Process for making an apparatus with fluid-flow-through cooling of circuit boards

Abstract

A disclosed apparatus for use with a conduction-cooled card assembly may include a frame comprising first and second thermally conductive portions adapted to engage respective thermal management interfaces on opposite sides of a conduction cooling frame for at least one circuit card. The apparatus may also include a passageway extending between first and second openings in the frame so as to allow cooling fluid to flow into the first opening, through the passageway, and out of the second opening. According to a disclosed method, an insert may be installed between components of a mezzanine connector so as to increase a height of the connector. In some implementations, the installing of the insert may be performed while the first and second components of the mezzanine connector are mounted on a host card and a mezzanine card, respectively, so that installation of the insert between the first and second components increases a spacing between the host card and the mezzanine card.

Claims

1. A method for altering a conduction-cooled card assembly, comprising acts of: providing the conduction-cooled card assembly; removing a wedgelock fastener from a thermal management interface of the conduction-cooled card assembly; providing an adaptor frame, the adaptor frame having a passageway extending therethrough, mounting portions, and openings; and attaching the adaptor frame to the thermal management interface so as to allow heat from the thermal management interface to be dissipated via fluid flowing through the passageway.

2. The method of claim 1, wherein attaching comprises: attaching the adaptor frame to the thermal management interface via mounting points on the thermal management interface that were also used to attach the removed wedgelock fastener to the thermal management interface.

3. The method of claim 1, further comprising an act of: installing the adaptor frame into a chassis so that first and second openings in the adaptor frame engage corresponding openings in the chassis and allow fluid to flow from a first portion of the chassis into the first opening, through the passageway, and then out of the second opening into a second portion of the chassis.

4. The method of claim 3, wherein the corresponding openings in the first and second portions of the chassis are located in opposing interior walls of the chassis.

5. The method of claim 3, wherein the conduction-cooled card assembly comprises a first card thermally coupled to a conduction cooling frame and having a multi-electrode electrical connector for establishing a bus connection with a motherboard of the chassis.

6. The method of claim 5, wherein the conduction-cooled card assembly further comprises a second card parallel to and electrically coupled to the first card and thermally coupled to the conduction cooling frame.

7. The method of claim 6, wherein the first card is a host card, the second card is a mezzanine card, and the conduction-cooled card assembly further comprises at least one mezzanine connector configured and arranged to electrically couple the mezzanine card to the host card.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. In the drawings:

(2) FIG. 1 is a perspective view of a conventional conduction-cooled card assembly;

(3) FIG. 2 is a perspective view of an example of a novel adaptor frame disclosed herein;

(4) FIG. 3 is a perspective view of an example of a module in which the adaptor frame of FIG. 2 is mounted on a conduction-cooled card assembly;

(5) FIG. 4A is a bottom perspective view of the module shown in FIG. 3;

(6) FIG. 4B is a bottom view of the module shown in FIG. 3;

(7) FIG. 4C is a first side view of the module shown in FIG. 3;

(8) FIG. 4D is a first rear view of the module shown in FIG. 3;

(9) FIG. 5A is a top perspective view of the module shown in FIG. 3;

(10) FIG. 5B is a top view of the module shown in FIG. 3;

(11) FIG. 5C is a second side view of the module shown in FIG. 3;

(12) FIG. 5D is a second rear view of the module shown in FIG. 3;

(13) FIG. 6 is cut-away side view illustrating how cooling fluid may flow through the frame of FIG. 2 when it is installed within a fluid-flow-through cooled chassis;

(14) FIG. 7A is a first perspective view of an example of a novel insert disclosed herein;

(15) FIG. 7B is a second perspective view of the insert shown in FIG. 7A;

(16) FIG. 8 is a perspective view illustrating how the insert of FIG. 8 can be installed between components of a mezzanine connector;

(17) FIG. 9 is a perspective view illustrating how the assembly of FIG. 8 can be installed between a host card and a mezzanine card;

(18) FIG. 10 is a perspective view illustrating how the assembly of FIG. 9 can be mounted on a frame so as to allow it to be deployed in a fluid-flow-through cooled chassis;

(19) FIG. 11A is a first side view illustrating how cooling fluid may flow through the assembly of FIG. 10 when it is installed within a fluid-flow-through cooled chassis; and

(20) FIG. 11B is a second side view of the assembly of FIG. 10 which excludes the frame of the assembly so as to reveal the internal components of the assembly for illustrative purposes.

DETAILED DESCRIPTION

(21) Although suitable for some applications, the inventors have recognized certain limitations and disadvantages to the conventional approaches discussed above for allowing conduction-cooled card assemblies or circuit cards from such assemblies to be deployed within an air-cooled chassis environment, and have thus come up with alternative solutions that may provide significant benefits and advantages in at least some circumstances.

(22) In accordance with some embodiments disclosed herein, an adaptor frame is provided that can be mounted to wedgelock locations on a conduction-cooled card assembly, such as the assembly 100 shown in FIG. 1. In some embodiments, for example, the wedgelock fasteners 114 may be removed from the assembly 100 and replaced with an adaptor frame such as that disclosed herein. In some embodiments, the adaptor frame may be attached to the card assembly 100 via fasteners that interface with same mounting points on the thermal management interfaces 112 as did the removed wedgelock fasteners 114.

(23) An example embodiment of such an adaptor frame 200 is shown in FIG. 2. Various views of a module 302 including the frame 200 mounted on a conduction-cooled card assembly 100 (with the wedgelock fasters 114 removed) are shown in FIGS. 3-5. Specifically, FIG. 3 is a perspective view of an example of a module in which the adaptor frame of FIG. 2 is mounted on a conduction-cooled card assembly; FIGS. 4A and 5A are bottom and top perspective views, respectively, of the module shown in FIG. 3; FIGS. 4B and 5B are bottom and top views, respectively, of the module shown in FIG. 3; FIGS. 4C and 5C are side views of the module shown in FIG. 3; and FIGS. 4D and 5D are rear views of the module shown in FIG. 3.

(24) FIG. 6 illustrates how air may flow through the adaptor frame 200 from one side 602 of a chassis 600 to the other side 604 of the chassis 600 in the illustrative embodiment shown.

(25) As shown in FIGS. 2, 3, 4A, 4C, 5A, and 5C, the frame 200 may include openings 202 on either side and form a passageway 602 (see FIG. 6) that allows air (e.g., supplied by a blower 614) or another suitable cooling fluid to flow from one side to the other through the passageway, as illustrated by the arrows in FIG. 6. In some embodiments, the planes occupied by the openings 202 may be oriented substantially orthogonal to the planes in which the cards 102, 106 are disposed. Such a configuration may, for example, allow air to flow into the passageway 602 without first having to flow into one of the struts 606, thus increasing the linearity and efficiency of the air flow. When the frame 200 is installed on a conduction-cooled card assembly 100, heat from components on the cards 102, 106 may flow to the conduction cooling frame 108, to the thermal management interfaces 112, and then to the frame 200 where it is dissipated into the air or other fluid flowing through the passageway 602 of the frame 200.

(26) Although not illustrated, the frame 200 may include fins or other protrusions within the interior of the passageway 602 so as to increase the surface area of the interior portion of the frame 200 exposed to the fluid flowing through it and thereby increase the amount of heat that may be dissipated via the moving fluid. The frame 200 may be made of any suitable material capable of adequately conducting heat from the thermal management interfaces 112 and allowing the heat so conducted to be dissipated via fluid flowing through the passageway 602. In some embodiments, for example, the frame 200 may be made of aluminum. The interface between the frame 200 and the thermal management interfaces 112 may be dry, or may alternatively be treated in some way so as to improve the thermal conductivity between the interfacing materials.

(27) As illustrated best in FIGS. 4B and 5B, the portions of the frame 200 including the openings 202 may be tapered between a point 204 and a point 206, with the section at the point 204 being thicker than the section at the point 206. Because of these tapered portions, the end 212 of the frame 200 that is further away from the motherboard connector 104 is wider than the end 214 of the frame 200 that is closer to a motherboard connector 104 (compare measurementsW.sub.1 and W.sub.2 in FIGS. 4B and 5B, where W.sub.1>W.sub.2).

(28) In some embodiments, these tapered portions of the frame 200 may be formed of an elastomeric material and the openings 202 may include gaskets that create seals with corresponding openings in interior opposing walls 612 of the chassis 600 in which the module 302 is installed. Insertion of a module 302 in a slot between struts 606 of a chassis 600 (as shown in FIG. 6) may, for example, result in the deformation of the elastomeric material and thereby create a force that holds the module 302 in place within the chassis 600. In some embodiments, the portions of the chassis 600 containing corresponding openings may be additionally or alternatively formed of a suitable elastomeric material and the tapered portions of the frame need not, but may also be, elastomeric. In any event, in some embodiments, once a module 302 is fully inserted in a slot of a chassis 600, captivated screws 608 (shown in FIG. 6) may be inserted through holes 208 in ear portions 210 of the frame 200 and corresponding holes 610 in a strut 606 of the chassis 600 (the holes 610 for an adjacent slot of the chassis 600 are identified in FIG. 6) to thereby secure the module 302 within the slot.

(29) In the embodiment shown in FIGS. 2-6, the module 302 may be held in place within the chassis, and the gasket seals between the openings 202 and the corresponding openings in the interior walls 612 of the chassis may be maintained, by a vertical force applied against the interior walls 612 of the chassis, e.g., via the elastomeric material on the edge of the frame 200 and/or the chassis interior walls 612. The use of such a vertical force for such purposes may be contrasted with the technique employed in the embodiment shown in FIG. 1 of the '336 patent, in which wedgelock fasteners 34 are used to apply horizontal forces between rails 34 so as to hold a plate 24 and cooling adaptor 40 in place within the chassis as well as to maintain seals between each of an inlet 84 and an outlet 86 of the cooling adaptor 40 and a corresponding opening in the side of a rails 34. Accordingly, in some embodiments, a wedgelock faster 114 need not be employed to secure the module 302 within the chassis and/or to form a suitable gasket seal to allow air flow through the passageway 602. In alternative embodiments, however, one or more wedgelock fasteners 114 could be additionally or alternatively be employed so as to provide additional or different benefits.

(30) As noted above, another known approach for allowing cards of conduction-cooled card assemblies, such as cards 102, 106 of assembly 100 shown in FIG. 1, to be employed within an fluid-flow-through cooled chassis is to replace the mezzanine connectors (e.g., PMC or XMC connectors) on one or both of the cards with taller connectors so as to create a gap that allows air to flow between the cards, and to mount the cards on a different frame that is designed to allow air to flow between the cards from one side of the chassis to the other. Without such a modification, the existing mezzanine connectors, which typically provide only a 10 mm space between the cards, do not provide sufficient room for airflow between the cards for certain applications.

(31) The inventors have recognized, however, that replacing the mezzanine connectors in such a manner (e.g., by unsoldering the Ball Grid Array (BGA) connections of the mezzanine connectors and soldering new BGA connections for replacement mezzanine connectors in place) can be undesirable, as such a procedure can be expensive, could potentially damage the board, and may lead to the board supplier voiding its manufacturing warranty.

(32) To overcome such drawbacks, an insert is proposed that may be plugged into an existing mezzanine connector so as to extend the height of the connector to an optimal position to allow flow of air or another suitable fluid between a primary, or host, card 102, and a secondary, or mezzanine, card 106, when those cards are mounted on a frame that allows for such fluid flow. In some embodiments, for example, one or more inserts that are approximately 8 mm in length may be employed so as to create a gap of approximately 18 mm between the two cards. Different length inserts can, of course, be used for other applications where more or less fluid flow is desired. In some embodiments, for instance, the insert(s) may alternatively be sized such that the resulting spacing between the cards is 11 mm, 12 mm, 13, mm, 14 mm, 15 mm, 16 mm, 17 mm, 19 mm, 20 mm, or any other suitable distance.

(33) Two views of an example embodiment of insert 702 are shown in FIGS. 7A and 7B. As shown, the insert 702 includes pins 704 and holes 706 that may mate with corresponding holes and pins in the mezzanine connector into which it is to be plugged.

(34) FIG. 8 illustrates how an insert 702 such as that shown in FIG. 7 may be disposed between respective mating portions 802a, 802b of a mezzanine connector 802. FIG. 9 illustrates how the use of inserts 702 can increase the spacing between a primary card 102 and a secondary card 106. FIG. 10 shows an example of how two cards 102, 106 having an additional spacing provided by inserts 702 can be mounted on a frame 1002 so as to form a card assembly 1004 that allows fluid to flow from one side of a chassis to another when inserted into an fluid-flow-through cooled chassis. FIGS. 11A-B are side views illustrating how cooling fluid (e.g., air supplied by the blower 614) may flow through the assembly of FIG. 10 (in the direction indicated by the arrows) when it is installed within a fluid-flow-through cooled chassis 600. FIG. 11A illustrates the assembly 1004 including the frame 1002. FIG. 11B excludes the frame 1002 so as to reveal the internal components of the assembly 1004 for illustrative purposes.

(35) As shown if FIGS. 10 and 11, the assembly 1004 may have openings 1006 on either side that may mate with corresponding openings in a chassis 600. As also shown in FIG. 10, the frame 1002 may additionally comprise fins 1008 or other protrusions to increase the surface area of the inner part of the frame 1002 that is exposed to the air or other cooling fluid flowing between the cards 102, 106. In some embodiments, the frame 1002 can further be provided with elastomeric, tapered edges and holes to receive captivated screws 608, generally configured like the corresponding components of the module 302 discussed above in connection with FIGS. 2-6, so as to allow the assembly 1004 to be releasably inserted into and maintained in place within the same type of chassis 600 as the module 302 discussed above. In the embodiments shown, heat from components on the circuit cards 102, 106 may be dissipated via the fluid flowing through the frame 1002 between the cards 102, 106.

(36) Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated that various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description and drawings are by way of example only.

(37) Various aspects of the present invention may be used alone, in combination, or in a variety of arrangements not specifically discussed in the embodiments described in the foregoing and is therefore not limited in this application to the details and arrangement of components set forth in the foregoing description or illustrated in the drawings. For example, aspects described in one embodiment may be combined in any manner with aspects described in other embodiments.

(38) Also, the invention may be embodied as a method, of which an example has been provided. The acts performed as part of the method may be ordered in any suitable way. Accordingly, embodiments may be constructed in which acts are performed in an order different than illustrated, which may include performing some acts simultaneously, even though shown as sequential acts in illustrative embodiments.

(39) Use of ordinal terms such as first, second, third, etc. in the claims to modify a claim element does not by itself connote any priority, precedence or order of one claim element over another or the temporal order in which acts of a method are performed, but are used merely as labels to distinguish one claimed element having a certain name from another element having a same name (but for use of the ordinal term) to distinguish the claim elements.

(40) Also, the phraseology and terminology used herein is used for the purpose of description and should not be regarded as limiting. The use of including, comprising, or having, containing, involving, and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.