Conformable Cold Plate Tube Forming for Tight Server Chassis
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Solution Overview
Problem
Existing liquid cooling technologies face challenges in achieving precise dimensions and conforming to the limited space within server chassis, particularly in 1U height systems, due to manufacturing limitations in shaping tubes, leading to deformed or out-of-specification cooling solutions that affect cooling performance and efficiency.
Innovation Solution
A fabrication process that applies hydrostatic pressure and vacuum control during tube forming to shape tubes conformally to heat-emitting devices, using clamping dies with heating and cooling systems to achieve precise dimensions and conformability, enabling cooling solutions for components like DIMMs and other high-power devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional tube forming methods are used, then manufacturing simplicity is maintained, but manufacturing precision deteriorates resulting in deformed or out-of-specification tubes
Solution Approach 1:
The tube is heated to soften it before forming, preparing the material in advance to be more pliable and easier to shape without deformation. This preliminary thermal preparation enables precise dimensional control during the subsequent forming operation.
Solution Approach 2:
The patent replaces conventional mechanical forming methods with a combination of thermal softening and controlled pressure application. This substitution allows for more precise dimensional control by reducing material resistance during forming.
2Adaptability or versatility
If rigid tube structures are used, then structural strength is maintained, but adaptability deteriorates preventing conformance to limited chassis spaces
Solution Approach 1:
The tube structure transitions from rigid to flexible during installation through thermal softening, allowing it to conform to complex chassis geometries. After forming, the tube maintains its shaped configuration while accommodating spatial constraints that rigid tubes cannot meet.
Solution Approach 2:
The patent changes the thermal and mechanical parameters of the tube material through heating and pressure application. This transforms the material properties temporarily during forming to achieve conformability, while the final cooled structure retains sufficient strength for structural integrity.
3Adaptability or versatility
If tube deformation is increased to fit spaces, then adaptability improves, but manufacturing precision deteriorates causing out-of-specification products
Solution Approach 1:
The forming process incorporates controlled pressure application and thermal management that provides feedback mechanisms to maintain dimensional accuracy. The gradual softening and controlled deformation prevent excessive distortion while achieving the necessary conformability to fit specifications.
Solution Approach 2:
By pre-heating the tube to soften it before forming, the material becomes more compliant and easier to shape accurately. This preliminary preparation reduces the force needed during forming and minimizes the risk of deformation beyond specification limits.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process ensures improved cooling performance by fitting tubes into smaller spaces, maintaining optimal heat transfer and flow rates, and enhancing cooling efficiency for high-density device configurations.
Implementation Method 1
clamping dies with heating and cooling systems to achieve precise dimensions and conformability
Implementation Method 2
A fabrication process that applies hydrostatic pressure and vacuum control during tube forming to shape tubes conformally to heat-emitting devices
Implementation Method 3
clamping dies with heating and cooling systems to achieve precise dimensions and conformability
Implementation Method 4
A fabrication process that applies hydrostatic pressure and vacuum control during tube forming
Data Source
AI summary
Methods, systems, and apparatus described herein relate to a conformable cold plate for fluid cooling applications. An example method includes re-shaping a tube to contour non-uniform surfaces; and assembling a fluid cooling assembly using the re-shaped tube, the re-shaped tube capable to transfer fluid for cooling of one or more devices.