Dual-Plenum Coolant Manifold for Uniform Low-Profile Flow
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Solution Overview
Problem
Existing coolant distribution manifolds for faceplate optical devices in limited height applications face challenges in efficiently distributing parallel coolant flows due to space constraints and uneven pressure drops, leading to inadequate cooling of high-power QSFP-DD devices.
Innovation Solution
A dual flow low profile coolant distribution manifold assembly integrates two plenums into a single unit, utilizing tapered channels and offset ports to evenly distribute coolant flows and minimize vertical space, achieving consistent flow rates and reduced pressure drops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a manifold is designed to fit within the width of an engine block, then the manifold height is constrained, but adequate coolant flow distribution becomes difficult to achieve
Solution Approach 1:
The manifold is divided into a modular assembly comprising a manifold body, a separate manifold cover, and an integrated coolant distribution plate. This segmentation allows each component to be optimized independently for its specific function while maintaining overall compact dimensions suitable for engine block integration.
Solution Approach 2:
The coolant distribution plate is positioned in a horizontal plane within the manifold assembly, creating a two-dimensional flow distribution network that expands the functional area without increasing the vertical height of the manifold, thereby maintaining compact footprint while improving flow distribution.
2Reliability
If coolant distribution plates are positioned away from the engine block, then flow distribution is improved, but the manifold height increases
Solution Approach 1:
The coolant distribution plate is nested within the manifold assembly, positioned between the manifold body and the manifold cover. This nested configuration allows the distribution plate to be located at an optimal distance from the engine block for flow distribution while maintaining a compact overall manifold height through vertical stacking of components.
3Ease of manufacture
If manifold components are separated for optimization, then manufacturing flexibility is improved, but assembly complexity increases
Solution Approach 1:
The coolant distribution plate is merged with the manifold cover to form an integrated assembly, reducing the number of separate components that need to be handled during assembly. This merging maintains the manufacturing flexibility benefits of separate component optimization while simplifying the final assembly process by reducing the number of assembly steps and fastening operations required.
Data Source
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AI summary
A coolant distribution manifold assembly (110,210,310,610) for use in a module or circuit pack (118,218,626) of an optical networking system, including: a body (130,230,330) defining a main inlet port (132,232,322) at one end, a main outlet port (134,234,324) at another end, and a plurality of cooling plate inlet ports (136,236) and cooling plate outlet ports (138,238) disposed between the main inlet port and the main outlet port; where the body (130,230,330) further defines an upper internal plenum (112,212,322) and a lower internal plenum (114,214,324) 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.