] 6 illustrates certain dimensions of the flow deflector shown in FIG. 5. [Figure 7] 6 illustrates certain dimensions of the flow deflector shown in FIG. 5. DETAILED DESCRIPTION OF THE INVENTION

[0016] FIG. 1 shows a cutaway view of a prior art cold plate 100, which includes an upper portion 102 and a lower portion 104, with an inlet nozzle 106 and an outlet nozzle (not shown to avoid clutter) connected to the upper portion. The upper and lower portions 102, 104 enclose an inlet plenum 108, an effective volume 110, and an outlet plenum 112. Note that the outer walls 116, 118 of the inlet plenum 108 and the outlet plenum 112 are smooth, continuous, and planar. Also note the openness of the effective volume 110 along the entire length of the inlet plenum 108 and the outlet plenum 112. Individual features, such as fins, pins, or mesh, are present within the effective volume 110 but are not shown to avoid clutter. As will be appreciated by those skilled in the art, each feature of the effective volume defines a route for fluid flow from the inlet plenum 108 to the outlet plenum 112 and typically provides an extended surface area to facilitate heat transfer.

[0017] In conventional cold plates, flow from the inlet of the cold plate typically enters through the top of the inlet plenum at a significant angle relative to the length of the inlet plenum (e.g., greater than 70°), strikes the bottom of the inlet plenum, and "splatters" in a manner that results in uneven coolant flow through the effective volume of the cold plate. For example, in conventional cold plates, the coolant flow floods into a first section of the effective volume near the inlet opening, partially bypasses a second section of the effective volume downstream of the first section, and then enters a third section of the effective volume downstream of the second section.

[0018] Embodiments of the present invention advantageously correct at least some of this flow non-uniformity, i.e., improve flow uniformity through the useful volume, by providing (i) a flow obstruction near the inlet opening that mitigates excessive flow through a first section of the useful volume, and (ii) a flow deflection proximal to (and in some embodiments slightly upstream of) a second section of the useful volume that promotes flow through the second section.

[0019] FIG. 2 shows a first cutaway view of a cold plate 200 having a wall including an upper portion 202 and a lower portion 204 that enclose a regulated inlet plenum 208 that opens to an effective volume 210, which opens to an outlet plenum 212. Individual features, such as fins, pins, or mesh, are not shown within the effective volume 210 to avoid clutter. As will be appreciated by those skilled in the art, such features define a route for fluid flow from the inlet plenum 208 to the outlet plenum 212 and typically provide an extended surface area to facilitate heat transfer. The upper portion 202 may be a single plate or billet or multiple laminates, and the lower portion 204 may be a single plate or billet or multiple laminates 230 (further described with reference to FIG. 5). An inlet nozzle 206 is connected to the inlet plenum 208 through the upper portion 202. In one or more embodiments, outlet plenum 212 is symmetrical to inlet plenum 208, allowing the flow through cold plate 200 to be conveniently reversed without compromising the effectiveness of the exemplary cold plate. In one or more embodiments, a shield 220 (described further with respect to FIG. 3 ) is located at plenum opening 221 (see FIG. 3 ) between a portion of inlet plenum 208 and a portion of effective volume 210. Inlet plenum 208 includes first region 234, second region 236, and third region 238. In normal operation, the third region is downstream of the second region, and the second region is downstream of the first region.

[0020] 3 , which shows a second cutaway view of cooling plate 200, an inlet opening 209 is formed in top portion 202 for receiving an inlet nozzle (206 shown in FIG. 2 ). A shield 220 partially separates inlet plenum 208 from effective volume 210. Shield 220 is positioned adjacent to inlet transition section 207, where inlet nozzles (206 shown in FIG. 2 ) would normally be attached via inlet opening 209. The shield is structurally configured to preferentially redirect flow from the inlet plenum toward the effective volume, thereby preventing too much flow “splashing” from the inlet opening onto the underside of the inlet plenum into a first section of the effective volume near the inlet opening and too little flow into a second section of the effective volume away from the inlet opening. For example, in one or more embodiments, the shield 220 includes multiple fingers 222 of different lengths and is structurally configured to preferentially redirect flow in that the fingers near the top portion 202, or near the top surface of the inlet plenum 208, are shorter (and do not extend more distally from the inlet transition 207) than the fingers near the bottom plate 204, or near the bottom surface of the inlet plenum 208. For example, in one or more embodiments (shown in FIG. 4 ) in which the lowest finger has a length of L, the reduction in length from each lower finger to the next upper finger is (L / number of fingers N), so that for three fingers, each upper finger is ⅓ the length of the longest / lowest finger, and the top finger is L / N, or ⅓, of the length of the bottom finger. One effect of the unequal finger lengths is that the shields 220 near the upper portion 202 restrict flow into the effective volume 210 less than the shields near the lower portion 204. During operation of the cold plate 200, the flow from the nozzles impinges on the lower surface of the inlet plenum, which can create high velocities along that surface, causing the coolant flow near the lower portion 204 to move at a higher velocity toward the effective volume 210 than the coolant flow near the upper portion 202. This flow can force more coolant into the effective area near the nozzles than desired, particularly near the lower surface of the inlet plenum.Generally, the shielding 220 helps direct this high-velocity coolant flow away from a first region of the effective volume 210 closest to the inlet transition 207, downstream along the inlet plenum 208, and toward regions 236 and 238 of the effective volume 210 that may otherwise be "starved for flow."

[0021] In one or more embodiments, the dimensions of the shielding portion 220 are obtained by performing a computational fluid dynamics (CFD) analysis of the flow entering the effective volume 210 from the inlet plenum 208 using CFD software, starting with a predetermined initial mesh density (e.g., at least 100 elements across the plenum opening 221 in the mesh of a finite element calculation). In one or more embodiments, the mesh size is reduced (i.e., more and smaller elements) until the maximum and minimum velocity values ​​obtained with the smaller mesh size remain within 5% of the values ​​obtained with the next larger mesh size. The dimensions of the shielding portion are varied until the CFD analysis yields flow uniformity across the plenum opening within a predetermined percentage (e.g., 10%) of the average flow rate through the plenum opening 221. Those skilled in the art are familiar with suitable CFD software, such as, by way of example and not limitation, ANSYS FLUENT® or ANSYS CFX® software available from Ansys, Inc. of Canonsburg, Pennsylvania, USA. Those skilled in the art are familiar with constructing a suitable mesh for a finite element analysis with appropriate element types and mesh fineness, including more mesh detail in areas of higher flow gradients, and iteratively arriving at a suitable mesh size.

[0022] 3, the outer wall 216 of the inlet plenum 208 includes a deflection portion 224 that protrudes from the outer wall toward the effective volume 210 and is generally aligned near a second region of the effective volume. Also referring now to FIG. 5, in one or more embodiments, the outer wall 217 of the outlet plenum 212 includes a deflection portion 225. The outlet deflection portion 225 directs flow from the effective volume 210 (as seen in FIGS. 2 and 3) toward an outlet transition portion 227 that leads to an outlet nozzle 228 via an outlet opening 229.

[0023] Referring again to FIG. 3 , in one or more embodiments, the deflection section 224 protrudes more toward the effective volume 210 near the lower surface of the lower plate 204 or inlet plenum and protrudes less toward the effective volume near the upper surface of the upper plate 202 or inlet plenum. For example, in one or more embodiments (shown in FIG. 6 ), the distance of protrusion varies linearly with the height of the deflection section 224, with the lowest point protruding a distance P and the highest point protruding a distance (P / N), where N is the distance in layers or dimensional units from the bottom to the top of the deflection section. Thus, in one or more embodiments, the deflection section 224 has a slope toward the effective volume 210. Again, this is associated with faster flow near the bottom surface. However, in one or more embodiments, the deflection section 224 protrudes the same distance toward the effective volume throughout its entire height and is therefore not sloped. In one or more embodiments, the maximum protrusion of the deflection portion 224 may be spaced apart from the inlet transition 207 in proportion to the amount of protrusion, such that a larger portion of the deflection portion protrudes further from the inlet transition. That is, (as shown in FIG. 7 ) the deflection portion 224 of each layer i is spaced apart from the centerline of the inlet opening 209 by a distance X i It may be protruding from the X i is P iHowever, in one or more embodiments, regardless of the magnitude of the maximum protrusion, the maximum protrusion of deflection portion 224 is the same distance from inlet transition 207 at each level. Thus, in one or more embodiments, the maximum protrusion of deflection portion 224 is the same distance from inlet transition 207 near upper portion 202 as it is near lower portion 204.

[0024] In one or more embodiments in which the deflection portion 224 protrudes more toward the effective volume 210, the deflection portion begins its protrusion closer to the inlet transition 207. Thus, the deflection portion 224 extends closer to the inlet transition 207 near the lower portion 204 than near the upper portion 202. For example, in one or more embodiments, the distance Y from the centerline of the inlet opening 209 to the beginning of the deflection portion 224 in each layer i of the deflection portion is i (PP i / P), where P i is the distance that the deflector 224 protrudes in layer i, and P is the maximum distance of protrusion from the outer wall of the inlet plenum 208.

[0025] Referring again to FIG. 5 , in one or more embodiments, the cold plate 200 between the top plate 202 and bottom plate 204 is constructed from intermediate layers 230, each of which is 0.25 millimeters (mm) to 0.5 mm (e.g., about 0.3 mm) thick. In one or more embodiments, there are six intermediate layers 230, such that the interior height of the cold plate 200 is 1.5 mm to 3.0 mm (e.g., about 1.8 mm) deep, and the thickness of the cold plate 200 is 2.0 mm to 4.0 mm (e.g., about 2.5 mm). In one or more embodiments, the cold plate 200 includes extended surfaces (e.g., pins, fins, or mesh) within the effective volume 210. For example, in one or more embodiments, the cold plate 200 has vertical fins within the effective volume 210, formed by cutouts in the intermediate layers 230 or by machining or shaping extensions in the bottom plate 204. Any suitable extended surface may be used. Fins, which are omitted from the drawings to avoid clutter, extend generally (generally vertically) from the upper and lower plates and define flow paths between the plenums.

[0026] Given the foregoing discussion, it will be appreciated that, broadly speaking, an exemplary cold plate apparatus according to one aspect of the present invention includes an upper plate 202 having an inlet opening 209 therethrough, a lower plate 204, and a stack of intermediate plates 230 sandwiched between and attached to each other and to the upper and lower plates. Each intermediate plate has a cutout defining an inlet plenum 208 and an outlet plenum 212, which are enclosed by the upper, lower, and intermediate plates. An interior volume 205 includes an effective volume 210, an inlet plenum 208 on one side of the effective volume, and an inlet transition section 207 overlying the inlet opening. The exemplary apparatus 200 also includes a shield 220 separating the inlet plenum 208 from the effective volume 210, the shield having multiple fingers 222 at different levels of the stack, with the fingers higher in the stack providing less separation than the fingers lower in the stack. In addition to stacks of plates, other approaches such as machining techniques, 3D printing techniques, etc. may be used, in which case the "steps" mentioned in the plates may be "smoothed."

[0027] In one or more embodiments, the exemplary apparatus also includes a deflection portion 224 that protrudes from the outer wall 216 of the inlet plenum 208 toward the effective volume 210. In one or more embodiments, the deflection portion near the bottom plate 204 protrudes closer to the inlet transition portion 207 than the deflection portion near the top plate 202. In one or more embodiments, the deflection portion near the bottom plate protrudes further toward the effective volume 210 than the deflection portion near the top plate.

[0028] In one or more embodiments, in normal operation, the inlet plenum encompasses a first region 234 immediately adjacent the inlet transition, a second region 236 downstream from the first region, and a third region 238 downstream from the second region. The turning portion 224 is in the second region 236, where the turning portion 224 promotes the flow of coolant toward the effective volume 210.

[0029] In one or more embodiments, each intermediate plate 230 is 0.2 to 0.5 millimeters (mm) thick and the interior volume 205 is 1.5 to 3.0 mm deep.

[0030] According to another aspect, an exemplary cold plate apparatus 200 includes an upper plate having an inlet opening 209 therethrough, a lower plate 204, and a stack of intermediate plates 230 sandwiched between the upper and lower plates and attached to each other and to the upper and lower plates. Each intermediate plate has a central opening. The central openings of the stack of intermediate plates overlap to define an interior volume 205 bounded by the upper, lower, and intermediate plates. The interior volume 205 includes an effective volume 210, an inlet plenum 208 on one side of the effective volume, and an inlet transition section 207 overlapping the inlet opening. A deflection section 224 protrudes from an outer wall 216 of the inlet plenum 208 toward the effective volume 210. The deflection section 224 near the lower plate 204 protrudes closer to the inlet transition section 207 than the deflection section near the upper plate 202. In one or more embodiments, the deflection section near the bottom plate protrudes more toward the effective volume than the deflection section near the top plate. In one or more embodiments, the device also includes a shield 220 that separates the inlet plenum 208 from the effective volume 210. The shield includes multiple fingers 222 at different levels of the stack, with the fingers higher in the stack being less restrictive to flow than the fingers lower in the stack.

[0031] According to another aspect, an exemplary cold plate apparatus includes an upper portion having an inlet opening therethrough and a lower portion enclosing an interior volume enclosed by the upper portion. In some embodiments, the upper and lower portions may be fabricated integrally, for example, by three-dimensional printing or other additive manufacturing. In other embodiments, the lower portion may comprise multiple laminated plates, i.e., a lower plate and one or more intermediate plates. The interior volume includes an active volume, an inlet plenum on one side of the active volume, and an inlet transition portion overlapping the inlet opening. The inlet plenum includes a deflection portion that protrudes toward the active volume from an outer wall of the inlet plenum, the deflection portion protruding toward the active volume more toward the lower portion of the interior volume than toward the upper plate. The inlet plenum encloses a first region immediately adjacent the inlet transition portion, a second region downstream of the first region, and a third region downstream of the second region during normal operation.

[0032] In one or more embodiments, the deflection portion protrudes closer to the inlet transition near the bottom of the interior volume than near the top plate. In one or more embodiments, the interior volume is 1.5 to 3.0 millimeters (mm) deep.

[0033] In one or more embodiments, the "top" plate should be understood to refer to a given plenum area as the plate into which the nozzles penetrate. In some cases, both nozzles penetrate into the same plate, but this is not required. In fact, the nozzles may penetrate into the end of the cooling plate, or the nozzles may penetrate into the opposite plate.

[0034] According to another aspect, an exemplary cold plate apparatus encloses an interior volume. The interior volume includes an effective volume, an inlet plenum on one side of the effective volume, and an inlet opening overlying the inlet plenum. A shield restricts flow from the inlet plenum into the effective volume. A portion of the shield near the top plate is less restrictive than a portion further from the top plate.

[0035] In one or more embodiments, the exemplary apparatus also includes a deflection portion that protrudes from the outer wall of the inner plenum toward the effective volume. The deflection portion protrudes more toward the effective volume near the lower portion of the inner volume than near the top plate. In one or more embodiments, the deflection portion protrudes closer to the inlet transition near the lower portion of the inner volume than near the top plate.

[0036] According to another aspect, an exemplary cold plate apparatus includes a wall surrounding an effective volume adjacent an inlet plenum and a shielding portion partially separating the inlet plenum from the effective volume. The wall includes an inlet opening at one end of the inlet plenum and a plenum opening between the inlet plenum and the effective volume. The shielding portion is structurally configured to preferentially redirect flow from the inlet plenum toward the effective volume. In one or more embodiments, the shielding portion shields the plenum opening to a greater extent near a lower side of the plenum opening compared to a higher side of the plenum opening, or shields the plenum opening at the end of the inlet plenum to a greater extent near the inlet opening compared to a greater distance from the inlet opening, or both, or the shielding portion shields the plenum opening to a greater extent near the inlet opening compared to a greater distance from the inlet opening and shields the plenum opening to a greater extent near the lower side of the plenum opening compared to a greater distance from the inlet opening.

[0037] In one or more embodiments, the shield comprises a plurality of N fingers extending from the inlet opening along the inlet plenum, with the bottom finger being the longest and the top finger being the shortest. In one or more embodiments, the bottom finger has a length L and the top finger has a length L / N, with each finger in ascending order from bottom to top being L / N shorter than the next lower finger.

[0038] In one or more embodiments, the shield comprises a plurality of fingers extending from below the plenum opening to above the plenum opening, with the fingers closest to the inlet opening being the longest and the fingers furthest from the inlet opening being the shortest, and in one or more embodiments, each finger is separated from an adjacent finger by a gap.

[0039] In one or more embodiments, the shielding separates the inlet plenum from the effective volume over at least a 10 percent section of the plenum opening, where the section is at least 10 percent of the area of ​​the plenum opening. In one or more embodiments, the shielding separates the inlet plenum from the effective volume over at least a 30 percent section of the plenum opening.

[0040] The shielding portion may be continuous, may be divided into multiple sections, or may include perforations.

[0041] One or more embodiments also include a deflection portion that protrudes from the outer wall of the inlet plenum toward the effective volume. In one or more embodiments, the deflection portion near the lower surface of the inlet plenum protrudes closer to the inlet opening than the deflection portion near the upper surface of the inlet plenum. In one or more embodiments, the deflection portion near the lower surface of the inlet plenum protrudes further toward the effective volume than the deflection portion near the upper surface of the inlet plenum. In one or more embodiments, the deflection portion adjacent the lower surface protrudes a distance P and the deflection portion adjacent the upper surface protrudes a distance P / N, where N is a measurement of the height of the inlet plenum. In one or more embodiments, the inlet plenum, in normal operation, encloses a first region immediately adjacent the inlet opening, a second region downstream of the first region, and a third region downstream of the second region, and the deflection portion is in the second region.

[0042] In one or more embodiments, the wall comprises a stack of upper and lower plates and intermediate plates between the upper and lower plates, each intermediate plate having a thickness of 0.2 to 0.5 millimeters (mm) and an internal volume of 1.5 to 3.0 mm in depth. The "upper" plate, as described and illustrated, includes the inlet opening in some embodiments.

[0043] According to another aspect, an exemplary cold plate apparatus includes an upper portion having an inlet opening therethrough and a lower portion surrounding an active volume and an inlet plenum on one side of the active volume. The inlet plenum overlies the inlet opening. The apparatus also includes a deflector portion projecting from an outer wall of the inlet plenum toward the active volume. In some cases, the deflector portion near the lower surface of the inlet plenum projects closer to the inlet opening than the deflector portion near the upper surface of the inlet plenum. Generally, the shields and deflectors are configured (e.g., using computational fluid dynamics as described herein) depending on the coolant properties and operating conditions.

[0044] In one or more embodiments, the deflection portions near the lower surface project more toward the effective volume than the deflection portions near the upper surface (this feature may be provided separately or in conjunction with the feature that the deflection portions near the lower surface of the inlet plenum generally project closer to the inlet opening than the deflection portions near the upper surface of the inlet plenum).

[0045] In one or more embodiments, the inlet plenum, in normal operation, encloses a first region immediately adjacent the inlet opening, a second region downstream of the first region, and a third region downstream of the second region, and the deflector is in the second region.

[0046] One or more embodiments also include a shielding portion that partially separates the inlet plenum from the effective volume. The shielding portion shields the entire height of the plenum opening adjacent the inlet opening, shields a portion of the height of the plenum opening that decreases as one moves along the plenum opening away from the inlet opening, and shields the plenum opening to a greater extent near a lower side of the plenum opening than near an upper side of the plenum opening. In one or more embodiments, the shielding portion separates the inlet plenum from the effective volume over at least 10 percent of a section of the plenum opening, where the section is at least 10 percent of the area of ​​the plenum opening.

[0047] In one or more embodiments, the lower portion comprises a lower plate opposite the upper portion and at least one intermediate plate attached between the lower plate and the upper portion, each intermediate plate having a thickness of 0.2 to 0.5 millimeters (mm) and an internal volume of 1.5 to 3.0 mm in depth.

[0048] According to another embodiment, an exemplary cold plate apparatus includes an upper plate having an inlet opening therethrough, a lower plate, and a stack of N intermediate plates sandwiched between and attached to each other and to the upper and lower plates. Each intermediate plate has a central opening. The central openings of the stack of intermediate plates overlap to define an interior volume bounded by the upper, lower, and intermediate plates. The interior volume includes an effective volume, an inlet plenum on one side of the effective volume, and an inlet opening overlapping the inlet plenum. This embodiment also includes a deflector projecting from an outer wall of the inlet plenum toward the effective volume. The deflection portions near the bottom plates protrude more into the effective volume than the deflection portions near the top plates, so that at the bottom intermediate plate, the deflection portions protrude a distance P from the outer wall of the inlet plenum, and at the top intermediate plate, the deflection portions protrude a second distance P / N from the outer wall of the inlet plenum, with each intermediate plate ascending from the bottom plate to the top plate having a shorter protrusion of the deflection portions by P / N.

[0049] According to another aspect, a cold plate apparatus is constructed by an exemplary process including: obtaining an initial cold plate design including an effective volume, an inlet plenum adjacent to the effective volume and connected to the effective volume through a plenum opening, and an inlet opening overlapping the inlet plenum; conducting a computational fluid dynamics analysis of the initial cold plate design; identifying a simulated flow in a first section of the effective volume proximal to the inlet opening that is greater than a simulated flow in a second section of the effective volume distal to the inlet opening; and creating a modified cold plate design by incorporating a shielding portion into the initial cold plate design that partially separates the inlet plenum from the effective volume. The shielding portion shields the entire height of the plenum opening adjacent to the inlet opening and a portion of the height of the plenum opening that decreases as one moves along the plenum opening away from the inlet opening. The shielding portion shields the plenum opening to a greater extent near a lower side of the plenum opening than near an upper side of the plenum opening. Further steps include performing a computational fluid dynamics analysis of the modified cold plate design, determining that the simulated flow in the first section and the simulated flow in the second section are within 10 percent of the average flow rate across the plenum opening, and fabricating a cold plate apparatus according to the modified cold plate design. In one or more embodiments, fabricating the cold plate apparatus includes building an intermediate layer on the bottom plate by additive manufacturing. In one or more embodiments, fabricating the cold plate apparatus includes bonding an intermediate plate to the bottom plate.

[0050] According to another aspect, a method for improving flow uniformity through an active volume of a cold plate device includes introducing coolant into an inlet plenum of the cold plate device through an inlet opening of the cold plate device, shielding a portion of the coolant from entering from the inlet plenum into a first section of the active volume, the first section being proximate to the inlet opening, and deflecting a portion of the coolant from the inlet plenum to enter a second section of the active volume, the second section being downstream from the first section along the inlet plenum. In one or more embodiments, the coolant is shielded and deflected more near a lower surface of the inlet plenum than near a top surface of the inlet plenum.

[0051] While the descriptions of various embodiments of the present invention have been presented for illustrative purposes, they are not intended to be exhaustive or to be limited to the disclosed embodiments. Numerous modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terms used herein have been selected to most clearly explain the principles of the embodiments, practical applications, or technical improvements over commercially available technology, or to enable others skilled in the art to understand the embodiments disclosed herein. [Explanation of symbols]

[0052] 100 Cooling plate 102 Upper part 104 Lower part 106 Inlet nozzle 108 Entrance Plenum 110 Effective volume Exit 112 Plenum 116 Outside wall 118 Outer wall 200 Cooling plate 202 Upper part 204 Lower part 205 internal volume 206 Inlet nozzle 207 Entrance Transition 208 Entrance Plenum 209 Entrance opening 210 Effective Volume 212 Exit Plenum 216 Outside wall 220 Shielding part 221 Plenum Opening 222 Finger part 224 Deflection section 225 Deflection section 227 Exit Transition 228 Exit Nozzle 229 Exit opening 230 Laminates, Interlayers, Interlayers 234 First Area 236 Second Area 238 The Third Realm

Claims

1. 1. A cold plate device comprising: a wall enclosing an effective volume adjacent an inlet plenum, the wall including an inlet opening at one end of an upper side of the inlet plenum and a plenum opening between the inlet plenum and the effective volume; a shielding portion that partially separates the inlet plenum from the effective volume, the shielding portion being structurally configured to preferentially redirect flow from the inlet plenum toward the effective volume; wherein the shielding portion shields the plenum opening to a greater extent near a lower side of the plenum opening opposite the inlet opening than near an upper side of the plenum opening near the inlet opening.

2. 2. The apparatus of claim 1, wherein the shield comprises a plurality of N fingers extending from the inlet opening along the inlet plenum, the bottom finger being the longest and the top finger being the shortest.

3. 3. The device of claim 2, wherein the bottom finger has a length L and the top finger has a length L / N, each finger in ascending order from bottom to top being L / N shorter than the next lower finger.

4. A cooling plate device, a wall enclosing an effective volume adjacent an inlet plenum, the wall including an inlet opening at one end of an upper side of the inlet plenum and a plenum opening between the inlet plenum and the effective volume; a shielding portion that partially separates the inlet plenum from the effective volume, the shielding portion being structurally configured to preferentially redirect flow from the inlet plenum toward the effective volume; wherein the shielding portion shields the plenum opening to a greater extent near the one end of the inlet plenum than farther from the inlet opening along the inlet plenum.

5. 5. The apparatus of claim 4, wherein the shielding portion shields the plenum opening to a greater extent near a lower side of the plenum opening opposite the inlet opening than near an upper side of the plenum opening near the inlet opening.

6. 5. The apparatus of claim 4, wherein the shield comprises a plurality of fingers extending from a lower side of the plenum opening toward a higher side of the plenum opening, the fingers closest to the entrance opening being longest and the fingers furthest from the entrance opening being shortest.

7. 7. The device of claim 6, wherein each finger is separated from an adjacent finger by a gap.

8. 8. The apparatus of claim 1, wherein the shield separates the inlet plenum from the effective volume over at least a 10 percent section of the plenum opening, the section being at least 10 percent of the area of ​​the plenum opening.

9. The apparatus of any one of claims 1 to 8, further comprising a deflector projecting from an outer wall of the inlet plenum towards the effective volume.

10. A cooling plate device comprising: a wall enclosing an effective volume adjacent an inlet plenum, the wall including an inlet opening at one end of an upper side of the inlet plenum and a plenum opening between the inlet plenum and the effective volume; a shielding portion partially separating the inlet plenum from the effective volume, the shielding portion being structurally configured to preferentially redirect flow from the inlet plenum toward the effective volume; a deflector projecting from an outer wall of the inlet plenum toward the effective volume; wherein the deflection portion near a lower surface of the inlet plenum projects more toward the effective volume than the deflection portion near an upper surface of the inlet plenum.

11. the inlet plenum, in normal operation, encloses a first region immediately adjacent the inlet opening, a second region downstream of the first region, and a third region downstream of the second region; The device of claim 9 , wherein the deflection portion is in the second region.

12. 12. The device of any one of claims 1 to 11, wherein the wall comprises a stack of upper and lower plates and intermediate plates between the upper and lower plates, each intermediate plate having a thickness of 0.2 to 0.5 millimeters (mm), and an internal volume having a depth of 1.5 to 3.0 mm.

13. 1. A cold plate device comprising: an upper portion having an inlet opening therethrough; a lower portion surrounding an effective volume and an inlet plenum on one side of the effective volume, the inlet plenum overlying the inlet opening; a deflector projecting from an outer wall of the inlet plenum toward the effective volume; a shield separating the inlet plenum from the effective volume; wherein the shielding portion shields a portion of the height of the plenum opening that decreases moving along the plenum opening away from the inlet opening, or wherein the shielding portion shields the plenum opening to a greater extent near a lower side of the plenum opening than near an upper side of the plenum opening.

14. The apparatus of claim 13 , wherein the deflection portion near a lower surface of the inlet plenum protrudes closer to the inlet opening than the deflection portion near an upper surface of the inlet plenum.

15. 15. The device of claim 14, wherein the deflecting portions near the lower surface protrude more toward the effective volume than the deflecting portions near the upper surface.

16. the inlet plenum in normal operation encloses a first region immediately adjacent the inlet opening, a second region downstream of the first region, and a third region downstream of the second region; The device according to any one of claims 13 to 15, wherein the deflection portion is in the second region.

17. 17. The device of any one of claims 13 to 16, wherein the lower portion comprises a lower plate opposite the upper portion and at least one intermediate plate attached between the lower plate and the upper portion, each intermediate plate having a thickness of 0.2 to 0.5 millimeters (mm) and an internal volume of 1.5 to 3.0 mm in depth.

18. 1. A cold plate device comprising: a top plate having an inlet opening therethrough; The bottom plate and a stack of N intermediate plates sandwiched between and attached to each other and to the upper and lower plates, each intermediate plate having a central opening, the central openings of the stack of intermediate plates overlapping to define an internal volume bounded by the upper, lower, and intermediate plates, the internal volume including an effective volume, an inlet plenum on one side of the effective volume, and an inlet opening overlapping the inlet plenum; a deflection portion protruding from an outer wall of the inlet plenum toward the effective volume, the deflection portion near the bottom plate protruding more toward the effective volume than the deflection portion near the top plate, the deflection portion protruding a distance P from the outer wall of the inlet plenum at a bottom intermediate plate and a second distance P / N from the outer wall of the inlet plenum at a top intermediate plate, the deflection portion protruding P / N decreasingly from the bottom intermediate plate to the top intermediate plate; A cooling plate device comprising:

19. 1. A method of manufacturing a cold plate apparatus, comprising: obtaining an initial cold plate design including an effective volume, an inlet plenum adjacent to the effective volume and connected to the effective volume through a plenum opening, and an inlet opening overlapping the inlet plenum; conducting a computational fluid dynamics analysis of the initial cold plate design; determining a simulated flow in a first section of the effective volume proximal to the inlet opening that is greater than a simulated flow in a second section of the effective volume distal to the inlet opening; creating a modified cold plate design by incorporating into the initial cold plate design a shielding portion that partially separates the inlet plenum from the effective volume, the shielding portion shielding the entire height of the plenum opening adjacent the inlet opening, the shielding portion shielding a portion of the height of the plenum opening that decreases moving along the plenum opening in a direction away from the inlet opening, and the shielding portion shielding the plenum opening to a greater extent near a lower side of the plenum opening than near an upper side of the plenum opening; conducting a computational fluid dynamics analysis of the modified cold plate design; determining that the simulated flow in the first section and the simulated flow in the second section are within 10 percent of an average flow rate across the plenum opening; fabricating the cold plate apparatus according to the modified cold plate design; A method comprising:

20. 20. The method of claim 19, wherein fabricating the cold plate apparatus comprises building an intermediate layer on a bottom plate by additive manufacturing.

21. The method of claim 19 , wherein creating the cold plate apparatus includes bonding a middle plate to a bottom plate.

22. 1. A method for improving flow uniformity through an effective volume of a cold plate device, comprising: introducing a coolant into an inlet plenum of the cold plate apparatus through an inlet opening of the cold plate apparatus; shielding a portion of the coolant from entering a first section of the effective volume from the inlet plenum, the first section being proximate to the inlet opening; deflecting a portion of the coolant from the inlet plenum to flow into a second section of the effective volume, the second section being downstream from the first section along the inlet plenum; wherein the coolant is shielded and deflected more near a lower surface of the inlet plenum than near an upper surface of the inlet plenum.

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