COOLING MODULE FOR PROVIDING ENHANCED LOCALIZED COOLING OF A HEATSINK

Abstract

A cooling module comprising a porous media that is at least partially inserted into a coolant channel of a heatsink. Generally the coolant is a liquid, though in some instances it may be a gas. More specific, a cooling module for providing enhanced localized cooling of a heatsink comprising a porous media having a volume and a seal plate connected to the porous media, wherein a portion of the volume of the porous media extends through a wall and/or a heatframe of the heatsink into a coolant channel such that coolant flows through the porous media extending into the coolant channel. The seal plate provides a seal for the wall and/or the heatframe so that the coolant does not flow out the wall and/or the heatframe. The seal plate provides enhanced localized cooling to a heat producing device that is at least in partial contact with the seal plate.

Claims

1. A heatsink having enhanced localized cooling, said heatsink comprising: a wall; a heatframe, a coolant channel between the wall and the heatframe, wherein a coolant flows through the coolant channel; and a porous media having a volume, wherein at least a portion of the volume of the porous media extends into the coolant channel such that at least some of the coolant flows through the portion of the porous media extending into the coolant channel, wherein the wall and/or the heatframe proximate to the porous media provides enhanced localized cooling to at least a portion of a heat producing device that is at least in partial contact with the wall or the heatframe proximate to the porous media.

2. The heatsink of claim 1, further comprising one or more seal plates, wherein the porous media extends through the wall and/or the heatframe and the one or more seal plate provides a seal for the wall and/or the heatframe so that the coolant does not flow through the porous media and out the wall and/or the heatframe, wherein the one or more seal plates are comprised of copper.

3. (canceled)

4. The heatsink of claim 2, wherein the one or more seal plates proximate to the porous media provides enhanced localized cooling to at least a portion of the heat producing device that is at least in partial contact with the one or more seal plates proximate to the porous media.

5. The heatsink of claim 4, wherein the porous media extends through the wall, through the coolant channel and partially into the heatframe, wherein the one or more seal plates comprises one wall seal plate that seals the wall so that the coolant does not flow through the porous media and out the wall.

6. (canceled)

7. The heatsink of claim 4, wherein the porous media extends through the heatframe, through the coolant channel and partially into the wall, wherein the one or more seal plates comprises one heatframe seal plate that seals the heatframe so that the coolant does not flow through the porous media and out the heatframe.

8. (canceled)

9. The heatsink of claim 4, wherein the porous media extends through the heatframe, through the coolant channel and through the wall, wherein the one or more seal plates seals the heatframe and the wall so that the coolant does not flow through the porous media and out the heatframe or out the wall.

10. (canceled)

11. The heatsink of claim 1, wherein the porous media is comprised of thermally-conductive material having a thermal-conductivity rating of equal to or greater than 150 W/mK.

12. (canceled)

13. The heatsink of claim 1, wherein the porous media is comprised of material configured to cause turbulence in the coolant flow through the portion of the porous media extending into the coolant channel comprising 3D printed metal porous media, a metal foam, or a wire mesh.

14. (canceled)

15. (canceled)

16. (canceled)

17. The heatsink of claim 13, wherein the porous media has a heat transfer coefficient of 20,000 W/m.sup.2K, or greater.

18. The heatsink of claim 1, wherein the heat producing device comprises one or more of a central processing unit (CPU), a graphics processing unit (GPU), a field-programmable gate array (FPGA), a platform control hub (PCH), or a PCI express switch.

19. (canceled)

20. The heatsink of claim 1, wherein the coolant is a gas (ambient, compressed, or refrigerated), or the coolant is a liquid.

21. (canceled)

22. (canceled)

23. A cooling module for providing enhanced localized cooling of a portion of a heatsink, said module comprising: a porous media having a volume; and a seal plate connected to the porous media, wherein at least a portion of the volume of the porous media extends through a wall and/or a heatframe of the heatsink into a coolant channel of a heatsink that is located between the wall and the heatframe of the heatsink such that at least some of the coolant flows through the portion of the porous media extending into the coolant channel, wherein the seal plate provides a seal for the wall and/or the heatframe so that the coolant does not flow through the porous media and out the wall and/or the heatframe, wherein the seal plate connected to the porous media provides enhanced localized cooling to at least a portion of a heat producing device that is at least in partial contact with the seal plate.

24. The cooling module of claim 23, wherein the seal plate is comprised of copper.

25. The cooling module of claim 23, wherein the porous media extends through the wall, through the coolant channel and partially into the heatframe, wherein the seal plate seals the wall so that the coolant does not flow through the porous media and out the wall.

26. (canceled)

27. The cooling module of claim 23, wherein the porous media extends through the heatframe, through the coolant channel and partially into the wall, wherein the one or more seal plates comprises one heatframe seal plate that seals the heatframe so that the coolant does not flow through the porous media and out the heatframe.

28. (canceled)

29. The cooling module of claim 23, wherein the porous media extends through the heatframe, through the coolant channel and through the wall, wherein the seal plate comprises two seal plates, one that seals the heatframe and one that seals the wall so that the coolant does not flow through the porous media and out the heatframe or out the wall.

30. (canceled)

31. The cooling module of claim 23, wherein the porous media is comprised of thermally-conductive material having a thermal-conductivity rating equal to or greater than 150 W/mK.

32. (canceled)

33. The cooling module of claim 23, wherein the porous media is comprised of a material configured to cause turbulence in the coolant flow through the portion of the porous media extending into the coolant channel comprising a 3D printed metal porous media, a metal foam, or a wire mesh.

34. (canceled)

35. (canceled)

36. (canceled)

37. The cooling module of claim 33, wherein the porous media has a heat transfer coefficient of 20,000 W/m.sup.2K, or greater.

38. The cooling module of claim 23, wherein the heat producing device comprises one or more of a central processing unit (CPU), a graphics processing unit (GPU), a field-programmable gate array (FPGA), a platform control hub (PCH), or a PCI express switch.

39. (canceled)

40. (canceled)

41. (canceled)

42. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments and together with the description, serve to explain the principles of the methods and systems:

[0018] FIG. 1A is a cross-section view of a heatsink having a porous media in a portion of the coolant channel of the heatsink with the porous media proximate to the wall of the heatsink;

[0019] FIG. 1B is a cross-section view of a heatsink having a porous media in a portion of the coolant channel of the heatsink with the porous media proximate to the heatframe of the heatsink;

[0020] FIG. 1C is a cross-section view of a heatsink having a porous media in a portion of the coolant channel of the heatsink with the porous media extending from the wall to the heatframe such that the porous media is proximate to a portion of the wall of the heatsink and proximate to a portion of the heatframe of the heatsink;

[0021] FIG. 2A is a cross-section view of a cooling module comprised of a porous media and a seal plate where the porous media extends through the wall and into a portion of the coolant channel of the heatsink with the porous media proximate to the wall seal plate of the heatsink;

[0022] FIG. 2B is a cross-section view of a cooling module comprised of a porous media and a seal plate where the porous media extends through the wall and across a portion of the coolant channel of the heatsink to the heatframe, with the porous media proximate to the wall seal plate of the heatsink;

[0023] FIG. 2C is a cross-section view of a cooling module comprised of a porous media and a seal plate where the porous media extends through the wall and across a portion of the coolant channel of the heatsink to the heatframe, and partially into the heatframe, with the porous media proximate to the wall seal plate of the heatsink;

[0024] FIG. 2D is a cross-section view of a cooling module comprised of a porous media and a seal plate where the porous media extends through the heatframe and into a portion of the coolant channel of the heatsink with the porous media proximate to the heatframe seal plate of the heatsink;

[0025] FIG. 2E is a cross-section view of a cooling module comprised of a porous media and a seal plate where the porous media extends through the heatframe and across a portion of the coolant channel of the heatsink to the wall, with the porous media proximate to the heatframe seal plate of the heatsink;

[0026] FIG. 2F is a cross-section view of a cooling module comprised of a porous media and a seal plate where the porous media extends through the heatframe and across a portion of the coolant channel of the heatsink and partially into the wall, with the porous media proximate to the heatframe seal plate of the heatsink;

[0027] FIG. 2G is a cross-section view of a cooling module comprised of a porous media and seal plates where the porous media extends through the wall and across a portion of the coolant channel of the heatsink and through the heatframe, with the porous media proximate to the wall seal plate of the heatsink and the heatframe seal plate of the heatsink;

[0028] FIG. 3A is an exploded top view of a heatsink with two embedded cooling modules used to provide enhanced localized cooling for heat producing devices (e.g., electronic chips) on a PC board;

[0029] FIG. 3B is an exploded bottom view of a heatsink with two embedded cooling modules used to provide enhanced localized cooling for heat producing devices (e.g., electronic chips) on a PC board; and

[0030] FIG. 4 is a plan view of a heatsink with two enhanced localized cooling areas.

DETAILED DESCRIPTION

[0031] Before the present methods and systems are disclosed and described, it is to be understood that the methods and systems are not limited to specific synthetic methods, specific components, or to particular compositions. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

[0032] As used in the specification and the appended claims, the singular forms a, an and the include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from about one particular value, and/or to about another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent about, it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0033] Optional or optionally means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

[0034] Throughout the description and claims of this specification, the word comprise and variations of the word, such as comprising and comprises, means including but not limited to, and is not intended to exclude, for example, other additives, components, integers or steps. Exemplary means an example of and is not intended to convey an indication of a preferred or ideal embodiment. Such as is not used in a restrictive sense, but for explanatory purposes.

[0035] Disclosed are components that can be used to perform the disclosed methods and systems. These and other components are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these components are disclosed that while specific reference of each various individual and collective combinations and permutation of these may not be explicitly disclosed, each is specifically contemplated and described herein, for all methods and systems. This applies to all aspects of this application including, but not limited to, steps in disclosed methods. Thus, if there are a variety of additional steps that can be performed it is understood that each of these additional steps can be performed with any specific embodiment or combination of embodiments of the disclosed methods.

[0036] The present methods and systems may be understood more readily by reference to the following detailed description of preferred embodiments and the Examples included therein and to the Figures and their previous and following description.

[0037] The embodiments disclosed herein facilitate providing enhanced localized cooling in areas of a heatsink. As shown at least in FIG. 1A, a heatsink 100 is comprised of a wall 102 and a heatframe 104, with one or more coolant channels 108 sandwiched between the wall 102 and the heatframe 104. Generally, the coolant channels 108 form a closed loop, so it is to be appreciated that the drawings herein show only a cross-sectional view of the heatsink 100. In some instances, cooling fins (not shown) may be located on portions of the heatsink 100 and would generally be located on a portion of the exterior of the wall and/or the heatframe.

[0038] Further comprising the heatsink 100 of FIG. 1A is a cooling module comprised of porous media 106. As shown in FIG. 1A, in this embodiment the porous media 106 has a volume, and at least a portion of the volume of the porous media 106 extends into a portion of at least one of the coolant channels 108. Generally, the porous media 106 is comprised of thermally-conductive material. For example, the thermal-conductivity rating of the porous media 106 may be equal to or greater than 150 W/mK. The porous media 106 may have any volumetric shape including a cube, a cylinder, a sphere, and the like. The porous media 106 is comprised of materials that cause a turbulence (i.e., non-laminar flow) in the flow of coolant in the coolant channel 108 through the portion of the porous media extending into the coolant channel 108. For example, the porous media 106 may be comprised of a 3D printed metal porous media, a metal foam, a wire mesh, and the like. In one non-limiting example, the porous media 106 is comprised of aluminum foam. In one example, the heatsink 100 with the cooling module comprised of the porous media 106 may be 3D-printed as one piece.

[0039] Also shown in FIG. 1A is a heat producing device 110. The enhanced localized cooling caused by the cooling module in the heatsink 100 is used to cool the heat producing device. In some instances, the heat producing device 110 is at least in partial contact with the wall 102 or the heatframe 104 proximate to the porous media 106, such that enhanced localized cooling is provided to the heat producing device 110. Generally, the heat producing device 110 is an electronic device such as, for example, one or more of a central processing unit (CPU), a graphics processing unit (GPU), a field-programmable gate array (FPGA), a platform control hub (PCH), a PCI express switch, and the like. In some instances the electronic device may be mounted on a PC board. In other instances, the heat producing device may be mechanical or chemical. The embodiments disclosed herein can be used to provide enhanced localized cooling to any form of heat producing device 110.

[0040] FIGS. 1B and 1C are illustrations of non-limiting variations of the embodiment of a heatsink 100 shown in FIG. 1A. FIG. 1B is a cross-section view of a heatsink 100 having a porous media 106 in a portion of the coolant channel 108 of the heatsink 108 with the porous media 106 proximate to the heatframe 104 of the heatsink 100. FIG. 1C is a cross-section view of a heatsink 100 having a porous media 106 in a portion of the coolant channel 108 of the heatsink 108 with the porous media 106 extending through at least a portion of one of the coolant channels 108 from the wall 102 to the heatframe 104 such that the porous media 106 is proximate to a portion of the wall 102 of the heatsink 100 and proximate to a portion of the heatframe 104 of the heatsink 100.

[0041] FIG. 2A is a cross-section view of a cooling module 200 in a heatsink 100 comprised of a porous media 106 and a seal plate 112 where the porous media 106 extends through the wall 102 and into a portion of the coolant channel 108 of the heatsink 100 with the porous media 106 proximate to the wall seal plate 112 of the heatsink 100. The seal plate 112 produces an area of enhanced localized cooling. The area may range from approximately 100 mm 2 to 2500 mm.sup.2. Generally, a heat producing device 110 will be at least partially in contact with the seal plate 112 or at least in very close proximity to the seal plate 112. Furthermore, the wall seal plate 112 seals the wall 102 so that the coolant does not flow through the porous media 106 and out the wall 102. The seal plate 112 may be comprised of copper, aluminum, silver and other thermally-conductive materials. The wall seal plate 112 may welded, soldered, brazed, glued, compression fit, screwed, or use any other attachment means to attach to the wall 102 to form the seal. In some instances, a gasket may be used between the wall 102 and the wall seal plate 112. This is better shown in FIGS. 3A and 3B.

[0042] FIG. 2B is a variant of the heatsink 100 with a cooling module 200 shown in FIG. 2A. FIG. 2B illustrates a cross-section view of a cooling module 200 in a heatsink 100 comprised of a porous media 106 and a seal plate 112 where the porous media 106 extends through the wall 102 and across a portion of the coolant channel 108 of the heatsink 100 to the heatframe 104, with the porous media 106 proximate to the wall seal plate 112 of the heatsink 100.

[0043] FIG. 2C is a variant of the heatsink 100 with a cooling module 200 shown in FIGS. 2A and FIG. 2B. FIG. 2C illustrates a cross-section view of a cooling module 200 in a heatsink 100 comprised of a porous media 106 and a seal plate 112 where the porous media 106 extends through the wall 102, across a portion of the coolant channel 108 of the heatsink 100, and partially into the heatframe 104, with the porous media 106 proximate to the wall seal plate 112 of the heatsink 100.

[0044] FIG. 2D is a cross-section view of a cooling module 200 comprised of a porous media 106 and a seal plate 112, where the porous media 106 extends through the heatframe 104 and into a portion of the coolant channel 108 of the heatsink 100 with the porous media 106 proximate to the heatframe seal plate 112 of the heatsink 100.

[0045] FIGS. 2E and 2F are variants of the cooling module 200 shown in FIG. 2D. FIG. 2E illustrates a cross-section view of a cooling module 200 comprised of a porous media 106 and a seal plate 112, where the porous media 106 extends through the heatframe 104 and across a portion of the coolant channel 108 of the heatsink 100 to the wall 102, with the porous media 106 proximate to the heatframe seal plate 112 of the heatsink 100. FIG. 2F is an illustration of a cross-section view of a cooling module 200 comprised of a porous media 106 and a seal plate 112, where the porous media 106 extends through the heatframe 104 and across a portion of the coolant channel 108 of the heatsink 100 and partially into the wall 102, with the porous media 106 proximate to the heatframe seal plate 112 of the heatsink 100.

[0046] FIG. 2G is a cross-section view of an embodiment of a cooling module 200 comprised of a porous media 106 and two seal plates 112, where the porous media 106 extends through the wall 102 and across a portion of the coolant channel 108 of the heatsink 100 and through the heatframe 104, with the porous media 106 proximate to the wall seal plate 112 of the heatsink 100 and the heatframe seal plate 112 of the heatsink 110. In this way, areas of enhanced localized cooling are created on both sides of the heatsink 100. Such a configuration would allow one heatsink 100 to be sandwiched between two PC boards and cool heat production devices 110 on each of the PC boards.

[0047] FIG. 3A is an exploded top view of a heatsink 300 with two embedded cooling modules used to provide enhanced localized cooling for heat producing devices 302 (e.g., electronic chips) on a PC board 304. In this embodiment, each cooling module is comprised of porous media 306 connected to a seal plate 308. In this embodiment, a gasket 310 is placed between the seal plate 308 and the heatsink 300. The cooling module comprised of the porous media 306 and seal plate 308 is attached to the heatsink using mounting screws 312. FIG. 3B is an exploded bottom view of the heatsink 300 with two embedded cooling modules used to provide enhanced localized cooling for heat producing devices 302 (e.g., electronic chips) on a PC board 304. In this view, the machined cutouts 314 that go through the heatframe and partially into the wall are visible. The porous media 306 fits into these cutouts 314 when assembled.

[0048] FIG. 4 is a plan view of a heatsink 400 with two enhanced localized cooling areas 402, 404. As can be seen in FIG. 4, the size of the enhanced localized cooling areas 402, 404 can vary. Typically, the enhanced localized cooling areas 402, 404 range between approximately 100 mm.sup.2 to approximately 2500 mm.sup.2. This figure also illustrates that a heatsink 400 can have a plurality of cooling modules.

[0049] Benefits of the embodiments described herein include solving the downgrade of thermal performance of liquid flow through cooling solution due to its low heat transfer coefficient limited by high pressure drop or high machining cost for complex channel geometries. The disclosed cooling module provides a significantly improved heat transfer characteristics over a conventional channel cold plate heat frame at least because of a significant increase in effective liquid contact area (for example, the improvement may be 100%, or greater); a significant increase in Nusselt number thru swirling motion, turbulence, etc. (Usually, the Nusselt number for laminar flow is up to 10. The Nusselt number for conventional liquid cooling's turbulent flows is in the range of 100-150, but the reported Nusselt number for porous media flow is 200-300); a relatively lower pressure drop than complex geometries channels (i.e. Micro-channels) (for example, porous media flow may reduce the pressure drop approximately in half); as well as lower cost and ease of manufacture.

[0050] While the methods and systems have been described in connection with preferred embodiments and specific examples, it is not intended that the scope be limited to the particular embodiments set forth, as the embodiments herein are intended in all respects to be illustrative rather than restrictive.

[0051] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; the number or type of embodiments described in the specification.

[0052] Throughout this application, various publications may be referenced. The disclosures of these publications in their entireties are hereby incorporated by reference into this application in order to more fully describe the state of the art to which the methods and systems pertain.

[0053] It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the scope or spirit. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit being indicated by the following claims.