U.S. patent application number 10/763303 was filed with the patent office on 2005-07-28 for apparatus and methodology for cooling of high power density devices by electrically conducting fluids.
This patent application is currently assigned to NANOCOOLERS, INC.. Invention is credited to Ghoshal, Uttam, Miner, Andrew Carl.
Application Number | 20050160752 10/763303 |
Document ID | / |
Family ID | 34795009 |
Filed Date | 2005-07-28 |
United States Patent
Application |
20050160752 |
Kind Code |
A1 |
Ghoshal, Uttam ; et
al. |
July 28, 2005 |
Apparatus and methodology for cooling of high power density devices
by electrically conducting fluids
Abstract
A system to extract heat from a high power density device and
dissipate heat at a convenient distance. The system circulates
liquid metal in a closed conduit using one or more electromagnetic
pumps for carrying away the heat from high power density device and
rejecting the heat at a heat sink located at a distance. The system
may make use of a thermoelectric generator to power the
electromagnetic pumps by utilizing the temperature difference
between the inlet and outlet pipes of the heat sink. The system
also provides networks of primary and secondary closed conduits
having series and parallel arrangements of electromagnetic pumps
for dissipating heat from multiple devices at a remotely located
heat sink.
Inventors: |
Ghoshal, Uttam; (Austin,
TX) ; Miner, Andrew Carl; (Austin, TX) |
Correspondence
Address: |
ZAGORIN O'BRIEN GRAHAM LLP
7600B N. CAPITAL OF TEXAS HWY.
SUITE 350
AUSTIN
TX
78731
US
|
Assignee: |
NANOCOOLERS, INC.
Austin
TX
|
Family ID: |
34795009 |
Appl. No.: |
10/763303 |
Filed: |
January 23, 2004 |
Current U.S.
Class: |
62/259.2 ;
165/104.28; 257/E23.098; 62/118 |
Current CPC
Class: |
G06F 2200/201 20130101;
G06F 1/203 20130101; H01L 2924/0002 20130101; G06F 1/206 20130101;
H01L 23/473 20130101; H01L 35/00 20130101; H01L 2924/00 20130101;
H02K 44/02 20130101; H01L 2924/0002 20130101 |
Class at
Publication: |
062/259.2 ;
165/104.28; 062/118 |
International
Class: |
F28D 015/00; F25D
017/02; F25D 023/12 |
Claims
What is claimed is:
1. A system for dissipating heat from a high power density device,
the system comprising: a. a liquid metal chamber placed adjacent to
the high power density device; b. means for cooling the liquid
metal, the cooling means being placed at a predefined distance away
from the liquid metal chamber; c. at least one conduit passing
through the liquid metal chamber and the cooling means in the form
of a closed loop, the conduit circulating the liquid metal between
the liquid metal chamber and the cooling means; d. at least one
electromagnetic pump for pumping the liquid metal through the
conduit, wherein heat is transferred away from the high power
density device to the cooling means through the liquid metal
contained in the conduit, the liquid metal being circulated in the
conduit by the electromagnetic pump.
2. The system as recited in claim 1 wherein the high power density
device is located in a folding electronic device.
3. The system as recited in claim 2 wherein the conduit is
constructed using a flexible material to allow bending.
4. The system as recited in claim 2 wherein the conduit comprises a
flexible portion for transferring the liquid metal across a
bend.
5. The system as recited in claim 2 further comprising a hinge, the
hinge comprising: a. an integrated conduit, the integrated conduit
allowing transfer of the liquid metal across a bend from at least
one conduit to at least one other conduit.
6. The system as recited in claim 1 wherein the means for cooling
the liquid metal is a heat sink.
7. The system as recited in claim 1 wherein the means for cooling
the liquid metal comprises a liquid-heat pipe heat exchanger, a
heat pipe and a heat sink.
8. The system as recited in claim 1 wherein the liquid metal
chamber is a solid-fluid heat exchanger.
9. The system as recited in claim 1 wherein the liquid metal
chamber is a sealed liquid metal container, the sealed liquid metal
container being sealed around the edges of the high power density
device, the sealed liquid metal container allowing direct contact
between the high power density device and the liquid metal.
10. The system as recited in claim 1 wherein the high power density
device is an integrated circuit.
11. The system as recited in claim 1 wherein the conduit includes a
heat pipe.
12. A system for dissipating heat from a high power density device,
the system comprising: a. a heat pipe placed adjacent to the high
power density device; b. a liquid-heat pipe heat exchanger, the
liquid-heat pipe heat exchanger containing liquid metal, the
liquid-heat pipe heat exchanger transferring heat from the heat
pipe to the liquid metal; c. means for cooling the liquid metal,
the cooling means being placed at a predefined distance away from
the liquid-heat pipe heat exchanger; and d. at least one conduit
passing through the liquid-heat pipe heat exchanger and the cooling
means in the form of a closed loop, the conduit containing the
liquid metal, the conduit circulating the liquid metal between the
liquid-heat pipe heat exchanger and the cooling means; wherein heat
is transferred away from the high power density device to the
cooling means through the combination of the heat pipe and the
conduit.
13. The system as recited in claim 12 wherein the high power
density device is located in a folding electronic device.
14. The system as recited in claim 12 wherein the conduit is
constructed using a flexible material to allow bending.
15. The system as recited in claim 12 a flexible portion for
transferring the liquid metal across a bend.
16. The system as recited in claim 12 wherein the conduit Includes
a hinge, the hinge permitting rotation between parts of the
conduit.
17. The system as recited in claim 12 wherein the high power
density device is an integrated circuit.
18. A method for dissipating heat from a high power density device,
the high power density device placed adjacent to a heat pipe, the
method comprising the steps of: a. transferring heat from the high
power density device to the heat pipe, the heat pipe transporting
heat to a predefined distance away from the high power density
device; b. transferring heat from the heat pipe to a liquid metal
system; and c. dissipating heat at the liquid metal system.
19. The method as recited in claim 11 wherein the step of
dissipating further comprises the step of transferring heat from
the liquid metal loop system to a heat sink.
20. A method for dissipating heat from a high power density device,
the high power density device placed adjacent to a sealed liquid
metal container containing liquid metal, the sealed liquid metal
container allowing direct contact between the high power density
device and the liquid metal, the method comprising: a. transferring
heat from the high power density device to the liquid metal placed
in the chamber; b. transporting the heated liquid metal away from
the chamber through a conduit passing through the chamber; c.
dissipating heat from the heated liquid metal; d. transporting
cooled liquid metal back to the sealed liquid metal container.
21. The method as recited in claim 13 wherein the step of
dissipating heat from the heated liquid metal further comprises: a.
transferring heat from the heated liquid metal to a heat pipe; b.
transferring heat from the heat pipe to a heat sink.
22. The method as recited in claim 13 wherein the step of
dissipating heat from the heated liquid metal further comprises: a.
transferring heat from the heated liquid metal to a heat sink.
Description
BACKGROUND
[0001] The present invention relates to a system for dissipating
heat from a high power density device (HPDD). More specifically,
the invention relates to a system that helps in effective
dissipation of heat at a distance away from the HPDD.
[0002] This application sets forth improvements to our previous
apparatus which is described in U.S. Pat. No. 6,658,861 entitled
"Cooling Of High Power Density Devices By Electrically Conducting
Fluids" which issued Dec. 9, 2003.
[0003] Electronic devices such as central processing units,
graphic-processing units, laser diodes etc. generate a lot of heat
during operation. If the generated heat is not dissipated properly
from high power density devices, temperature buildup may occur. The
buildup of temperature can adversely affect the performance of
these devices. For example, excessive temperature buildup may lead
to malfunctioning or breakdown of the devices. So, it is important
to remove the generated heat in order to maintain normal operating
temperatures of these devices.
[0004] The heat generated by HPDD is removed by transferring the
heat to ambient atmosphere. Several methods are available to
transfer heat from a HPDD to the atmosphere. For example, an
electric fan placed near a HPDD can blow hot air away from the
device. However, a typical electric fan requires a large amount of
space and thus it may not be desirable to place a fan near the HPDD
due to space constraints in the vicinity of the HPDD. In case of
notebook computers or laptops, there is additional constraint on
the positioning of the fans due to the compact size of these
devices. For at least the foregoing reasons, it would be desirable
to provide heat dissipation (e.g. using a fan) at a location away
from the HPDD.
[0005] Another way to dissipate heat from a HPDD involves the use
of a large surface area heat sink. Essentially, the heat sink is
placed in contact with the HPDD to transfer heat away from the HPDD
into the heat sink. The transferred heat is then dissipated through
the surface area of the heat sink, thereby reducing the amount of
temperature buildup in the HPDD. In case a significant amount of
heat is generated, a larger-sized heat sink is necessary to
adequately dissipate the heat. Also in some cases the heat sink
cannot be placed adjacent to HPDD due to form factor restriction.
This may be due to non-availability of space near the HPDD or due
to other devices/components located nearby that cannot withstand
the rise in temperature due to dissipated heat. One way of dealing
with the form factor limitation is to place a heat sink at a
sufficiently large distance from the HPDD. In this case, heat has
to be transferred from HPDD to the heat sink before being
dissipated to the atmosphere.
[0006] A heat pipe is a device that can effectively transfer heat
from one point to another. It consists of a sealed metal tubular
container whose inner surfaces may also include a capillary wicking
material. A heat transfer fluid flows along the wick structure of
the heat pipe. FIG. 1 shows a heat pipe 101. It has an inner lining
103 of micron scale wick structures. A HPDD 105 transfers heat to
an end 107 of heat pipe 101. Liquid at end 107 absorbs the heat,
evaporates and moves to a cold end 109 of the heat pipe. The
evaporated vapor comes in contact with cold end 109, condenses and
dissipates heat. The condensed liquid moves back to end 107 by
gravity or by capillary action of the inner lining 103. The wick
like structure of lining 103 provides a capillary driving force to
return the condensate to end 107.
[0007] A Heat pipe is useful in transferring heat away from the
HPDD when the form factor and other constraints limit dissipation
of heat near the HPDD itself. Further, it has the ability to
transport heat against gravity with the help of porous capillaries
that form the wick.
[0008] Heat pipes exploit liquid-vapor phase change properties.
Thus, maximum heat transfer is limited by the vapor/liquid
nucleation properties. Interface resistance between the metal
surface and the liquid layer also limits the maximum heat flow.
Heat pipes do not solve the problems of interface resistances at
the hot source end and the cold sink end. Interface resistance
between the metal surface and the liquid layer also limits the
maximum heat flow. It is also not possible to cool multiple hot
sources using a single heat pipe. Often these heat pipes contain
CFC fluids that are not environment-friendly. The performance of
these heat pipes depend on the orientation of the heat pipe
structure with respect to the gravitational forces, operating
temperatures, and the nature of fluids in the loop. The dependence
of performance on orientation restricts the flexible positioning of
heat pipes.
[0009] The above-discussed limitations of heat pipes have made
forced fluid cooling an attractive option. The forced fluid cooling
is based on circulating water through a HPDD. Water carries away
heat from the HPDD and dissipates the heat at a sink placed at a
distance. The heat is dissipated at the sink using fluid-fluid heat
exchangers such as finned radiators with natural or forced
convection. In forced fluid cooling, more than one HPDD can be
cooled in a single loop.
[0010] However, the use of water in forced fluid cooling has some
limitations. The low thermal conductivity of water limits its
effectiveness as a heat transfer fluid. So, in this case the only
mode of transfer of heat is convection. Transfer of heat by
conduction is negligible. Also, water is circulated using
mechanically moving pumps that may be unreliable, occupy large
volumes, and contribute to vibration or noise.
[0011] U.S. Pat. No. 3,654,528 entitled "Cooling Scheme For A High
Current Semiconductor Device Employing Electromagnetically-Pumped
Liquid Metal For Heat And Current Transfer" describes the use of
liquid metal to spread heat uniformly in the heat sink placed in
contact with a wafer. However, this patent describes heat
dissipation in the proximity of the heat-generating device and does
not address to the form factor limitation. Further, the use of
electromagnetic (EM) pumps requires an extra power supply that
generates heat. Removal of this additional heat adds to the
burden.
[0012] In light of the above discussion it is clear that methods
provided by the prior art do not satisfactorily address the issue
of removal of heat at a desirable distance away from a high power
density device. Thus there is a need for a flexible method for
managing dissipation of heat at a distance away from the high power
density device.
SUMMARY
[0013] It is an object of the invention to provide an efficient and
flexible method of dissipating heat away from a high power density
device.
[0014] It is another object of the invention to provide a system
for effective dissipation of heat from high power density devices,
while taking care of the form factor limitations.
[0015] It is another object of the invention to provide a system
for the effective transfer of heat from high power density devices
at a predefined distance away from the device.
[0016] It is another object of the invention to provide a system
that uses electromagnetic pumps for circulating liquid metal for
carrying away the heat generated by high power density device.
[0017] It is another object of the invention to provide
electromagnetic pumps that use polymers or refractory metals as the
material of construction of the conduit and gallium indium alloy as
the liquid metal.
[0018] It is yet another object of the invention to provide an
electromagnetic generator to power the electromagnetic pumps.
[0019] It is yet another object of the invention to enable the use
of fluid-fluid heat exchangers (including condensers, radiators
etc.) for dissipating heat generated by high power density
device.
[0020] The invention provides a system for effective removal of
heat from a high power density device and dissipating the heat at a
distance. The system in accordance with the invention has a liquid
metal chamber mounted on a high power density device. The liquid
metal chamber can be either a solid-fluid heat exchanger or a
sealed liquid metal container allowing direct contact of the liquid
metal with the high power density device. a conduit carrying liquid
metal passes through the liquid metal chamber. The liquid metal is
circulated in the conduit. The liquid metal carries away the heat
generated by the high power density device and dissipates it at a
heat exchanger or heat sink provided at a predefined distance away
from the device. This system is highly flexible and can be used in
different embodiments depending on form factor limitations. The
same conduit (carrying the liquid metal) can be used for carrying
heat away from multiple devices. multiple pumps arranged in series
or parallel arrangements may also be provided. two or more loops
(of the conduit) can use a common pump or common s liquid metal
chamber. A loop can dissipate heat, which is further carried away
by another loop, more complex networks of loops can also be
formed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The preferred embodiments of the invention will hereinafter
be described in conjunction with the appended drawings provided to
illustrate and not to limit the invention, wherein like
designations denote like elements, and in which:
[0022] FIG. 1 shows the design of a heat pipe existing in the prior
art;
[0023] FIG. 2 shows a system for dissipating heat from a high power
density device at a distance in accordance with the preferred
embodiment of the invention;
[0024] FIG. 3 shows the principle of an electromagnetic pump
provided by the abovementioned system for circulating liquid
metal;
[0025] FIG. 4 shows a system for dissipating heat from a high power
density device in a folding microelectronic device using flexible
conduits in accordance with another embodiment of the
invention;
[0026] FIG. 5 shows a system for dissipating heat from a high power
density device in a folding microelectronic device using a hinge
with an integrated conduit in accordance with another embodiment of
the invention;
[0027] FIG. 6 shows the structure of the hinge shown in FIG. 5;
[0028] FIG. 7 shows a system for dissipating heat from a high power
density device that uses a liquid metal system and a heat pipe, in
accordance with another embodiment of the invention;
[0029] FIG. 8 shows another embodiment of a system for dissipating
heat from a high power density device using a liquid metal system
and a heat pipe, in accordance with yet another embodiment of the
invention;
[0030] FIG. 9 shows a system for dissipating heat from a high power
density device in which liquid metal comes in direct contact with
the high power density device, in accordance with another
embodiment of the invention;
[0031] FIG. 10 shows the use of thermoelectric generator and
thermoelectric cooler in the system shown in FIG. 1 in accordance
with an alternate embodiment of the invention;
[0032] FIG. 11 shows an alternate embodiment that has a fluid-fluid
heat exchanger in combination with the heat sink;
[0033] FIG. 12A shows an embodiment that has two electromagnetic
pumps in series;
[0034] FIG. 12B shows an embodiment that has two electromagnetic
pumps placed in parallel; and
[0035] FIG. 13 shows a complex network that utilizes a combination
of multiple primary and secondary closed conduits for removing heat
from multiple high power density devices.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0036] The present invention provides a system for dissipating heat
from high power density devices. The system has a liquid metal
chamber placed adjacent to a high power density device. In an
embodiment, the liquid metal chamber is a solid-fluid heat
exchanger. In another embodiment, the liquid metal chamber is a
sealed liquid metal container allowing direct contact of the liquid
metal with the high power density device. FIG. 2 shows solid-fluid
heat exchanger 201 placed adjacent to a high power density device
202. Solid-fluid heat exchanger 201 is filled with liquid metal
that absorbs the heat from the high power density device 202. A
conduit 203 passes through solid-fluid heat exchanger 201 that
takes away the liquid metal through an end 205 of solid-fluid heat
exchanger 201 and brings liquid metal back into solid-fluid heat
exchanger 201 through an end 207. Section 203a of conduit 203
carries hot liquid metal away from end 205 of solid-fluid heat
exchanger 201 to a heat sink 209 provided at a predefined distance
from solid-fluid heat exchanger 201. Heat sink 209 releases the
heat to the atmosphere. The cooled liquid metal is then circulated
back to solid-fluid heat exchanger 201 through section 203b of
conduit 203. An electromagnetic pump 211 provides the power for
circulating the liquid metal in the form of a closed loop. In this
manner, system 200 provides for the transport and dissipation of
heat at a predefined distance away from high power density device
202. This distance is determined based on the form factor (the
configuration and physical arrangement of the various components in
and around the high power density device 202). Thus system 200
provides for heat dissipation in the cases where dissipating heat
in the proximity of the high power density device 202 is not
desirable. For example, in a computer, in case the heat dissipated
by components such as the microprocessor or the power unit is in
proximity of components like memory, this heat may lead to
permanent loss of data from memory. Thus it is desirable that the
heat generated by the microprocessor/power unit is dissipated at a
position away from components that may get damaged.
[0037] Heat sink 209 is constructed of a low thermal resistance
material. Examples of such materials include copper and aluminum.
Heat sink 209 has a large surface area for effectively dissipating
heat to the atmosphere. Heat sink 209 may dissipate heat by natural
convection or by forced convection with the use of a fan. A finned
structure (as shown in the figures) is sometimes used as a heat
sink. In fact, the finned structure may also have liquid metal
circulating through its fins. It will be apparent to one skilled in
the art that any heat sink structure (used for transferring heat to
the atmosphere) may be employed in the system without departing
from the scope of the invention.
[0038] Conduit 203 is constructed of polymer materials such as
teflon or polyurethane. Alternatively, refractory metals such as
vanadium or molybdenum may also be used as the material of
construction of conduit 203. Polymers like teflon prove to be good
conduit materials as they are inert to most chemicals, provide low
resistance to flow of liquids and are resistant to high temperature
corrosion. Solid-fluid heat exchanger 201 comprises a thermally
conducting surface closely attached to the high power density
device and a housing containing the liquid metal. For processor
chip cooling applications, the thermally conducting surface could
be a thin-film tungsten, nickel layer on the backside of the
processor or a discrete surface of tungsten, nickel, anodized
aluminum or nickel-coated aluminum soldered to the backside of the
chip. The housing material could be an inert polymer (Teflon,
polyurethane, etc.), glass or thermally conductive material such as
tungsten, nickel, nickel-coated aluminum, anodized aluminum,
nickel-coated copper etc.
[0039] System 200 may be used for dissipating heat from a wide
variety of devices. For example high power density device 202 of
FIG. 2 may be a micro scale device like a microelectronic chip, an
optoelectronic chip, arrays of hot chips, a laser diode, light
emitting diodes (LEDs), an array of LEDs etc. High power density
device 202 may also be a central processing unit of a computer,
graphical processor unit or a light bulb. System 200 also finds
application in biological, chemical, or nuclear reactors to
dissipate heat generated by these reactors.
[0040] FIG. 3 shows the principle of operation of electromagnetic
pumps 211 employed in the above-mentioned embodiment.
Electromagnetic pump 211 comprises of a pair of electrode plates
305 placed vertically facing each other. A DC (direct current)
voltage is applied across the electrode plates. The DC voltage
produces an electric field across electrode plates 305. A pair of
permanent magnets 307 is arranged facing each other above and below
the plane containing electrode plates 305. A tube 309 carries
liquid metal. The direction of magnetic field generated by the
permanent magnets 307 is perpendicular to the direction of electric
field provided by the electrode plates 305. An electromagnetic
force acts on the liquid metal causing it to flow in a direction
perpendicular to the plane of electric and magnetic fields (as
shown by the block arrow in FIG. 3). It would be evident to one
skilled in the art that the method of pumping can be implemented in
several different ways based on the abovementioned principle. For
example, DC electromagnetic pumps (as described above) can be
utilized in applications where DC sources are available while
induction electromagnetic pumps utilizing polyphase induction coils
can be used in cases where physical contact to the liquid metal is
undesirable (say, where the liquid metal is corrosive).
[0041] In certain applications, the system may need to be provided
with electromagnetic interference (EMI) shielding to shield the
high power density device from electromagnetic radiations generated
by the pump. These electromagnetic radiations, if not shielded,
might adversely affect the performance of the high power density
device or its components. Accordingly, the electromagnetic pump is
enclosed within a housing that shields the high power density
device. This EMI shielding may be provided using standard methods
such as magnetic shields and EMI shielding tapes. As shown in FIG.
3, magnetic shield 310 confines the magnetic field within the pump.
The magnetic shield 310 may be made using high magnetic
permeability materials such as steel, nickel, alnico, or permandur
or other specially processed materials.
[0042] In the preferred embodiment, tube 309 is constructed of
polymer materials such as Teflon or polyurethane. Teflon has the
advantage that it can be easily machined. Alternatively, refractory
metals such as tungsten or molybdenum may also be used as the
material of construction of tube 309. Ultra-thin anodized aluminum
or nickel-coated aluminum or copper can also be used.
[0043] In the preferred embodiment, the liquid metal carried by
tube 309 is an alloy of gallium and indium. Preferred compositions
comprise 65 to 75% by mass gallium and 20 to 25% indium. Materials
such as tin, copper, zinc and bismuth may also be present in small
percentages. One such preferred composition comprises 66% gallium,
20% indium, 11% tin, 1% copper, 1% zinc and 1% bismuth. Some
examples of the commercially available Gain alloys include
galistan--a concoction popular as a substitute for mercury (Hg) in
medical applications, and newmerc. The various properties of Ga--In
alloy make it desirable liquid metal for use in heat spreaders. The
Ga--In alloy spans a wide range of temperature with high thermal
and electrical conductivities. It has melting points ranging from
-15.degree. C. to 30.degree. C. and does not form vapor at least
upto 2000.degree. C. It is not toxic and is relatively cheap. It
easily forms alloys with aluminum and copper. It is inert to
polyimides, polycarbonates, glass, alumina, Teflon, and conducting
metals such as tungsten, molybdenum, and nickel (thereby making
these materials suitable for construction of tubes).
[0044] However, it is apparent to one skilled in the art that a
number of other liquid metals may be used without departing from
the scope of the invention. For example, liquid metals having high
thermal conductivity, high electrical conductivity and high
volumetric heat capacity can be used. Some examples of liquid
metals that can be used in an embodiment of the invention include
mercury, gallium, sodium potassium eutectic alloy (78% sodium, 22%
potassium by mass), bismuth tin alloy (58% bismuth, 42% tin by
mass), bismuth lead alloy (55% bismuth, 45% lead) etc. Bismuth
based alloys are generally used at high temperatures (40 to
140.degree. C.). Pure indium can be used at temperatures above
156.degree. C. (i.e., the melting point of indium).
[0045] In accordance with another embodiment of the invention, the
present invention provides a system for dissipating heat from a
high power density device in a folding microelectronic device. This
embodiment is shown in FIG. 4. Examples of folding microelectronic
devices include notebook computers, a personal digital assistants
(PDA's), tablet PC's or mobile phones. As shown in FIG. 4, a
folding microelectronic device 402 comprises a base member 402a and
a folding member 402b. Base member 402a contains at least one high
power density device 202. For example, in a laptop, base member
402a contains a processor, a graphics card and other such high
power density devices.
[0046] The system consists of a solid-fluid heat exchanger 201, a
conduit 203, at least one electromagnetic pump 211 and a heat sink
209. Solid-fluid heat exchanger 201 is filled with liquid metal
that absorbs heat from high power density device 202. Conduit 203
passes through solid-fluid heat exchanger 201 and carries the
heated liquid metal away. The liquid metal is pumped by at least
one electromagnetic pump 211.
[0047] Conduit 203 comprises a portion 404 that carries the heated
liquid metal from base member 402a across the bend of folding
microelectronic device 402 to folding member 402b. Further, portion
404 allows folding member 402b to bend with respect to base member
402a. Portion 404 is made of a flexible material that is inert to
liquid metal. Exemplary materials include rubber, elastomer and
Teflon.TM.. Alternatively, entire conduit 203 is made of the
flexible material such that there is no need of the flexible
portion.
[0048] Conduit 203 carries the liquid metal into folding member
402b of folding microelectronic device 402. Heat from the liquid
metal in conduit 203 is transferred to heat sink 209, which is
located in folding member 402b. Heat sink 209 then releases the
heat to the atmosphere. After transferring heat to heat sink 209,
the liquid metal returns to base member 402a through conduit 203 to
complete the closed loop.
[0049] Another embodiment of the invention for dissipating heat
from a high power density device in a folding microelectronic
device is shown in FIG. 5. The system comprises a hinge with an
integrated conduit that allows heated liquid metal to flow from the
base member to the folding member of a folding microelectronic
device, while allowing the folding member to bend with respect to
the base member.
[0050] FIG. 5 shows solid-fluid heat exchanger 201 filled with
liquid metal. The liquid metal absorbs heat from high power density
device 202. Conduit 203 carries the heated liquid metal away from
solid-fluid heat exchanger 201. The liquid metal is pumped by at
least one electromagnetic pump 211. Further, conduit 203 attaches
to a hinge 502. Hinge 502 has an integrated conduit and allows the
bending of folding member 402b with respect to base member 402a.
Hinge 502 allows the liquid metal to flow through it and enter
folding member 402b through a second conduit 504. Hinge 502 is made
from materials that provide the mechanical rigidity required for
bending of folding member 402b and are inert to the liquid metal.
Examples of such materials include Teflon.TM., thermoplastics and
metals such as copper, stainless steel and nickel. Alternatively,
hinge 502 may be made of any other metal that are coated with a
coating that is chemically resistant to the liquid metal.
[0051] Further, in folding member 402b, the liquid metal transfers
heat to heat sink 209, which rejects heat to the atmosphere. Cold
liquid metal returns to hinge 502 and flows through it to reach
base member 402a through conduit 203. Further, the liquid metal
flows to solid-fluid heat exchanger 201, hence completing a closed
loop.
[0052] Referring to FIG. 6, hinge 502 comprises portions 602a and
602b. Each of the portions 602a and 602b include a seal 604 that
allows hinge 502 to rotate while preventing liquid metal from
leaking. The seal may be formed by compressive contact between
members 602a and 602b. It could also be formed using rotary joints
with O-rings acting as seals. The O-rings may be made of materials
such as Teflon.TM., Buna-n, and Viton.TM.. Liquid metal enters
hinge 502 through a port 606 on portion 602a. Thereafter, it flows
along axis of rotation 608 of hinge 502. Further, liquid metal
leaves hinge 502 through a port 610 and enters conduit 612. After
rejecting heat to heat sink 209, the liquid metal then returns to
hinge 502 through a port 614 on portion 602b. The liquid metal
leaves hinge 502 through port 616 and returns to conduit 203.
Conduit 203 takes liquid metal back to solid-fluid heat exchanger
201. It will be apparent to those skilled in the art that portions
602a and 602b may also be implemented as separate hinges in
microelectronic device 402.
[0053] The arrangement described with respect to FIG. 5 and FIG. 6
can also be used to distribute the hot liquid metal into a
plurality of conduits in folding member 402b. The distribution of
liquid metal into conduits helps in spreading the heat for better
heat dissipation. The various conduits carry the liquid metal into
a plurality of heat sinks in folding member 402b. This will require
that portion 602a of hinge 502 have a plurality of outlet ports
that distribute the liquid metal into the plurality of conduits in
folding member 402b. After rejecting heat through heat sink 209,
cooled liquid metal collects and enters hinge 502 through port 616
and returns to base member 402a. Furthermore, the embodiment
described with respect to FIG. 5 and FIG. 6 does not require the
conduit to be flexible. Hence, the system is more reliable and the
wear and tear of the conduit is reduced.
[0054] The embodiments described with the help of FIG. 4 and FIG. 5
allow the dissipation of heat from the folding member of the
microelectronic device. For example, heat is transferred from the
base member of a laptop to the folding member of a laptop. The
folding member offers more space for incorporating a heat sink.
Further, other components in the base member, such as memory and
storage are protected from the heat.
[0055] FIG. 7 shows yet another embodiment of the invention. FIG. 7
shows a system for dissipating heat from a microelectronic device.
The system comprises a solid-fluid heat exchanger 201, a conduit
203, at least one electromagnetic pump 211, a liquid-heat pipe heat
exchanger 706, a heat pipe 702 and a heat sink 704. Liquid metal in
solid-fluid heat exchanger absorbs heat from high power density
device 202. The liquid metal flows through conduit 203.
Electromagnetic pump 211 pumps the liquid metal in conduit 203. In
liquid-heat pipe heat exchanger 706, heat from the liquid metal is
transferred to heat pipe 702. The cold liquid metal returns to
solid-fluid heat exchanger 201 to complete the closed loop.
[0056] As described with respect to FIG. 1, liquid at an end 708 of
heat pipe 702 absorbs heat from the liquid metal, evaporates and
moves to a cold end 710 of heat pipe 702. At cold end 710, the
liquid condenses and dissipates heat to heat sink 704. The
condensed liquid moves back to end 708 by gravity or capillary
action of the inner lining of heat pipe 702. Heat sink 704 then
rejects the heat to the atmosphere.
[0057] As will be apparent to those skilled in the art, the system
as described above may be used with the flexible conduit as shown
in FIG. 4 or the hinge with the integrated conduit as shown in FIG.
5. In such a system, the liquid metal system (comprising a
solid-fluid heat exchanger, a conduit and a pump) carries heat from
a high power density device across a bend in a microelectronic
device. In the folding member of the microelectronic device, heat
is transferred to at least one heat pipe with the help of a
liquid-heat pipe heat exchanger. The heat pipe then carries the
heat and dissipates the heat to the atmosphere through a heat
sink.
[0058] Yet another embodiment of the invention is shown in FIG. 8.
The system shown in FIG. 8 comprises a heat pipe 802, a liquid-heat
pipe heat exchanger 808, a conduit 810, at least one
electromagnetic pump 812 and a heat sink 814. Heat pipe 802 is
placed adjacent to high power density device 202. A plate of any
material having a high thermal conductivity may be used to ensure
uniform heat transfer between high power density device 202 and
heat pipe 802. In the preferred embodiment, a plate of copper is
used. Heat pipe 802 may also be soldered onto high power density
device 202. Liquid at hot end 804 of heat pipe 802 absorbs heat
from high power density device 202, evaporates and moves through
heat pipe 802 to cold end 806. Cold end 806 is in direct contact
with liquid metal in liquid-heat pipe heat exchanger 808. The
evaporated vapor rejects heat to the liquid metal, condenses and
moves back to hot end 804 by gravity or capillary action of the
inner lining of heat pipe 802.
[0059] Heated liquid metal in liquid-heat pipe heat exchanger 808
is carried away by conduit 810. Electromagnetic pump 812 pumps the
liquid metal through conduit 810. The liquid metal transfers heat
to heat sink 814. Heat sink 814 rejects the heat to the atmosphere.
Cooled liquid metal returns to liquid-heat pipe heat exchanger 808
through conduit 810, hence forming a closed loop.
[0060] The systems of liquid metal and heat pipes described above
may be used for effective heat dissipation over large distances
without requiring a large amount of liquid metal. This reduces the
overall weight and the cost of the heat dissipation system.
[0061] FIG. 9 shows another possible embodiment of the invention. A
sealed liquid metal container 902 replaces the solid-fluid heat
exchanger of FIG. 2. Within sealed liquid metal container 902,
liquid metal comes in direct contact with high power density device
202. This increases the efficiency of heat transfer to the liquid
metal as there is no interface between high power density device
202 and the liquid metal. The material of the surface of high power
density device 202, which comes in direct contact with, the liquid
metal should be such that it is not corroded by the liquid metal.
Exemplary materials for such a surface include copper plated with
nickel, silicon dioxide and silicon coated with silicon nitride.
Sealed liquid metal container 902 is sealed around the edges of
high power density device 202. Sealed liquid metal container 902
could be constructed using a rigid and inert polymer (Teflon.TM.,
polyurethane, etc.), thermoplastics or metals such as copper,
nickel.
[0062] Sealed liquid metal container 902 may be sealed in a number
of ways depending on the nature of high power density device 202 to
be cooled. A seal may be made using an interference fit between
sealed liquid metal container 902 and high power density device
202. A seal may also be made using compressed o-rings or similar
compression seals. The o-rings may be made of materials such as
Teflon.TM., Buna-n, and Viton.TM.. Addition of a bonding agent or a
sealant, such as epoxy, may also be used to seal sealed liquid
metal container 902. Sealed liquid metal container 902 may also be
soldered or welded onto high power density device 202.
[0063] Furthermore, sealed liquid metal container 902 can be shaped
according to the distribution of heat generated by high power
density device 202, to enhance the heat transfer to the liquid
metal. For example, if the heat generated at a specific part of
high power density device 202 is more than the heat generated at
other parts, sealed liquid metal container 902 can be shaped such
that the volume of liquid metal that flows over this specific part
is more than the volume of liquid metal that flows over other parts
of high power density device 202. In this way, the total amount of
liquid metal required for the system may be reduced. This would
lead to a reduction in the weight and the cost of the system.
[0064] Liquid metal in liquid metal chamber is carried away by
conduit 203. The liquid metal is pumped by at least one
electromagnetic pump 211. Conduit 203 carries the liquid metal to
heat sink 209. Heat sink 209 dissipates the heat from the liquid
metal to the atmosphere. Cooled liquid metal is carried back to
sealed liquid metal container 902 through conduit 203.
[0065] This embodiment increases the efficiency of heat transfer to
the liquid metal by avoiding the use of a solid-fluid heat
exchanger. When a solid-fluid heat exchanger is used, an interface
exists between a high power density device and the solid-fluid heat
exchanger. Air gaps may exist on this interface due to the
roughness of the surfaces of the solid-fluid heat exchanger and the
high power density device. Air gaps reduce the heat transfer
between the high power density device and the liquid metal.
Removing the solid-fluid heat exchanger eliminates with the
interface and hence increases the efficiency of heat transfer.
[0066] FIG. 10 shows another embodiment of the invention. The
embodiment comprises a thermoelectric generator 1001 and a
thermoelectric cooler 1003. Thermoelectric generator 1001 is
provided for powering electromagnetic pump 211 while thermoelectric
cooler 1003 is provided for a first stage spot cooling of the high
power density device 202.
[0067] A face 1001a of thermoelectric generator 1001 is placed in
contact with section 203a of conduit 203. Section 203a carries hot
liquid metal to heat sink 209 and has a high temperature. A Face
1001b of thermoelectric generator 1001 is placed in contact with
section 203b of conduit 203 that carries liquid metal (that has
been cooled after dissipating heat) away from the heat sink 209 to
solid-fluid heat exchanger 201. Face 1001b is thus at a relatively
low temperature. The temperature difference between the two faces
of thermoelectric generator 1001 is utilized to produce potential
difference for powering electromagnetic pump 211. Thus, in this
case there is no need of external power source to run
electromagnetic pump 211. The external power supply, if used,
generates heat that has to be removed. This adds to the burden of
heat removal from the system. By using potential difference
generated by thermoelectric generator 213 to run electromagnetic
pump 211; this added burden is done away with.
[0068] Thermoelectric generator 1001 is comprised of series of p
type semiconductor members and n type semiconductor members
sandwiched between thermally conducting, electrically-insulating
substrates such as oxide-coated silicon wafers, aluminum nitride
(AIN) and other thin ceramic wafers. Thermoelectric generator 1001
utilizes the "Seebeck effect" to convert the temperature difference
between the hot section 203a and the cold section 203b of conduit
203 to electrical energy in the form of a potential difference. The
voltage generated by thermoelectric generator 1001 depends on the
temperature difference between the sections 203a and 203b. The
performance (i.e. the ratio of electrical power to the heat flow
into the hot end) of thermoelectric generator 1001 is governed by
the Seebeck coefficient and thermal conductivity of p and n type
semiconductor members used to form the device. Alloys of bismuth
(Bi), tellurium (Te), antimony (Sb) and selenium (Se) are the most
commonly used materials for manufacturing the semiconductor members
of thermoelectric generator 1001 for devices operating near room
temperature.
[0069] The use of thermoelectric generators provides sufficient
power to drive the electromagnetic pumps. This may be illustrated
using the following representative example:
[0070] The power requirement is dependent on the distance the fluid
needs to move. Typically, this power requirement may range from few
milli-watts (say for moving the fluid a distance of 10 cm in case
of a laptop), to a watt (say for moving the fluid several meters in
a server rack).
[0071] The coefficient of performance of a thermoelectric generator
i.e. the ratio of electrical power to the heat flow into the hot
end, is roughly:
.eta.=.epsilon.(.DELTA.T/T.sub.h)
[0072] where .epsilon. is the thermodynamic conversion efficiency,
.DELTA.T is the temperature differential between the hot and cold
ends, and T.sub.h is the temperature of the hot end. The value of
.DELTA. is 0.1 for conventional Bi/Sb/Te/Se alloys and Pb/Te/Se
alloy materials. The typical temperature differential across the
two ends of thermoelectric generator would be around 15-40K (i.e.,
Kelvin). Assuming .DELTA.T=30 K and T.sub.h=358 K (85.degree. C.)
the coefficient of performance .eta. of the thermoelectric
generator comes out to be 0.0084. If the high power density device
dissipates 100 W, the electrical power generated by the
thermoelectric generator will be 0.84 W, which is sufficient for
driving the electromagnetic pump. Of course, better thermoelectric
generators can easily double the performance.
[0073] Thermoelectric cooler 1003 provides a first stage spot
cooling of the high power density device 202. Thermoelectric cooler
1003 utilizes the "Peltier effect" to cool the high power density
device 202. The construction of thermoelectric cooler 1003 is
similar to thermoelectric generator 1001. A direct current supplied
to the thermoelectric cooler 1003 produces a temperature difference
between its two surfaces. Thus, surface of thermoelectric cooler
1003 in contact with high power density device 202 is at low
temperature (with respect to high power density device 202) and
surface of thermoelectric cooler in contact with solid-fluid heat
exchanger 201 is at higher temperature (with respect to solid-fluid
heat exchanger 201). The amount of cooling provided by
thermoelectric cooler 1003 is a function of the current supplied to
it. The use of thermoelectric cooler 1003 is desirable in cases
where surface of high power density device 202 has uneven
temperature distribution with some regions having temperature much
greater than other regions. The first stage spot cooling provided
by thermoelectric cooler 1003 helps to make temperature
distribution uniform on the surface of high power density device
202.
[0074] FIG. 11 shows yet another embodiment of the invention. In
this embodiment a fluid-fluid heat exchanger 1101 is provided in
addition to heat sink 209 for dissipating heat from the liquid
metal. Fluid-fluid heat exchanger 1101 is provided for cases where
additional cooling is required or the rate of cooling of liquid
metal needs to be regulated. As shown in FIG. 11, liquid metal
coming out through heat sink 209 is further cooled using heat
exchanger 1101 before being circulated back to solid-fluid heat
exchanger 201. Fluid-fluid heat exchanger 1101 makes use of a fluid
to absorb the heat from liquid metal. This fluid enters fluid-fluid
heat exchanger 1101 at one end absorbs heat from liquid metal and
comes out through another end. Thus, heat is transferred from
liquid metal to the fluid. The cooled liquid metal is then
circulated back to solid-fluid heat exchanger 201 through section
203b of conduit 203. Electromagnetic pump 211 provides the power
for circulating the liquid metal in form of a closed loop. In this
manner, this embodiment provides for the transport and dissipation
of heat at multiple positions away from high power density device
202 (shown using dashed lines).
[0075] Fluid-fluid heat exchangers make use of transfer of heat
between two fluids over a common surface. Thus, use of liquid metal
in the invention makes it possible to use a heat exchanger for
dissipating heat. Fluid-fluid heat exchanger 1101 provides
controlled cooling such that the rate of cooling may be regulated
depending on requirements. The regulation of cooling rate may be
achieved by varying the flow rate or temperature of the fluid in
fluid-fluid heat exchanger 1101.
[0076] The fluids that are most commonly used in heat exchangers
are water, air or freon. Fluid-fluid heat exchanger 1101 can be
tubular shell and tube type of heat exchanger with counter or
concurrent flow. Heat exchanger 1101 can also be a plate type heat
exchanger. Fluid-fluid heat exchanger 1101 may be replaced by
multiple heat exchangers connected in series or parallel. In fact,
in place of the combination of heat exchanger 1101 and heat sink
209, heat exchanger 1101 alone can be used to dissipate heat. It
will be apparent to one skilled in the art that any device that can
dissipate/extract heat from liquid metal (e.g. thermoelectric
cooler, vapor compression cooler) can replace heat exchanger 1101
without departing from the scope of the invention.
[0077] FIG. 12A shows two electromagnetic pumps 1201 and 1203 in
series that pump liquid metal through conduit 203. Multiple
electromagnetic pumps 1201 and 1203 are provided in series
configuration where power supplied by one pump is not sufficient to
circulate the liquid metal in the form of a closed loop. This may
be the case when heat sink 209 is placed at a relatively large
distance away from solid-fluid heat exchanger 201 (e.g. in case of
a server rack). Two electromagnetic pumps 1201 and 1203 may also be
useful where there is sudden loss in the pressure head. In case
where the pipes take sharp turns (like in case of laptop joints) a
significant drop in the pressure is observed. Due to reasons
mentioned above more than two electromagnetic pumps may need to be
provided in series.
[0078] FIG. 12B shows an alternate arrangement where two
electromagnetic pumps 1205 and 1207 arranged in parallel. A
parallel arrangement of electromagnetic pumps may be used in case
there are some restrictions on the diameter of the conduit (say,
due to form factor limitations). The parallel arrangement of pumps
may also be used where there is a restriction on the size of the
pump due to form factor limitations. Here many small pumps in
parallel can be used instead of a one big sized pump.
[0079] It will be apparent to one skilled in the art that the
abovementioned embodiments may be combined in many ways to achieve
flexibility in construction of heat dissipation systems. FIG. 13
shows one such design of a heat dissipating system. A solid-fluid
heat exchanger 1301 placed adjacent to high power density device
(not shown in FIG. 13) contains liquid metal. A conduit 1303 passes
through solid-fluid heat exchanger 1301, carries away hot liquid
metal and dissipates heat at a fluid-fluid heat exchanger 1305. EM
pump 1307 powers the flow of liquid metal in closed conduit 1303. A
solid-fluid heat exchanger 1309 (containing liquid metal) is placed
adjacent to a second high power density device. A conduit 1311
carries hot liquid metal away from solid-fluid heat exchanger 1309
and dissipates heat at fluid-fluid heat exchanger 1305. Two
electromagnetic pumps 1313 and 1315 power the flow of liquid metal
in closed conduit 1311. Electromagnetic pumps 1313 and 1315 are
connected in parallel. The heat transferred by conduits 1303 and
1311 to fluid-fluid heat exchanger 1305 is carried away by the
liquid metal in closed conduit 1317. This heat is dissipated at
heat sink 1319. A pair of electromagnetic pumps 1321 and 1323 power
the flow of liquid metal in closed conduit 1317. Electromagnetic
pumps 1321 and 1323 are connected in series.
[0080] This embodiment demonstrates the flexibility achieved by
using liquid metal as a heat transfer medium. Closed conduits 1303
and 1309 (where liquid metal absorbs heat directly from high power
density device) can be seen as primary closed conduits. Closed
conduit 1317 can be seen as a secondary closed conduit (where
liquid metal absorbs heat dissipated by other closed conduits).
Thus, liquid metal in primary closed conduits 1303 and 1311
dissipates heat at common fluid-fluid heat exchanger 1305. This
heat is carried away by liquid metal in secondary closed conduit
1317 and dissipated at heat sink 1319. It will be apparent that
more complex networks of primary closed conduits and secondary
closed conduits may be provided without departing from the scope of
the invention. For example a network may have a plurality of
primary and secondary closed conduits that dissipate heat at a
common heat exchanger.
[0081] Besides physical flexibility, the use of liquid metal also
provides design flexibility. As a result of the design flexibility,
design of circuits based on electric considerations can be first
worked out. Once the electric circuits have been designed, the
liquid loops can be designed based on the form factor limitations
(due to the circuit components). This approach enables the design
of a circuit without taking thermal considerations in account in
the first place.
[0082] The system may further include a heat spreader positioned
adjacent to the high power density device. The heat spreader can
include a plurality of cooling chambers containing liquid metal and
a plurality of electromagnetic pumps arranged in a configuration so
as to circulate the liquid metal in the cooling chambers.
[0083] From the above discussion it is evident that liquid metal
heat transfer provides a highly flexible method of heat removal.
The various embodiments provided by the invention may be used in
computational devices such as laptops to dissipate heat generated
by the central processing unit. The flow of liquid metal in
conduits (made of polymers) provides a lot of flexibility to carry
away the heat and dissipate it at a heat sink placed at bottom or
screen of the laptop. The fluid conduit can be flexed, or bent,
allowing the flow of liquid metal to be routed across hinges (in a
laptop).
[0084] The networks of primary and secondary closed conduits
provided by the invention can be used for cooling multiple
processors in a server where several discrete high power density
devices are located in close physical proximity. Primary closed
conduits may be used to dissipate heat locally while secondary
closed conduits can carry away this heat and dissipate it at
distant less-populated areas on the board.
[0085] While the preferred embodiments of the invention have been
illustrated and described, it will be clear that the invention is
not limited to these embodiments only. Numerous modifications,
changes, variations, substitutions and equivalents will be apparent
to those skilled in the art without departing from the spirit and
scope of the invention as described in the claims.
* * * * *