Note: Descriptions are shown in the official language in which they were submitted.
1
Efficient Cooled Channel Components
CROSS-REFERENCE TO RELATED APPLICATION
[01] This application claims the benefit of United States Provisional Patent
Application No.
62/525,535 entitled "Efficient Cooled Channel Components" filed June 27, 2017.
BACKGROUND
[02] Data centers are the backbone of the modern Internet and therefore
feature
prominently in modern life. Cooling of data center equipment is a foundational
part of the
modern data center and poor cooling technologies increase the data centers
operators costs and
risk of failure. Cost-efficiently cooling data centers therefore is of vital
importance.
[03] Previous work by this inventor disclosed in patent applications
published as
WO/2014/030046, WO/2016/004528 and WO/2016/004531 describes computer system
apparatus and cooled enclosures that can remove heat from data center
equipment by engaging
a rail type thermal connector with a cooled channel to transfer heat between
server and
enclosure.
[04] There is a need for channel type apparatus which can be used to
efficiently and cost-
effectively transfer heat between a rail thermal connector and cooled channel.
SUMMARY
[05] The present disclosure relates to cooled channel components which can be
used to
efficiently and cost-effectively transfer heat between a rail thermal
connector and a channel.
The cooled channel components are configured for use in an enclosure or
enclosure wall to be
used in a data center.
[06] According to a first broad aspect, the present disclosure provides a
cooled channel
component comprising: a channel configured to receive a rail thermal connector
within the
channel; and a means for cooling a surface of the channel. The cooled channel
component is
Date Recue/Date Received 2022-07-07
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configured to be affixable to one or more supports as part of an enclosure
wall such that the
cooled channel component is mechanically independent of one or more other
cooled channel
components adjacently installed as part of the enclosure wall.
[07] In some embodiments of the first aspect, the channel comprises a pair of
spaced apart
arms having a normalized deflection of less than 0.0375 for a bracing force
applied between
the arms of the channel which is approximately equivalent to a pressure of at
least 69kPa.
[08] In some embodiments of the first aspect, the cooled channel component is
configured
such that, when the cooled channel component is affixed to the one or more
supports at one or
more points of attachment, deflection of the arms of the channel for a bracing
force applied
between the arms of the channel which is approximately equivalent to a
pressure of between
69kPa to 690kPa is limited to a range that prevents contact with the one or
more adjacently
installed cooled channel components and the one or more supports outside of
the one or more
points of attachment.
[09] In some embodiments of the first aspect, the cooled channel component
further
comprises a spacing feature configured to space the cooled channel component
apart from the
one or more supports outside the one or more points of attachment.
[010] In some embodiments of the first aspect, the cooled channel component is
configured
to have sufficient cooling for at least 0.25kW of power.
[011] In some embodiments of the first aspect, the cooled channel component is
configured
to cool a heat-flux between 10,000 W/m2 and 200,000 W/m2 when the means for
cooling uses
a water based coolant.
[012] In some embodiments of the first aspect, the means for cooling comprises
a first flow
path comprising a first inlet, a first outlet and a first at least one
internal channel connecting
the first inlet to the first outlet, whereby the surface of the channel is
coolable by flowing a
coolant through the first flow path.
[013] In some embodiments of the first aspect, the at least one internal
channel comprises a
spiral or serpentine configuration.
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[014] In some embodiments of the first aspect, the at least one internal
channel comprises
features configured to disrupt the laminar flow of coolant flowing through the
first flow path.
[015] In some embodiments of the first aspect, the cooled channel component
further
comprises a second flow path comprising a second inlet, a second outlet and a
second at least
one internal channel connecting the second inlet to the second outlet.
[016] In some embodiments of the first aspect, the first and second inlets and
the first and
second outlets are arranged so that a direction of a coolant flow through the
first flow path
along a lengthwise direction of the cooled channel component is generally
opposite to a
direction of a coolant flow through the second flow path along the lengthwise
direction of the
cooled channel component.
[017] In some embodiments of the first aspect, the first flow path and the
second flow path
have a substantially equal length thermal path to the surface of the channel.
[018] In some embodiments of the first aspect, the first at least one internal
channel
comprises a plurality of first internal channels and the second at least one
internal channel
comprises a plurality of second internal channels, the first internal channels
and second
internal channels alternating along a widthwise direction of the cooled
channel component.
[019] In some embodiments of the first aspect, the cooled channel component
comprises a
base component defining the channel, and the means for cooling comprises: a
flow director
affixed to the base component; and at least one lid plate affixed to the flow
director. In such
embodiments, the flow director and the at least one lid plate may form at
least part of a first
flow path, whereby the surface of the channel is coolable by flowing a coolant
through the
first flow path.
[020] In some embodiments of the first aspect, the base component comprises an
extrusion
and the flow director comprises a casting affixed to a surface of the base
component. In such
embodiment, the flow director may further comprise features to create internal
channels of the
first flow path when joined to the base component.
[021] In some embodiments of the first aspect, the base component and the flow
director
comprise features which when joined together create internal channels of the
first flow path.
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[022] In some embodiments of the first aspect, the internal channels are
rifled.
[023] In some embodiments of the first aspect, the cooled channel component
further
comprises a second flow director affixed to the base component.
[024] In some embodiments of the first aspect, the cooled channel component
comprises a
base component defining the channel, and the means for cooling comprises: a
seal plate
affixed to the base component; and at least one guide component affixed to the
seal plate. In
such embodiments, the seal plate and the at least one guide component may form
at least part
of a first flow path when joined to the base component, whereby the surface of
the channel is
coolable by flowing a coolant through the first flow path. In some
implementations, the base
component may comprise features to create internal channels of the first flow
path when
joined to the seal plate.
[025] In some embodiments of the first aspect, the seal plate is manufactured
from a plastic
material.
[026] In some embodiments of the first aspect, the at least one guide
component comprises a
first guide component and a second guide component, the seal plate and the
first guide
component forming at least part of the first flow path, and the seal plate and
the second guide
component forming at least part of a second flow path when joined to the base
component,
whereby the surface of the channel is coolable by flowing a coolant through
the first and
second flow paths. In some implementations, the base component may further
comprise
features to create internal channels of the second flow path when joined to
the seal plate.
[027] In some embodiments of the first aspect, the internal channels of the
first flow path
and the internal channels of the second flow path are alternating along a
widthwise direction
of the cooled channel component.
[028] In some embodiments of the first aspect, the cooled channel component
further
comprises a second flow director affixed to the base component.
[029] In some embodiments of the first aspect, the cooled channel component
comprises a
base component defining the channel, the base component comprising an
extrusion having a
plurality of internal channels forming at least part of the means for cooling.
The internal
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channels may be contained within at least the arm of the channel that includes
the cooled
surface, whereby the surface of the channel is coolable by flowing a coolant
through the
internal channels of the extrusion.
[030] In some embodiments of the first aspect, the means for cooling further
comprises a
first manifold affixed to the extrusion and a second manifold affixed to the
extrusion opposite
the first manifold. The first manifold may comprise a first inlet and a second
outlet, the first
inlet being in fluid communication with a first subset of the internal
channels of the extrusion,
and the second outlet being in fluid communication with a second subset of the
internal
channels of the extrusion. Similarly, the second manifold may comprise a
second inlet and a
first outlet, the second inlet being in fluid communication with the second
subset of the
internal channels of the extrusion, and the first outlet being in fluid
communication with the
first subset of the internal channels of the extrusion.
[031] In some embodiments of the first aspect, the first subset of the
internal channels and
the second subset of the internal channels are alternating along a widthwise
direction of the
cooled channel component.
[032] In some embodiments of the first aspect, the cooled channel component
comprises a
base component defining the channel, and the means for cooling comprises: a
multi-port
extrusion (MPE) affixed to the base component. In such embodiments, the MPE
may have a
plurality of internal channels forming at least part of a first flow path,
whereby the surface of
the channel is coolable by flowing a coolant through the first flow path.
[033] In some embodiments of the first aspect, the base component and the MPE
are joined
via correspondingly shaped interlocking features on surfaces thereof.
[034] In some embodiments of the first aspect, the base component and the MPE
are joined
via fins generally projecting away from a surface of the base component
opposite the cooled
surface of the channel, and correspondingly shaped features on the MPE, the
correspondingly
shaped features on the MPE defining, at least in part, the internal channels
of the MPE.
[035] In some embodiments of the first aspect, the means for cooling further
comprises a
first manifold affixed to the MPE and a second manifold affixed to the MPE
opposite the first
manifold. The first manifold may comprise a first inlet and a second outlet,
the first inlet
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being in fluid communication with a first subset of the internal channels of
the MPE, and the
second outlet being in fluid communication with a second subset of the
internal channels of
the MPE. Similarly, the second manifold may comprise a second inlet and a
first outlet, the
second inlet being in fluid communication with the second subset of the
internal channels of
the MPE, and the first outlet being in fluid communication with the first
subset of the internal
channels of the MPE. The first subset of the internal channels and the second
subset of the
internal channels may alternate along a widthwise direction of the cooled
channel component.
[036] In some embodiments of the first aspect, the channel is generally u-
shaped.
[037] In some embodiments of the first aspect, the cooled channel component
includes only
the single channel.
[038] According to a second broad aspect, the present disclosure provides a
wall of a cooled
enclosure of a type which cools installed equipment by thermal contact with an
elongated
thermal connector element on at least one side of the equipment. A wall
according to this
broad aspect comprises one or more supports and a plurality of cooled channel
components
affixed to the one or more supports for engaging and supporting respective
equipment inserted
into the cooled enclosure. Each cooled channel component is mechanically
independent of
the other cooled channel components installed as part of the wall, comprises
an elongated
thermal connector element having a cooled surface, and is configured to
establish a male-
female progressive engagement with the elongated thermal connector element of
a respective
equipment as the equipment is inserted into the enclosure.
[039] In some embodiments of the second aspect, for each of at least one of
the cooled
channel components, the elongated thermal connector element of the cooled
channel
component comprises a channel having two spaced apart arms configured to
receive a rail
thermal connector of a respective equipment.
[040] In some embodiments of the second aspect, the channel comprises a pair
of spaced
apart arms, the arms having a normalized deflection of less than 0.0375 for a
bracing force
applied between the arms of the channel which is approximately equivalent to a
pressure of at
least 69kPa.
[041] In some embodiments of the second aspect, deflection of the arms of the
channel for a
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bracing force applied between the arms of the channel which is approximately
equivalent to a
pressure of between 69kPa to 690kPa is limited to a range that prevents
contact with the other
adjacently installed cooled channel components and the one or more supports
outside of
points of attachment to the one or more supports.
[042] In some embodiments of the second aspect, for each of at least one of
the cooled
channel components, the elongated thermal connector element of the cooled
channel
component comprises a rail thermal connector configured to be received within
a channel
thermal connector of a respective equipment.
[043] In some embodiments of the second aspect, each cooled channel component
is
configured to provide sufficient cooling for at least 0.25kW of power.
[044] In some embodiments of the second aspect, each cooled channel component
is
configured to cool a heat-flux between 10,000 W/m2 and 200,000 W/m2 when using
a water
based coolant to cool the cooled surface.
[045] In some embodiments of the second aspect, each of at least one of the
cooled channel
components comprises a first flow path comprising a first inlet, a first
outlet and a first at least
one internal channel connecting the first inlet to the first outlet, whereby
the cooled surface is
cooled by flowing a coolant through the first flow path.
[046] In some embodiments of the second aspect, the at least one internal
channel comprises
a spiral or serpentine configuration.
[047] In some embodiments of the second aspect, the at least one internal
channel comprises
features configured to disrupt the laminar flow of coolant flowing through the
first flow path.
[048] In some embodiments of the second aspect, each of the at least one
cooled channel
component further comprises a second flow path comprising a second inlet, a
second outlet
and a second at least one internal channel connecting the second inlet to the
second outlet.
[049] In some embodiments of the second aspect, the first and second inlets
and the first and
second outlets are arranged so that a direction of a coolant flow through the
first flow path
along a lengthwise direction of the cooled channel component is generally
opposite to a
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direction of a coolant flow through the second flow path along the lengthwise
direction of the
cooled channel component.
[050] In some embodiments of the second aspect, the first flow path and the
second flow
path have a substantially equal length thermal path to the cooled surface.
[051] In some embodiments of the second aspect, the first at least one
internal channel
comprises a plurality of first internal channels and the second at least one
internal channel
comprises a plurality of second internal channels, the first internal channels
and second
internal channels alternating along a widthwise direction of the cooled
channel component.
DRAWINGS
[052] These and other features, aspects, and advantages of the present
invention will become
better understood with regard to the following description, appended claims,
and
accompanying drawings where:
Fig. la shows an isometric view of a cooled channel component comprising a
base
component and a flow director and two lid plates in accordance with one
embodiment;
Fig. lb shows an exploded isometric view of the cooled channel component of
fig. la;
Fig. 2 shows a side elevation view of the base component of the cooled channel
component of figs. la and lb;
Figs. 3a, b and c show respectively top view, side elevation view and bottom
view of
the flow director of the cooled channel component of figs. la and b;
Fig. 3d shows an enlarged view of an end portion of the flow director of figs.
3a, 3b and
3c;
Fig. 3e shows a cutaway view along the A-A axis of the flow director of fig.
3a,
showing the structure of the internal channels of the flow director;
Fig. 4a shows a side elevation view of a rail thermal connector in accordance
with one
embodiment contacting the cooled channel component of figs. la and b and the
space between
the cooled channel component and supports;
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Fig. 4b shows an exploded side elevation view of the cooled channel component
and
supports of fig. 4a illustrating how the component is fastened to a supporting
structure;
Fig. 4c shows a side elevation view of the cooled channel component of figs.
4a and 4b
undergoing deflection;
Fig. 5 shows an exploded isometric view of a cooled channel component in
accordance
with another embodiment;
Fig. 6 shows a side elevation view of three of the cooled channel component of
figs. la
and lb installed in an enclosure wall;
Fig. 7a shows an isometric view of a cooled channel component in accordance
with
another embodiment with a simplified assembly;
Fig. 7b shows an exploded isometric view of the cooled channel component of
fig. 7a,
the cooled channel component having a base component comprising internal
channels and a
seal plate;
Fig. 7c shows a cross-sectional view of the cooled channel component of figs.
7a and
7b;
Figs. 8a and 8b show top views of the base component of the cooled channel
component of fig. 7b showing the structure of the internal channels of the
base component;
Fig. 9 shows a top view of the seal plate of the cooled channel component of
figs. 7a
and 7b;
Figs. 10a, 10b and 10c show bottom, side elevation and top views of the guide
components of the cooled channel components of figs 7a and 7b, respectively;
Fig. 11 shows an exploded side elevation view of the cooled channel component
of
figs. 7a and 7b attached to a supporting structure;
Fig. 12a shows an isometric view of a cooled channel component with a plastic
seal
plate in accordance with another embodiment;
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Fig. 12b shows an exploded isometric view of the cooled channel component of
fig.
12a;
Fig. 12c shows a side elevation view of the cooled channel component of figs.
12a and
12b;
Fig. 12d shows a cross-sectional view of the cooled channel component of figs.
12a,
12b and 12c;
Figs 13a, 13b and 13c show bottom, side elevation and top views of the seal
plate of the
cooled channel component of figs. 12a, 12b and 12c, respectively;
Fig. 14a shows an isometric view of a cooled channel component with rifled
internal
channels and comprising a base component and a flow director and two lid
plates in
accordance with another embodiment;
Fig. 14b shows an exploded isometric view of the cooled channel component of
fig.
14a;
Fig. 14c shows a cross-sectional view of the cooled channel component of figs.
14a and
14b;
Fig. 15 shows a bottom view of the base component of the cooled channel
component
of figs. 14a, 14b and 14c;
Figs. 16a, 16b and 16c show bottom, side elevation and top views of the flow
director
of the cooled channel component of figs. 14a, 14b and 14c, respectively;
Fig. 17 shows a top view of a guide component of the cooled channel component
of
figs. 14a, 14b and 14c;
Fig. 18a shows an isometric view off a cooled channel component that comprises
a base
component comprising an extrusion with integrated channels in accordance with
another
embodiment;
Fig. 18b shows an exploded isometric view of the cooled channel component of
fig.
18a;
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Fig. 18c shows a cross-sectional view of the cooled channel component of figs.
18a and
18b;
Figs. 19a, 19b and 19c show top cutaway, side elevation and isometric views of
a
manifold of the cooled channel component of figs 18a, 18b and 18c in
accordance with one
embodiment;
Fig. 20 shows a dimensioned profile view of the extrusion of the cooled
channel
component of figs. 18a, b and c;
Fig. 21a shows an isometric view of a cooled channel component comprising a
base
component, a multi-port extrusion (MPE), a first manifold and a second
manifold in
accordance with another embodiment;
Fig. 21b shows an exploded isometric view of the cooled channel component of
fig.
21a;
Fig. 22a shows a side elevation view of the MPE of the cooled channel
component of
figs. 21a and 21b;
Fig. 22b shows a top view of the MPE and manifolds assembly of the cooled
channel
component of figs. 21a and b;
Fig. 22c shows a side elevation view of the base component of the cooled
channel
component of figs. 21a and 21b;
Fig. 22d shows an isometric view of the manifold of the cooled channel
component of
figs. 21a and 21b;
Figs. 23a and b show side elevation views of a cooled channel component in
accordance with another embodiment;
Figs. 24a and b show side elevation views of a cooled channel comprising a
base
component and a MPE in accordance with another embodiment;
Fig. 24c shows top and cutaway views cutaway view along the A-A axis of the
base
component of figs. 24a and 24b;
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Fig. 25a shows an isometric view of a cooled channel component in accordance
with
another embodiment;
Fig. 25b shows an exploded isometric view of the cooled channel component of
fig.
25a;
Fig. 25c and 25d show cross sectional side elevation views of the cooled
channel
component of figs. 24a and b showing the configuration of the internal
channels;
Figs. 26a, 26b and 26c show bottom, side elevation and top views of the middle
component of the cooled channel component of figs. 25a, 25b and 25c,
respectively;
Figs. 27a and 27b show the cooled channel component of figs. 25a, 25b and 25c
in use
and being clamped around by a receiving channel in a computer server; and
Figs. 28a, 28b, 28c 28d and 28e show cutaway views of alternate channel
configurations.
DESCRIPTION
[053] It is intended that the following description and claims should be
interpreted in
accordance with Webster's Third New International Dictionary, Unabridged
unless otherwise
indicated.
[054] Previous work by this inventor disclosed in patent cooperation treaty
application no.
WO/2016/004528, titled "Robust Redundant-Capable Leak-Resistant Cooled
Enclosure
Wall", the content of which is incorporated herein by reference in its
entirety, describes an
enclosure wall comprising a plurality of channels configured to receive a rail
of installed
equipment, each channel having a corresponding coolant guide arranged on a
surface of a face
component.
[055] The present disclosure relates to cooled channel components that can be
used to build
an enclosure wall comprising a plurality of channels configured to receive a
rail of installed
equipment. Described are cooled channel components that are configured to
receive a rail of
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installed equipment and when installed individually or as part of a group can
be used to build
an enclosure wall similar to the one described in the WO/2016/004528 patent
application.
[056] With reference to Figs. la, lb and 2, a cooled channel component 100 in
accordance
with a first non-limiting embodiment is shown. The cooled channel component
100 comprises
a base component 110, a flow director 130 and two lid plates 160.
[057] In this embodiment, the base component 110 comprises a generally u-
shaped channel
112 configured to receive a rail thermal connector. As shown in Fig. la, an
external surface
116 of the base component 110 is in direct contact with the flow director 130.
A cooled
surface 114 of the generally u-shaped channel 112 may be defined as a surface
of the
generally u-shaped channel 112 that is in the closest proximity of the
external surface 116.
The cooled surface 114 may be any other surface in other embodiments. While
the cooled
surface 114 is generally planar in this embodiment, the cooled surface 114 may
have any
other suitable configuration in other embodiments (e.g., non-planar). Also,
the generally u-
shaped channel 112 may have any other configuration in other embodiments
(e.g., the channel
112 may have any other suitable shape). The base component 110 may further
comprise a
positioning feature 120 configured to receive a portion of the flow director
130 to facilitate
positioning of the flow director 130 during assembly. In this embodiment, the
positioning
feature 120 is a recess in the base component 110 generally extending along a
longitudinal
direction of the base component 110 and configured to engage a correspondingly
shaped
portion of the flow director 130. In other embodiments, the positioning
feature 120 may be a
recess or a protrusion of any shape to facilitate positioning of the flow
director 130 during
assembly. The base component 110 may further comprise attachment points, such
as a
threaded hole 106 to attach the cooled channel component 100 to a support, as
further
described below.
[058] With further reference to Figs. 3a to 3e, in this non-limiting first
embodiment, the flow
director 130 comprises a first flow path 131 and a second flow path 141, the
first flow path
131 comprising a first inlet 132, a first outlet 133 and a plurality of first
internal channels 134,
the second flow path 141 comprising a second inlet 142, a second outlet 143
and a plurality of
second internal channels 144. The first inlet 132 and second inlet 142 are in
an upper portion
of the flow director 130 (see e.g. fig. 3a) while the plurality of first
internal channels 134 and
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second internal channels 144 are in a lower portion of the flow director 130
(see e.g. fig. 3c).
In this embodiment, the plurality of first and second internal channels 134
and 144 have a
serpentine configuration and are substantially parallel to each other along a
width of the flow
director 130, the plurality of first and second internal channels 134 and 144
being configured
such that the plurality of first and second internal channels 134 and 144
alternate along the
widthwise direction of the flow director 130. In other embodiments, the first
and second
internal channels 134 and 144 as well as the first outlet 133 and second
outlet 143 may have
any other suitable configuration.
[059] In this first embodiment, an approximately equal flow of coolant is
being directed
along each one of the plurality of first internal channels 134 and each one of
the plurality of
second internal channels 144. The flow director 130 further comprises a
plurality of fins 152
which transport heat from the base component 110 and increase the surface area
available to
communicate heat into the coolant.
[060] The number of first and second internal channels 134 and 144 is equal
such that an
approximately equal flow of coolant is being directed along the plurality of
first internal
channels 134 and along the plurality of second internal channels 144. The
number of first and
second internal channels 134 and 144 may be different in other non-limiting
embodiments.
[061] The lid plates 160 are configured for interfitting engagement with the
flow director
130 such that the inlet passages 136 and 146 are sealed save for the first and
second inlets 132
and 142 and apertures 138 and 148.
[062] With further reference to Figs. 3a to 3e, when the cooled channel
component 100 is
assembled, coolant entering the flow director 130 at first inlet 132 is guided
along the first
inlet passage 136 until it reaches apertures 138 which connect into the lower
section of the
flow director 130 comprising the plurality of first internal channels 134 and
outlet 133. The
coolant is then guided along the plurality of first internal channels 134
until exiting the flow
director 130 at outlet 133. Coolant entering inlet 142 follows a similar
pathway along the
second flow path 141, being guided along the second inlet passage 146 until it
reaches
apertures 148 which connect into the lower section of the flow director 130
comprising the
plurality of second internal channels 144 and outlet 143, the coolant being
then guided along
the plurality of second internal channels 134 until exiting the flow director
130 at outlet 143,
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flowing in a direction generally opposite to a direction of coolant flowing
along the first flow
path 131. When assembled, coolant flowing along the first flow path 131 and
the second flow
path 141 do not mix, that is there is no fluid connection between the first
flow path 131 and
the second flow path 141.
[063] As a result of the first flow path 131 and second flow path 141 having
substantially
similar configurations and substantially similar heat paths to the cooled
surface 114, each one
of the flow paths 131 or 141 exhibits a substantially similar cooling
capacity. This may in turn
enable an active-active type redundancy of the cooled channel component 100,
the cooled
channel component 100 configured to cool the cooled surface 114 with only a
single one of
the first and second flow paths 131, 141 having coolant flow. In other non-
limiting
embodiments, the cooled channel component 100 may not exhibit an active-active
type
redundancy and may comprise a single flow path or any other suitable number of
flow paths.
For example a cooled channel component 100 may comprise a single flow path
comprising a
single inlet and a single outlet.
[064] In this first embodiment, enabling an active-active form of redundancy
may enable
supplying the cooled channel component 100 with two or more distinct cooling
systems.
Because the cooled channel component 100 of the present embodiment can provide
cooling to
an attached rail theinial connector with coolant flowing through only one of
the first and
second flow paths 131, 141, the cooled channel component may continue cooling
during
failure of one supplying coolant system or allow a coolant system to be shut
down for
maintenance without interrupting the cooling of an attached rail thermal
connector.
[065] Also, having coolant flow through the first and second flow paths 131
and 141 in an
opposite direction may allow heat to be more evenly removed from the cooled
channel
component 100 when coolant is flowing through both the first and second flow
paths 131 and
141.
[066] The serpentine configuration of the first and second internal channels
134 and 144
may disrupt laminar flow through the internal channels 134 or 144 and
generally improve heat
transfer between coolant flowing through flow path 131 or 141 and the cooled
channel
component 100.
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[067] In this first embodiment, the cooled channel component 100 may be
configured to
prevent air entrapment. Specifically, when the cooled surface 114 is
substantially horizontal
and the flow director 130 is positioned below the base component 110, air
introduced at either
one of inlet 132 or 142 flows naturally through the appropriate flow path 131
or 141 and exits
at either one outlet 133 or 143.
[068] The flow director 130 may further comprise other features to facilitate
assembly of the
cooled channel component 100. This may include a projection 154 at the second
outlet 143 (or
a projection 155 at the first outlet 133) configured to be received by the
positioning feature
120 of the base component 110. Specifically, the projection 154 is configured
to engage with
the positioning feature 120 which generally facilitates the alignment of the
flow director 130
with the base component 110. Additional alignment may be provided by allowing
the lip of an
outlet, such as the first outlet 133 to rest against the surface 118 of base
component 110. In
this way accurate assembly may be simplified with minimal additional features.
In other
embodiments, any other means to facilitate assembly of the cooled channel
component 100
and/or positioning of the flow director 130 relative to the base component 110
may be used.
[069] In this first non-limiting embodiment, the cooled channel component 100
is made of
and manufactured from aluminum. For example, the base component 110 may be
manufactured as an aluminum extrusion which is then machined or otherwise
modified to
provide the attachment points 106 and the positioning feature 120. The flow
director 130 may
be manufactured using a process suitable for brazing or soldering. The flow
director 130 may
be designed to be suitable for high vacuum diecasting, however other processes
may also be
used such as but not limited to diecasting, low or high pressure diecasting,
vacuum assisted
diecasting, rapid-fill vacuum assisted diecasting, investment casting,
permanent mold casting,
plaster casting, sand casting, graphite mold casting, machining and the likes.
The lid plates
160 may be made of aluminum and manufactured from sheet aluminum by laser,
plasma,
water-jet cutting, stamping or any another suitable method. The cooled channel
component
100 may be assembled and brazed, soldered or welded in such a way that all the
joints are
sealed leaving openings only at the inlets 132 and 142 and the outlets 133 and
143 while
preventing any substantial fluid connection between the first flow path 131
and the second
flow path 141. This may be achieved by selecting suitable manufacturing
processes and
tolerances and ensuring that the mating surfaces (i.e., surfaces of the base
component 110, the
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flow director 130 and the lid plates 160) are substantially planar or
otherwise suitably aligned
for joining.
[070] In other non-limiting embodiments, the cooled channel component 100 may
be made
of other materials such as but not limited to thermally conductive metals,
themially
conductive plastics, plastics and the likes. The cooled channel component 100
may also be
manufactured using other suitable manufacturing methods such as but not
limited to forging,
casting, machining, sintering, additive manufacturing and the likes. With
further reference to
fig. 5, another embodiment of the cooled channel component 100 where the flow
director 130
is machined from aluminum is shown.
[071] In this first embodiment, the external surface 116 of the base component
110 to which
the flow director 130 is connected is substantially planar. In other non-
limiting embodiments,
for example if an alternate manufacturing method other than extrusion is used
to manufacture
the base component 110 or if an additional material is used, the external
surface 116 may be
modified with the addition of fins, pins, or other features which generally
project inside an
inner portion of the first and second internal channels 134 and 144, further
increasing the
surface area available for heat transfer. Other features such as recesses
which receive fins 152
and improve the joining of the flow director 130 and the base component 110
may also be
present in other embodiments. In yet further embodiments, the external surface
116 of the
base component 110 may be non-planar.
[072] A corrosion resistance of the cooled channel component 100 may be
improved by
anodizing the assembled cooled channel component 100 and performing a sealing
process
using, for example, polytetrafluoroethylene (PTFE), boiling water, nickel
fluoride, nickel
acetate, potassium dichromate and the likes. Alternatively, the sealing
process described in
U.S. patent No. 4,549,910 or any other suitable sealing process may be used.
[073] Heat transfer between two surfaces may be improved by pressing the two
surfaces
together with an increased force, with benefits in terms of heat transfer
being gained by
pressing together the surfaces with forces as small as 69kPa to over 690kPa.
Fig. 4a shows a
side elevation view of a rail thermal connector 170 in position to be cooled
by the cooled
channel component 100 (flow director 130 and lid plates 160 not shown). A
surface 172 of the
rail thermal connector 170 is in contact with the cooled surface 114 of the
cooled channel
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componentl 1 100. When installed, a bracing force F acting between the arms of
the u-channel
112 may be used to urge the surface 172 of the rail thermal connector 170
against the cooled
surface 114 without causing significant structural deflections within the
larger structure that
the cooled channel component 100 is installed in, preferably with each arm
deflecting in such
a way that the cooled channel component 100 does not deflect into a space
between the
support 180 and the base component 110 so far as to come in contact with the
support 180
outside of the point of attachment of the cooled channel component 100 to the
support 180.
With further reference to fig. 4c, the deflection of each arm of the u-channel
112 is defined to
be a distance d measured from the point pi which lies on the extremity of an
arm when the
respective arm undergoes no deflection to the point p2 when the respective arm
of the u-
channel 112 undergoes deflection. For u-channels 112 having dimensions similar
to the
dimensions described below, that may be less than 1.5mm of deflection in each
arm, in some
cases less than lmm, in some cases less than 0.5mm, in some cases less than
0.25mm, in some
cases less than 0.1mm and in some cases even less.
[074] For other u-channels 112 having different dimensions, the deflection in
each arm may
be normalized by a width d3 of the arms. In this case, the normalized
deflection may be less
than 0.0375, in some cases less than 0.025, in some cases less than 0.0125, in
some cases less
than 0.006, in some cases less than 0.003 and in some cases even less.
[075] Alternatively, the deflection may be characterized in terms of an angle
0 of each arm
relative to the centerline, each one of the arms of the u-channel 112 being at
an angle 0 = 00
when respective arms of the u-channel 112 undergo no deflection. For the u-
channel 112, 0
may be less than 2.2 , in some cases less than 1.4 , in some cases less than
0.36 , in some
cases less than 0.15 and in some cases even less.
[076] With further reference to fig. 4b, a base component 100 having
dimensions: d1=17mm,
d2=7.2mm, d3=40mm, d4=7.2mm and a total length of 710mm is shown. Using
aluminum
6061 with a T6 temper and having a tensile strength of approximately 262 MPa
and a yield
strength of approximately 241 MPa as material of the base component 100. FEA
predicted
deflections for the base component 100 of fig. 4a show that for a pressure P
equally applied
along the length of the extrusion to the u-channel internal arm surfaces 114
and 115 of
approximately 355 kPa each arm of the u-channel 112 was shown to deflect by no
more than
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approximately 0.1mm (i.e., 0.2mm total deflection).
[077] The amount of pressure that can be supported by the cooled channel
component 100 is
dependent at least upon the dimensions and the material of the base component
110.
Therefore, in other non-limiting embodiments, other operable ranges of
deflection within a
range of operable pressures are possible. As non-limiting examples, the base
component 110
being the same, increasing the dimensions of the cooled channel component 100
of Fig. 4b d2
and d4 by 50% and increasing the pressure such that P=710kPa, FEA predicted
deflections
show an estimated deflection of 0.09mm per arm. Furthermore, increasing the
pressure such
that P=710kPa, FEA predicted deflections show an estimated deflection of no
more than
approximately 0.25mm per arm. Therefore by varying dimensions, materials and
tolerances,
for example substituting steel, titanium or another metal or composite
material for aluminum,
a large range of pressure (e.g., between 5 kPa and 900 kPa, in some cases
between 50kPa and
700 kPA, in some cases between 100kPa and 500 kPa and in some cases between
200kPa and
350 kPa) and deflections may be accommodated by the cooled channel components
described
in the present disclosure.
[078] In order to prevent the deflection experienced by the arms of the base
component 110
from causing significant structural deflections within the larger structure
that the cooled
channel component 100 is installed in, a gap may be provided between the
support 180 and
the base component 110. The gap may allow the base component 110 to deform
without
contacting the support 180 beyond the point of attachment to the support 180,
thus reducing
the force being transmitted to the support 180. In one non-limiting
embodiment, the gap may
be created by positioning a washer 182 between the support 180 and the base
component 110.
In other embodiments, a boss or any other similar feature may be introduced in
the base
component 110, as further described below. The base component 110 may be
fastened to the
support 180 by a fastener such as screw 184 which is fastened to the
attachment point 106.
The base component may be connected to the support 180 by any suitable mean in
other
embodiments.
[079] For a cooled channel component 100 with a base component 110 having
dimensions as
described above and a flow director 130 having a length of 687mm and with
approximate
dimensions (see e.g. Fig. 3e): D1=5mm, D2=4.6mm, D3=38mm, D4=1.6mm the table
below
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provides computational fluid dynamics (CFD) estimated performance for a water
based
coolant flowing separately through both the first flow path 131 and the second
flow path 141
with an inlet temperature of 30 C. The cooled surface section is defined to be
the full width of
the cooled surface 114 that stops 20mm from either longitudinal end of the
base component
110, giving a total dimension of 670mm x 40mm and a total cooling surface of
268cm2 or
0.0268m2. Other dimensions of the base component 110 and the flow director 130
are possible
in other embodiments. For example, the width d3 of the arms of the u-channel
112 of the base
component 110 may be between 90mm and 5mm, in some cases between 80mm and
lOmm,
in some cases between 70mm and 20mm and in some cases between 60mm and 30mm.
The
remaining dimensions of the base component may then be selected to ensure that
the cooled
channel component provides sufficient cooling for at least 0.25kW of power per
cooled
channel component, in some cases at least 0.5kW of power per cooled channel
component, in
some cases at least lkW of power per cooled channel component, in some cases
at least 2kW
of power and in some cases even more.
[080] The table headings are as follows:
InVel ¨ Inlet velocity (m/s) of coolant as measured at inlet 132 and 142.
CSurfavg ¨ Average temperature ( C) of cooled surface section as defined
above.
Velavg ¨ Average velocity (m/s) of coolant flowing through flow path 131 and
141.
Flux ¨ Heat Flux evenly applied to cooled surface 114 section as defined
above.
FluxPer10 ¨ Heat Power applied (W) per 10cm length of cooled surface section.
OutTemp ¨ Max coolant temperature ( C) as measured at outlet 133 or 143.
Drop ¨ Coolant pressure (bulk) drop (kPa) between inlet 132 or 142 and outlet
133 or 143.
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InVel CSurfavg Velavg Flux FluxPer10 (W) OutTemp Drop
(kPa)
(m/s) ( C) (m/s) (W/m2) ( C)
1.25 54 2.8 187,500 750 34 27
1.25 42 2.8 93,750 375 32 27
1 57 2.3 187,500 750 35 19
1 44 2.3 93,750 375 32 19
0.75 61 1.6 187,500 750 36 13
0.75 46 1.6 93,750 375 33 13
0.5 65 1.2 187,500 750 39 9
0,5 49 1.2 93,750 375 35 9
0.5 44 1.2 75,000 300 34 9
0.5 43 1.2 67,500 270 33 9
0.5 41 1.2 60,000 240 33 9
[081] For a water based coolant flowing through each of the first flow path
and second flow
paths at a rate of 1.25m/s and having an inlet temperature of 30 C, the cooled
surface 114
temperature reaches approximately 54 C when cooling 750W of heat applied to
the cooled
surface 114 per 10 cm length of cooled surface 114 (i.e., a heat flux applied
to the cooled
surface 114 of 187.5kW/m2), with a coolant outlet temperature of approximately
34 C and a
pressure drop of 27kPa. Accordingly, the cooled channel component 100 may
provide a heat
flux of at least 10,000W/m2, is some cases at least 50,000W/m2, in some cases
at least
75,000W/m2, in some cases at least 100,000W/m2, in some cases at least
150,000W/m2, in
some cases at least 175,000 W/m2 and in some cases even more for a water based
coolant.
[082] The table below provides computational fluid dynamics (CFD) estimated
performance
for a water based coolant flowing through only the first flow path 131 with an
inlet
temperature of 30 C.
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InVel (m/s) CSurtvg ( C) Velavg (m/s) Flux (W/m2) FluxPeri OutTemp ( C) Drop
(kPa)
(W)
1.25 67 2.8 187,500 750 38 27
1.25 50 2.8 93,750 375 34 27
1 72 2.3 187,500 750 40 19
1 52 2.3 93,750 375 35 19
0.75 78 1.6 187,500 750 43 13
0.75 55 1.6 93,750 375 36 13
0.5 86 1.2 187,500 750 49 9
,
0,5 58 1.2 93,750 375 40 9
0.5 53 1.2 75,000 300 38 9
0.5 51 1.2 67,500 270 37 9
0.5 48 1.2 60,000 240 36.2 9
[083] While the results above are given for a water-based coolant, non water-
based coolants
may also be used in other embodiments such as, but not limited to, a glycol-
based coolant,
glycol, CO2, NH3, a coolant such as sold under the trade names Novec or
Fluorinet by 3M,
headquartered in Maplewood, Minnesota or any other suitable coolant. For non
water-based
coolants (e.g., exhibiting phase change), the cooled channel component 100 may
provide a
heat flux at least 2 times, in some cases at least 5 times, in some cases at
least 10 times and in
some cases even more that of the heat flux for a water based coolant as shown
above.
[084] With further reference to fig. 6, three cooled channel components 100
fixed to
supports 180 as might be found in an enclosure wall are shown, the cooled
channel
components 100 being installed in their operating orientation with the flow
director 130 being
below the cooled surface 114. As can be observed there are spaces between
adjacent cooled
channel component 100. These spaces and the gaps between supports 180 and the
base
component 110 allow each one of the cooled channel component 100 to be
mechanically
independent of the other cooled channel components 100. That is each cooled
channel
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component 100 being capable of deforming without the deformations
significantly affecting
other cooled channel components 100 installed in the enclosure wall.
[085] In another non-limiting embodiment, the cooled channel component 100 may
comprise two flow directors 130, each flow director 130 being fixed to an arm
of the cooled
channel component such that each one of the two arm of the u-channel 112
comprises a
cooled surface 114.
[086] With further reference to figs. 7a, b and c, a second non-limiting
embodiment of the
cooled channel component is shown. The cooled channel component 200 comprises
a base
component 210, a seal plate 290 and two guide components 260. When assembled
coolant
flows through the cooled channel component 200 in a manner similar to that of
the cooled
channel component 100.
[087] With further reference to figs. 8a and 8b, the base component 210
comprises a
generally u-shaped channel 212 having a cooled surface 214 configured to
receive a rail
thermal connector and, the arm of the generally u-shaped channel 212
comprising the cooled
surface 214 further comprising a plurality of channels, the plurality of
channels containing
sections of a first flow path 231 and a second flow path 241. A seal plate 290
and two guide
components 260 are configured to be fitted onto the base component 210 such
that the first
flow path 231 comprises a first inlet 232, a first outlet 233 and a plurality
of first internal
channels 234 and second flow path 241 comprises a second inlet 242, a second
outlet 243 and
a plurality of second internal channels 244. The first and second internal
channels 234 and
244 have a serpentine configuration and are substantially parallel to each
other along a width
of the base component 210, the plurality of first and second internal channels
234 and 244
being configured such that the plurality of first and second internal channels
234 and 244
channels alternate along the widthwise direction of the base component 210. In
other
embodiments, the first and second internal channels 234 and 244 may have any
other suitable
configuration. While the cooled surface 214 is generally planar in this
embodiment, the cooled
surface 214 may have any other suitable configuration in other embodiments
(e.g., non-
planar). Also, the generally u-shaped channel 212 may have any other
configuration in other
embodiments (e.g., the channel 212 may have any other suitable shape).
[088] In this embodiment, an approximately equal flow of coolant is being
directed along
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each one of the plurality of first internal channels 234 and each one of the
plurality of second
internal channels 244. The number of first and second internal channels 234
and 244 is equal
such that an approximately equal flow of coolant is being directed along the
plurality of first
internal channels 234 and along the plurality of second internal channels 244.
The number of
first and second internal channels 234 and 244 may be different in other non-
limiting
embodiments.
[089] In this embodiment, the plurality of first and second internal channels
234 and 244 are
directly integrated into the base component 210 such that there is no need for
a separate flow
director 130 which simplifies manufacturing by reducing the complexity of the
components
attached to the base component 210. Also, the flow of coolant occurs closer
from the cooled
surface 214 when compared to the first embodiment, thereby minimizing the path
that heat
must travel.
[090] The cooled channel component 200 may be made of and manufactured from
aluminum. The base component 210 may be manufactured using a process suitable
for
brazing, soldering or welding such as a casting or forging and processes such
as high-vacuum
diecasting or precision forging may produce a component that has a reduced
need for
subsequent machining or other operations. Other processes such as but not
limited to
diecasting, low or high pressure diecasting, vacuum assisted diecasting, rapid-
fill vacuum
assisted diecasting, investment casting, permanent mold casting, plaster
casting, sand casting,
graphite mold casting, machining, sintering or additive fabrication may also
be used.
[091] With further reference to fig. 9, the seal plate 290 may be manufactured
from sheet
aluminum by laser, plasma or water-jet cutting, stamping or any other suitable
fottning or
cutting method. Compared to the flow director 130 of the first embodiment, the
seal plate 290
is a simpler part. The seal plate 290 fits into a recess 219 within the base
component 210. The
seal plate 290 may further comprise apertures 292 cut into the seal plate 290
to facilitate
alignment of the seal plate 290 with the base component 210 and generally
facilitate assembly
of the cooled channel component 200. The seal plate 290 may also comprise
apertures 238
and 248 which allow coolant flowing within guide components 260 to communicate
with the
channels located within base component 210.
[092] In some embodiments, the seal plate 290 may also be manufactured from a
clad
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aluminium sheet that has cladding suitable for brazing, reducing or removing
the need for
additional brazing filler material during joining.
[093] With further reference to figs. 10a, 10b and 10c, the guide components
260 may be
made of aluminum and manufactured by using a sheet metal forming process such
as
stamping, hydro-forming, superplastic forming or another suitable process. The
guide
components 260 provide the inlets 232 and 242 and guide coolant from each
inlet 232 and 242
to the appropriate apertures 238 and 248 in the seal plate 290. The guide
components 260 may
further comprise keys 262 for interfitting engagement with the apertures 292
cut into the seal
plate 290 to provide positional alignment.
[094] The cooled channel component 200 may be assembled and brazed, soldered
or welded
in such a way that all the joints may be sealed leaving openings only at
inlets 232 and 242 and
outlets 233 and 243 and preventing any substantial fluid connection between
the first flow
path 231 and the second flow path 241. This may be achieved by selecting
suitable
manufacturing processes and tolerances and ensuring that the mating surfaces
(i.e, surfaces of
the base component 210, the seal plate 290 and the guide components 260) are
substantially
planar or otherwise suitably aligned for joining.
[095] A corrosion resistance of the cooled channel component 200 may be
improved by
anodizing the assembled cooled channel component 200 and sealing it using a
sealing process
using, for example, PTFE, boiling water, nickel fluoride, nickel acetate,
potassium dichromate
and the likes. Alternatively, the sealing process described in U.S. Patent No.
4,549,910 or any
other suitable sealing process may be used.
[096] In other non-limiting embodiments, the cooled channel component 200 may
be made
of aluminum or other alternative materials such as but not limited to
thermally conductive
metals, thermally conductive plastics and plastics. The cooled channel
component 200 may
also be manufactured using methods such as but not limited to forging,
casting, machining,
sintering or any other suitable manufacturing process.
[097] With further reference to fig. 11, the base component 210 may further
comprise a boss
282 which performs the same spacing function as the washer 182 described in
connection
with the first embodiment above. Any other spacer may be used in other
embodiments. In
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place of the threaded attachment point 106 the base component 210 may also
further comprise
a threaded shaft 206 or a shaft configured to receive a push nut, a retaining
ring and the likes.
In this embodiment, the cooled channel component 200 is connected to the
support 280 via
the use of a nut 284, a belleville washer 286 and a washer 288. The cooled
channel component
200 may be connected to the support 280 in any other suitable manner in other
embodiments.
[098] For a cooled channel component 200 as described and with a base
component 210
having dimensions d1=17mm, d2=7.2mm, d3=40mm, d4=7.2mm, D1=4.2mm, D2=4mm and a
total length of 710mm, the table below provides CFD estimated performance for
a water
based coolant flowing separately through both the first flow path 231 and
second flow path
241 with an inlet temperature of 30 C. As shown below, the cooled channel
component 200
may provide a heat flux of at least 10,000W/m2, is some cases at least
50,000W/m2, in some
cases at least 75,000W/m2, in some cases at least 100,000W/m2, in some cases
at least
150,000W/m2, in some cases at least 175,000 W/m2 and in some cases even more
for a water
based coolant.
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InVel (m/s) CSurfavg ( C) Velavg (m/s) Flux (W/m2) FluxPer10 OutTemp ( C) Drop
(kPa)
(W)
1.25 40 4.5 187,500 750 32 65
1.25 35 4.5 93,750 375 31 65
1 42 3.3 187,500 750 33 43
1 36 3.3 93,750 375 32 43
0.75 44 2.6 187,500 750 34 25
0.75 37 2.6 93,750 375 32 25
0.5 49 1.8 187,500 750 36 13
0,5 39 1.8 93,750 375 33 13
_
0.5 37 1.8 75,000 300 33 13
0.5 37 1.8 67,500 270 32 13
0.5 36 1.8 60,000 240 32 13
[099] The table below provides computational fluid dynamics (CFD) estimated
performance
for a water based coolant flowing through only the first flow path 131 with an
inlet
temperature of 30 C.
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InVel (m/s) CSurfavg ( C) Velavg (m/s) Flux (W/m2) FluxPer10 OutTemp ( C) Drop
(kPa)
(W)
1.25 45 4.5 187,500 750 35 65
'
1.25 37 4.5 93,750 375 33 65
1 47 3.3 187,500 750 36 43
1 39 3.3 93,750 375 33 43
0.75 50 2.6 187,500 750 38 25
0.75 40 2.6 93,750 375 34 25
0.5 58 1.8 187,500 750 43 13
0,5 44 1.8 93,750 375 36 13
0.5 41 1.8 75,000 300 35 13
0.5 40 1.8 67,500 270 35 13
0.5 39 1.8 60,000 240 34 13
[0100] With further reference to figs.12a, 12b, 12c and 12d, a third non-
limiting embodiment
of the cooled channel component is shown. The cooled channel component 300
comprises a
base component 310, a seal plate 390 and two guide components 360. When
assembled
coolant flow through cooled channel component 300 is similar to coolant flow
through the
cooled channel components 100 and 200.
[0101] The base component 300 may be similar to the base component 200
described above
and comprisie a generally u-shaped channel 312 configured to receive a rail
thermal connector
and having channels located within the at least one of the arms comprising
cooled surface 314
of the u-channel 312 containing sections of a first flow path and a second
flow path. The seal
plate 390 and the two guide components 360 may be configured to be fitted onto
the base
component 310 such that the first flow path comprises a first inlet 332, a
first outlet 333 and a
plurality of first internal channels 334 and the second flow path comprises a
second inlet 342,
a second outlet 343 and a plurality of second internal channels 344. The
plurality of first and
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second internal channels 334 and 344 have a serpentine configuration and are
substantially
parallel to each other along a width of the base component 310, the plurality
of first and
second internal channels being configured such that the plurality of first and
second internal
channels 334 and 344 alternate along the widthwise direction of the base
component 310. In
other embodiments, the first and second internal channels 334 and 344 may have
any other
suitable configuration. While the cooled surface 314 is generally planar in
this embodiment,
the cooled surface 314 may have any other suitable configuration in other
embodiments (e.g.,
non-planar). Also, the generally u-shaped channel 312 may have any other
configuration in
other embodiments (e.g., the channel 312 may have any other suitable shape).
[0102] In this non-limiting embodiment, the seal plate 390 and guide
components 360 may be
made of plastic such as but not limited to ABS, PVC, Nylon or any injection
moldable or
thermoset plastic including filled plastics, composites and the likes. The
seal plate 390 and the
guide components 360 may be manufactured using injection molding or other any
other
suitable manufacturing process. The cooled channel component 300 may be
assembled by
joining the base component 310, the seal plate 390 and the guide components
360 using an
adhesive, a brazing process or any other suitable process.
[0103] With further reference to figs. 13a, 13b and 13c, the seal plate 390
may comprise
features to improve and/or facilitate the adhesion of the seal plate 390 to
the base component
310. The seal plate 390 may comprise a plurality of recesses 394 configured to
receive the fins
352 of base component 310. This technique may also be applied to other cooled
channel
components described herein joined by other means such as brazing or welding.
[0104] As the seal plate 390 may be plastic injection molded, a number of
structural features
may be implemented on the seal plate 390 to simplify the corresponding
structural features of
the guide component 360. In a non-limiting example, the guide component 360
may be a sheet
of plastic received by a ledge or recess in the walls of the first inlet
passage 336 or the second
inlet passage 346. Any other suitable configuration of the guide component 360
and the seal
plate 390 may be possible in other embodiments.
[0105] The seal plate 390 may be joined to the base component 310 using an
adhesive. A
suitable adhesive may be Loctite UK U-05F or any suitable adhesive capable of
withstanding
immersion within the intended coolant and retaining adequate strength over the
life of the
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component. To improve adhesion, the areas of the base component 310 to be
contacted to by
the adhesive may be abraded, either mechanically or by an acid etch.
[0106] The aluminum base component 310 may have its corrosion resistance
improved by
anodization. In some embodiments, the aluminum base component 310 may be
anodized prior
to joining the seal plate 390 to the base component 310. The areas of the base
component 310
to be contacted with the adhesive may then be abraded as disclosed above. The
base
component 310 and the seal plate 390 may then be joined using adhesive. The
assembled
cooled channel component 300 may then be sealed using, for example, P1'1-E,
boiling water,
nickel fluoride, nickel acetate, potassium dichromate and the likes.
Alternatively, the sealing
process described in U.S. Patent No. 4,549,910 or any other suitable sealing
process may be
used. In other embodiments, the cooled channel component 300 may be assembled
prior to the
anodization step.
[0107] With further reference to figs. 14a, 14b and 14c, a fourth non-limiting
embodiment of
the cooled channel component is shown. The cooled channel component 400
comprises a base
component 410, a flow director 430 and two guide components 460. When
assembled coolant
flow through cooled channel component 400 is similar to coolant flow through
the previously
described cooled channel components 100, 200 and 300.
[0108] The base component 410 comprises a generally u-shaped channel 412
configured to
receive a rail thennal connector and having channels located within at least
one of the arms of
the generally u-shaped channel 412 comprising a cooled surface 414. The cooled
surface 414
of the u-channel 412 comprises sections of a first flow path 431 and a second
flow path 441.
A flow director 430 and two guide components 460 are configured to be fitted
onto to the base
component 410 such that the first flow path 431 comprises a first inlet 432, a
first outlet 433
and a plurality of first internal channels 434 and the second flow path
comprises a second inlet
442, a second outlet 443 and a plurality of second internal channels 444. The
plurality of first
and second internal channels 434 and 444 may be generally cylindrical. In some
non-limiting
embodiments, the generally cylindrical channels may have a rifling or helical
geometry. The
plurality of first and second internal channels 434 and 444 are generally
parallel to each other
along the width of the base component 410, the plurality of first and second
internal channels
434 and 144 being configured such that the plurality of first and second
internal channels 434
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and 444 alternate along the widthwise direction of the flow director 430. In
other
embodiments, the first and second internal channels 434 and 444 may have any
other suitable
configuration. While the cooled surface 414 is generally planar in this
embodiment, the cooled
surface 414 may have any other suitable configuration in other embodiments
(e.g., non-
planar). Also, the generally u-shaped channel 412 may have any other
configuration in other
embodiments (e.g., the channel 412 may have any other suitable shape).
[0109] The rifling or helical geometry of the plurality of cylindrical first
internal channels 434
and second internal channels 444 may improve the heat transferred between the
liquid coolant
flowing through the first flow path 431 and second flow path 432 and the base
component
410.
[0110] With further reference to fig. 15, the base component 410 may have a
recess 419
configured for interfitting engagement with the flow director 430. In this non-
limiting
embodiment, the base component 410 comprises the features of one-half of the
geometry of
the internal channels 434 and 444 and the outlets 433 and 443 with the flow
director 430
comprising the features of the opposing half of the geometry of the internal
channels 434 and
444 and the outlets 433 and 443 such that when the base component 410 and flow
director 430
are joined the features of each opposing half align to create the internal
channels 434 and 444,
and outlets 433 and 433 that comprise the first and second flow paths 431 and
432.
[0111] With further reference to figs. 16a, 16b, 16c and 17, the flow director
430 is shown. In
addition to comprising the features of the opposing halves of the internal
channels 434 and
444 and outlet 433 and 443 the flow director 430 also comprises half of the
first inlet passage
436 and the second inlet passage 446, the opposing half of the first inlet
passage 436 and the
second inlet passage 446 being a part of the guide components 460, one of
which is shown in
figure 17. Flow director 430 also contains apertures 438 and 448 which allow
coolant to flow
from inlet passages 436 and 446 to the internal channels 434 and 444.
[0112] In this embodiment, the base component 410 may be made of and
manufactured from
aluminum, however other materials such as thermally conductive plastics and
other thermally
conductive metals and composites may be used. The flow director 430 and guide
components
may be manufactured from either aluminum or plastic and may be joined to base
component
410 via a brazing, soldering or welding step or an adhesive as described
above. Subsequently
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the part may optionally be anodized in a manner similar to that described
above. A brazing
filler material may be applied via cold gas spraying or any other suitable
thermal spray
process when the parts are brazed as notably disclosed in "Thermally Sprayed
Solder/Braze
Filler Alloys for the Joining of Light Metals" by B. Wielage, A. Wank, Th.
Grund.
[0113] In the following example, the cooled surface section is defined to be
the full width of
the cooled surface that stops 20mm from either end of the base component, in
this case giving
a total dimension of 560mm x 40mm.
[0114] For a cooled channel component 400 as described and having dimensions
d1=17mm,
d2=7.5mm, d3=41mm, d4=7.5mm, D1=5mm and a total length of 600mm the table
below
provides CFD estimated performance for a water based coolant flowing
separately through
both the first flow path 431 and second flow path 441 with an inlet
temperature of 30 C. As
shown below, the cooled channel component 400 may provide a heat flux of at
least
10,000W/m2, is some cases at least 50,000W/m2, in some cases at least
75,000W/m2, in some
cases at least 100,000W/m2, in some cases at least 150,000W/m2, in some cases
at least
175,000 W/m2 and in some cases even more for a water based coolant.
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InVel (m/s) CSurtvg ( C) Velavg (m/s) Flux (W/m2) FluxPeri OutTemp ( C) Drop
(kPa)
(W)
1.25 43 2.7 187,500 750 36 52
1.25 37 2.7 93,750 375 33 52
1 45 2.2 187,500 750 37 34
1 37 2.2 93,750 375 34 34
0.75 47 1.7 187,500 750 40 19
0.75 39 1.7 93,750 375 35 19
0.5 52 1.1 187,500 750 45 9
0,5 41 1.1 93,750 375 37 9
0.5 39 1.1 75,000 300 35 9
0.5 38 1.1 67,500 270 35 9
0.5 37 1.1 60,000 240 35 9
[0115] With further reference to figs. 18a, 18b and 18c, a fifth non-limiting
embodiment of
the cooled channel component is shown. The cooled channel component 500
comprises a base
component 510, first manifold 595 and a second manifold (not shown) installed
opposite the
first manifold 595. The base component 510 comprises a generally u-shaped
channel 512
configured to receive a rail thermal connector. The base component 510 further
comprises a
first plurality of internal channels 534 and a second plurality of internal
channels 544
contained in at least the arm containing a cooled surface 514 of the u-channel
512.
[0116] The cooled channel component 500 comprises a first flow path and a
second flow
path, with the first flow path comprising a first inlet 532, a first outlet
(part of the second
manifold, not shown) and a plurality of first internal channels 534 and the
second flow path
comprising a second inlet (part of the second manifold, not shown), a second
outlet 543 and a
plurality of second internal channels 544. The first and second internal
channels 534 and 544
have a generally rectangular geometry and are substantially parallel to each
other along the
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width of the base component 510. The plurality of first and second internal
channels 534 and
544 may further comprise fins to increase the surface available for heat
exchange. The
plurality of first and second internal channels 534 and 544 are configured
such that the
plurality of first and second internal channels 534 and 544 alternate along a
widthwise
direction of the base component 510 and an approximately equal flow is
directed along each
one of the plurality of first internal channels 534 and each one of the
plurality of second
internal channels 544.
[0117] With further reference to figs. 19a, 19b and 19c, a first manifold 595
is shown
containing the first inlet 532 and the second outlet 543. The first manifold
595 is configured to
fit at one end of the base component 510 so as to direct a first coolant flow
flowing into inlet
532 through a first plurality of internal channels 534 in the base component
510 via apertures
538 and direct a second coolant flow being received through the second
plurality of internal
channels 544 in the base component to outlet 543 without allowing coolant
flowing through
inlet 532 and outlet 543 to mix. That is, there is no fluid connection between
the first coolant
flow and the second coolant flow in the first manifold 595. A second manifold
component
(not shown) is configured to fit at an opposite end of the base component 510
in a similar
manner so as to direct the second coolant flow flowing from the second
manifolds inlet
through the second plurality of internal channels 544 in the base component
510 and direct the
first coolant flow being received through the first plurality of internal
channels 534 in the base
component 510 to the second manifolds outlet without allowing coolant flowing
through the
second manifold inlet and second manifold outlet to mix. That is, there is no
fluid connection
between the first coolant flow and the second coolant flow in the second
manifold. The first
manifold 595 and the second manifold may have any other suitable configuration
in other
embodiments.
[0118] The component 510 may be manufactured as an extrusion from aluminum or
from
another thermally conductive metal such as but not limited to copper, from a
thermally
conductive plastic or from any other suitable material in other embodiments.
Once extruded
each end of the base component 510 may be machined to be configured to receive
the
manifold described above. The manifolds 595 may be made of aluminum, any other
metal,
plastic or any other suitable material in other embodiments. In some
embodiments, the
manifolds 595 may be joined to the base component 510 via a brazing step or by
the use of an
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adhesive as described above. The assembled cooled channel component 500 may
then be
anodized as described above.
[0119] A base component 510 fabricated from aluminum 6061 with a T6 temper and
having a
tensile strength of approximately 262 MPa and a yield strength of
approximately 241 Mpa
with a similar profile as shown in figure 20 with dimensions: d1=17mm,
d2=10mm, d3=40mm,
d4=12mm, D1=6.4mm, D2=4.5mm, D3=1.8mm and a total length of 710mm yielded the
following FEA predicted deflection. For a pressure P equally applied along the
length of the
extrusion to the u-channel internal aim surfaces of approximately 414 kPa each
arm of the u-
channel was shown to deflect no more than approximately 0.1mm (0.2mm total).
[0120] With further reference to figs. 21a and 21b, a sixth non-limiting
embodiment of the
cooled channel component is shown. The cooled channel component 600 comprises
a base
component 610, a multi-port extrusion (MPE) 630, a first manifold 695 and a
second manifold
696.
[0121] With further reference to figs. 22a to 22d, the MPE 630, the manifold
695 and 696 and
the base component 610 are shown.
[0122] In this non-limiting embodiment, the base component 610 comprises a
generally u-
shaped channel 612 configured to receive a rail thennal connector. The base
component 610 is
further configured to receive the MPE 630 on one of its external surfaces 616,
preferably
opposite a cooled surface 614 of the base component 610. In some embodiments,
the base
component 610 may further comprise recesses 619 to facilitate a correct
positioning of the
MPE 630 and manifolds 695 and 696 relative to the base component 610 while
maintaining
thermal contact between the MPE 630 and the base component 610. In other non-
limiting
embodiments, the manifolds 695 and 696 and the MPE 630 may have any other
suitable
design that does not require recesses to facilitate a positioning of the MPE
630 and manifolds
695 and 696 relative to the base component 610. In some embodiments, the base
component
610 may further comprise a spacing feature 682 configured to provide a spacing
between the
cooled channel component 600 and a support onto which the cooled channel
component 600
is connected.
[0123] The first manifold component 695 may be configured for interfitting
engagement at
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one end of the MPE 630. In this non-limiting embodiment, the first manifold
component 695
comprises a first inlet 632 and a second outlet 643 and is configured to
direct a first coolant
flow flowing into the first inlet 632 through a first plurality of internal
channels 634 in the
MPE 630 and to direct a second coolant flow being received through a second
plurality of
internal channels 644 of the MPE 630 to the second outlet 643 without allowing
coolant
flowing through the first inlet 632 and second outlet 643 to mix. That is,
there is no fluid
connection between the first coolant flow and the second coolant flow in the
first manifold
695.
[0124] The second manifold 696 may be configured for interfitting engagement
at an opposite
end of the MPE 630. In this non-limiting embodiment, the second manifold
component 696
comprises a second inlet 642 and a first outlet 633 and is configured to
direct the second
coolant flow flowing from the second inlet 642 through the second plurality of
internal
channels 644 in the MPE 630 and to direct the first coolant flow being
received through the
first plurality of internal channels 634 in the MPE 630 to the second outlet
633 without
allowing coolant flowing through the second inlet 642 and the first outlet 633
to mix. That is,
there is no fluid connection between the first coolant flow and the second
coolant flow in the
second manifold 696.
[0125] In this non-limiting embodiment, the first plurality of internal
channels 634 and the
second plurality of internal channels 644 are generally parallel to each other
along a width of
the MPE 630, the first plurality of internal channels 634 and second plurality
of internal
channels 644 being configured such that the first plurality of internal
channels 634 and the
second plurality of internal channels 644 alternate along the widthwise
direction of the MPE
630. In other embodiments, the first plurality of internal channels 634 and
the second plurality
of internal channels 644 may have any other suitable configuration.
[0126] In this embodiment, an approximately equal flow of coolant is being
directed along
each one of the plurality of first internal channels 634 and each one of the
plurality of second
internal channels 644. The plurality of first and second internal channels 634
and 644 may
further comprise fins along their respective lengths to increase the surface
area available for
heat transfer.
[0127] The number of first and second internal channels 634 and 644 may be
equal such that
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an approximately equal flow of coolant is being directed along the plurality
of first internal
channels 634 and along the plurality of second internal channels 644. The
number of first and
second internal channels 634 and 644 may be different in other non-limiting
embodiments.
[0128] In this embodiment, the base component 610 may be an extrusion
manufactured from
a thermally conductive metal such as aluminum or any other suitable conductive
metal. The
MPE 630 may be manufactured from a thermally conductive plastic, a thermally
conductive
metal such as but not limited to aluminum or from any other suitable material
in other
embodiments. The manifolds 634 and 644 may be manufactured from a metal
suitable for
joining to the MPE 630 such as aluminum, plastic and the likes. The material
of the manifolds
634 and 644 may be different from the material of the MPE 630 and the base
component 610
or may be the same material as either one of the MPE 630 or the base component
610. In
some embodiments, the manifolds 695 and 696 may be being cast using
dissolvable cores,
such as salt cores, or may be designed in a similar fashion as manifold 595
which can be
manufactured without requiring cores.
[0129] The base component 610 and MPE 630 may be joined together by brazing,
soldering,
by the use of a thermally conductive adhesive or in any other suitable manner.
The manifolds
695 and 696 may also be joined to the MPE 630 and the base component 610 by
brazing,
soldering, by the use of an adhesive or in any other suitable manner.
Anodization may be used
to improve corrosion resistance.
[0130] With further reference to figs. 23a and 23b, another embodiment of the
cooled channel
component having a MPE is shown. The cooled channel component 700 comprises a
base
component 710 and MPE 730 comprising a plurality of channels 734. These
component 710
and MPE 730 are configured to be joined to each other via interlocking
features 717 on the
base component 710 and correspondingly shaped features 739 on the MPE 730.
This increases
the heat transfer surface area between the base component 710 and the MPE 730
and may
improve a quality of the joint between the base component 710 and the MPE 730.
The MPE
730 may be manufactured from a thermally conductive plastic or any other
suitable material.
The base component 710 may also comprise a spacing feature 782 configured to
provide a
spacing between the base component 710 and a support onto which the base
component 710 is
connected. The base component 710 and the MPE 730 may have any other suitable
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configuration in other embodiments.
[0131] With further reference to figs. 24a, 24b and 24c, another embodiment of
the cooled
channel component having a MPE is shown. The cooled channel component 800
comprises a
base component 810 and MPE 830 comprising a plurality of channels 834. The
base
component 810 and MPE 830 may be configured to be joined to each other via
fins 817
generally projecting away from a surface of the base component 810 and
correspondingly
shaped features 839 on the MPE 830. This increases the heat transfer surface
area between the
base component 810 and the MPE 830 and may improve a quality of the joint
between the
base component 810 and the MPE 830. The fins 817 of the base component 810 may
also
improve thermal conductivity where the base component 810 is made from
aluminum by
allowing heat to travel further along the fins 817 before crossing the
possibly lower thermal
conductivity material of MPE 830. Any other suitable projections that project
away from the
surface of either the base component 810 or MPE 830 may be used in lieu of the
fins 817 in
other embodiments. The MPE 830 may be manufactured from a thermally conductive
plastic
or any other suitable material. The base component 810 may also comprise a
spacing feature
882 configured to provide a spacing between the base component 810 and a
support onto
which the base component 810 is connected. The base component 710 and the MPE
730 may
have any other suitable configuration in other embodiments.
[0132] With further reference to fig. 24c, the MPE 830 may also comprise
features 858
configured to disrupt laminar flow within the MPE 830 and improve heat
transfer. The
features 858 may be integrated within the MPE 830 where the MPE 830 is
manufactured by a
process other than extrusion, for example where the MPE 830 is manufactured by
joining two
halves together.
[0133] With further reference to figs. 25a, 25b, 25c and 25d, a seventh non-
limiting
embodiment of the cooled channel component is shown. The cooled channel
component 900
comprises an upper component 910, a middle component 930 and a lower component
950
configured to be joined together to form a rectangular rail. The cooled
channel component 900
may be used as a rail type thermal connector and may be fixed to a computer
server or any
other electronic equipment and brought into contact with a channel of a
counterpart enclosure.
Alternatively, the cooled channel component 900 may be fixed to an enclosure
and brought
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into contact with a channel of a computer server or other electronic
equipment. The cooled
channel component 900 may be configured to be clamped around by a channel, or
otherwise
urged into contact with a surface of a channel, such as a generally u-shaped
channel,
facilitating heat transfer.
[0134] In this embodiment, the assembled cooled channel component 900
comprises a first
flow path and a second flow path, first flow path comprising a first inlet
932, a first outlet 933
and a first plurality of internal channels 934 and is configured such that a
coolant flow
received by the first inlet 932 is directed through the first plurality of
internal channels 934
exiting at the first outlet 933. The second flow path comprises a second inlet
942, a second
outlet 943 and a second plurality of internal channels 944 and is configured
such that a
coolant flow received by the second inlet 942 is directed through the second
plurality of
internal channels 944 exiting at the second outlet 943. The first flow path
and the second flow
paths being configured such that coolant flowing throw each flow path does not
mix. That is,
there is no fluid connection between the first flow path and the second flow
path in the cooled
channel component 900. The plurality of first and second internal channels 934
and 944 are
generally parallel to each other along a width of the cooled channel component
900. In some
embodiments, the plurality of first and second internal channels 934 and 944
may have a
helical or rifled geometry or any other suitable geometry to improve heat
transfer. The
plurality of first and second internal channels 934 and 944 may be configured
such that the
plurality of first internal channels 934 and the plurality of second internal
channels 944
alternate between the first and second internal channels 934 and 944 along the
widthwise
direction of the cooled channel component 900. In other embodiments, the first
plurality of
internal channels 934 and the second plurality of internal channels 944 may
have any other
suitable configuration.
[0135] In this embodiment, an approximately equal flow of coolant is being
directed along
each one of the plurality of first internal channels 934 and each one of the
plurality of second
internal channels 944.
[0136] The number of first and second internal channels 934 and 944 may be
equal such that
an approximately equal flow of coolant is being directed along the plurality
of first internal
channels 934 and along the plurality of second internal channels 944. The
number of first and
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second internal channels 934 and 944 may be different in other non-limiting
embodiments.
[0137] In other embodiments, the cooled channel component 900 may comprise
only a single
inlet and a single outlet. In yet further embodiments, the cooled channel
component 900 may
only comprise an upper component and a lower component. The cooled channel
component
900 may have any other suitable configuration in other embodiments.
[0138] The upper component 910, the middle component 930 and the lower
component 950
each contain voids which comprise a portion of the first and second flow
paths, that is the first
and second flow paths being created when the parts are brought together. With
further
reference to figs. 26a, 26b and 26c, the middle component 930 is shown with
the first flow
path (via the plurality of first channels 934) and second flow paths (via the
plurality of the
second channels 944). Surface 905 is configured to contact the lower component
950 and
surface 901 is configured to contact the upper component 910. The middle
component may
further comprise positioning features 920 such as but not limited to pins to
facilitate an
alignment of the various components (that is, the upper component 910, the
middle
component 930 and the lower component 950).
[0139] In this embodiment, the second inlet 942 connecting to one of the
plurality of internal
channels 944 is connected to an aperture 948 through which coolant passes from
the lower
950 and middle 930 components to the middle 930 and upper 910 components, the
aperture
948 being connected to another of the plurality of internal channels 944
before connecting to
the outlet 943.
[0140] The components of cooled channel 900 may be manufactured from a
thermally
conductive metal such as but not limited to aluminum or from a thermally
conductive plastic
or composite or from any other suitable material. In other embodiments, a
combination of
both thermally conductive components (for the parts that are in contact with a
surface for the
purpose of facilitating heat transfer) and thermally non-conductive components
such as plastic
may be used. As non-limiting examples, the components 910, 930 and 950 may be
made from
aluminum and brazed or soldered together or the upper component 910 and the
lower
component 950 may be made of aluminum while the middle component 930 is made
from a
plastic with the parts being joined by an adhesive.
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[0141] With further reference to figs. 27a and 27b, the cooled component 900
in use is shown.
The cooled component 900 is clamped around, or otherwise contacted to, a
channel 974 of a
computer server 970 for the purpose of facilitating heat transfer between the
cooled
component 900 and the computer server 970. The cooled component 900 may be
fixed to a
support 980, the support 980 being attached to attachment point 906, a
threaded shaft, by a nut
984 and a washer 986. The cooled component 900 may be fixed to the support 980
using any
other appropriate mean in other embodiments.
[0142] A variety of cooled channel components have been shown and described
herein with
many varied and different types of internal channel configurations, it is to
be understood that a
person having ordinary skill in the art can devise many different internal
channel
configurations which, amongst other features, may have a different number of
channels,
ranging from one to many, or a variety of different geometric configurations
and profiles
without departing from the scope of the disclosure. Figs. 28a through 28e show
only a few
possible channel profiles and configurations, including profiles which are
slightly offset such
as are shown in figures 28b and 28e, and profiles which integrate fins such as
shown in
figures 28c and 28d. Examples of channel profiles include, but is not limited
to, geometric
shapes such as circles and 2-dimensional polygons such as triangles, squares,
pentagons,
hexagons as well as profiles that contain a mix of curves and straight lines.
[0143] The cooled channel components described herein are shown as having
multiple parts,
however it is anticipated that they are well suited to being 3D printed in
materials such as
aluminum and that the geometries described herein can be improved upon by the
application
of that technology. Specifically, by being unlimited in geometry similar
apparatus can be built
based upon the present disclosure that go beyond the limitations of the
manufacturing
technologies that these parts have been designed for. For example the internal
channels for
one or two flow paths of 3D printed cooled channel components embodying the
principles of
the present invention may comprise channels that are shaped like the double
helix, which, by
copying nature, may result in very high heat transfer rates.
[0144] Certain additional elements that may be needed for the operation of
some
embodiments have not been described or illustrated as they are assumed to be
within the
purview of those of ordinary skill in the art. Moreover, certain embodiments
may be free of,
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may lack and/or may function without any element that is not specifically
disclosed herein.
[0145] Any feature of any embodiment discussed herein may be combined with any
feature of
any other embodiment discussed herein in some examples of implementation.
[0146] Although specific embodiments of the invention have been shown and
described
herein, it is to be understood that these embodiments are merely illustrative
of the many
possible specific arrangements that can be devised in application of the
principles of the
invention. Numerous and varied other arrangements can be devised by those of
ordinary skill
in the art without departing from the scope and spirit of the invention.
