Dual-Plenum Coolant Manifold for Low-Profile Optical Cooling
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Solution Overview
Problem
Existing coolant distribution systems for faceplate optical devices in limited height applications face challenges due to space constraints, leading to inefficient coolant flow and temperature variations, particularly with devices like QSFP-DD that generate significant heat.
Innovation Solution
A dual flow low profile coolant distribution manifold integrates two plenums into a single unitary body, with tapered channels and flow modification structures to evenly distribute parallel coolant flows, minimizing vertical space and reducing pressure drops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two separate manifolds are used to distribute inlet and outlet coolant flows, then coolant distribution effectiveness is improved, but device height increases
Solution Approach 1:
The patent combines two separate manifolds (inlet and outlet) into a single integrated manifold structure. The body defines both upper and lower plenums that operate in parallel, with the upper plenum receiving inlet coolant and the lower plenum receiving outlet coolant. This merging eliminates the need for two separate manifold assemblies, reducing overall device height while maintaining effective parallel coolant distribution to multiple ports.
2Loss of energy
If parallel coolant flow arrangement is used, then heat dissipation efficiency is improved, but device complexity increases
Solution Approach 1:
The manifold is segmented into distinct upper and lower plenums with separate flow paths. The upper plenum contains inlet ports and associated flow distribution channels, while the lower plenum contains outlet ports and return flow channels. This segmentation allows independent optimization of inlet and outlet flow distribution, enabling efficient parallel coolant delivery to multiple ports while keeping the overall structure manageable through clear functional separation.
Solution Approach 2:
The single manifold body performs multiple functions: it distributes inlet coolant through the upper plenum to multiple ports, collects outlet coolant through the lower plenum from multiple ports, and provides structural support. The tapered channels in both plenums serve dual purposes of flow distribution and flow rate equalization, reducing device complexity by eliminating the need for additional flow control components.
3Manufacturing precision
If tapered channels are added to equalize flow rates, then flow distribution uniformity is improved, but manufacturing complexity increases
Solution Approach 1:
The channels in both plenums are designed with tapered cross-sectional areas that vary along their length. The taper ratio is optimized to compensate for pressure drops and ensure uniform flow distribution to each port. This parameter change from constant to variable cross-section achieves flow equalization while the taper geometry is designed to be manufacturable using standard machining or molding processes.
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 solution ensures even coolant distribution and reduced pressure drops, effectively managing heat dissipation in optical networking systems with improved temperature uniformity and flow consistency across ports.
Implementation Method 1
Thermal analysis has determined that it is much more efficient to distribute coolant fluid to faceplate optical devices of a module or circuit pack in a parallel flow arrangement, rather than serial flow arrangement
Implementation Method 2
The upper internal plenum and the lower internal plenum each have a variable cross-sectional area along a length of the body between the main inlet port and the main outlet port. The upper internal plenum and the lower internal plenum may each have a tapering cross-sectional area along a length of the body
Implementation Method 3
Liquid or hybrid liquid/air cooling is typically more effective and allows higher power to be used
Data Source
AI summary
A coolant distribution manifold assembly for use in a module or circuit pack of an optical networking system, including: a body defining a main inlet port at one end, a main outlet port at another end, and a plurality of cooling plate inlet ports and cooling plate outlet ports disposed between the main inlet port and the main outlet port; where the body further defines an upper internal plenum and a lower internal plenum each coupled to one of the main inlet port and the plurality of cooling plate inlet ports and the main outlet port and the plurality of cooling plate outlet ports. Optionally, the upper internal plenum and the lower internal plenum each have a variable cross-sectional area along a length of the body between the main inlet port and the main outlet port.