U.S. patent application number 11/756749 was filed with the patent office on 2008-12-04 for counterflow microchannel cooler for integrated circuits.
Invention is credited to Richard C. Blish, II.
Application Number | 20080298017 11/756749 |
Document ID | / |
Family ID | 40073809 |
Filed Date | 2008-12-04 |
United States Patent
Application |
20080298017 |
Kind Code |
A1 |
Blish, II; Richard C. |
December 4, 2008 |
COUNTERFLOW MICROCHANNEL COOLER FOR INTEGRATED CIRCUITS
Abstract
A plurality of channels are formed in a base, e.g., a substrate
of an integrated circuit, each channel extending between edges of
the base. Two pairs of manifolds are provided, the first pair
communicating with a first group of channels and the second pair
communicating with a second group of channels, the first group of
channels and the first pair of plena isolated from the second group
of channels and the second pair of plena. Each of the pairs of
manifolds includes multiple branches coupled to the channels and a
common plenum. Cooling fluid is injected into the channels from
different sides of the base, causing fluid to flow in different
directions in the two groups of channels, the channels in thermal
contact with the integrated circuit.
Inventors: |
Blish, II; Richard C.;
(Saratoga, CA) |
Correspondence
Address: |
ZAGORIN O'BRIEN GRAHAM LLP
7600B NORTH CAPITAL OF TEXAS HIGHWAY, SUITE 350
AUSTIN
TX
78731
US
|
Family ID: |
40073809 |
Appl. No.: |
11/756749 |
Filed: |
June 1, 2007 |
Current U.S.
Class: |
361/699 ; 29/829;
361/689; 361/701 |
Current CPC
Class: |
H01L 2924/1461 20130101;
F28F 2260/02 20130101; F28F 7/02 20130101; H01L 23/473 20130101;
H01L 2224/16 20130101; H01L 2924/00014 20130101; H01L 2224/73253
20130101; H01L 2924/15312 20130101; H01L 2924/00011 20130101; H01L
2224/0401 20130101; H01L 2924/00011 20130101; H01L 2924/00
20130101; H01L 2224/0401 20130101; Y10T 29/49124 20150115; H01L
2924/00014 20130101; H01L 2924/1461 20130101; H01L 2224/73204
20130101; H01L 2924/16152 20130101 |
Class at
Publication: |
361/699 ;
361/701; 29/829; 361/689 |
International
Class: |
H05K 7/20 20060101
H05K007/20; H05K 3/00 20060101 H05K003/00 |
Claims
1. An apparatus comprising: a plurality of channels formed in a
base, each channel having first and second ends, the channels
substantially parallel to a surface of the base and running from a
first to a second edge of the base; a first pair of manifolds, each
manifold of the first pair having a plurality of branches and a
plenum connected to the branches, a first manifold of the first
pair disposed at the first edge and a second manifold of the first
pair disposed at the second edge of the base, the first pair of
manifolds in fluid communication with a first group of the
channels; a second pair of manifolds, each manifold of the second
pair having a plurality of branches and a plenum connected to the
branches, a first manifold of the second pair disposed at the first
edge and a second manifold of the second pair disposed at the
second edge of the base, the second pair of manifolds in fluid
communication with a second group of channels and isolated from the
first pair of manifolds and the first group of channels; and
wherein the one or more channels of the first group are
substantially thermally non-blocking with respect to the one or
more channels of the second group of channels in a direction
towards a heat source.
2. The apparatus as recited in claim 1 wherein at least a portion
of each of the channels in the first group and at least a portion
of each of the channels in the second group are in a plane parallel
to the surface of the base.
3. The apparatus as recited in claim 1 wherein the channels in the
first and second group are configured to carry fluid in opposite
directions.
4. The apparatus as recited in claim 1 wherein the channels of the
first group are interleaved with channels of the second group.
5. The apparatus as recited in claim 1 wherein the base is a
substrate of an integrated circuit and the channels are formed in a
backside of the substrate.
6. The apparatus of claim 1, wherein the base is attached to a
substrate of the integrated circuit.
7. The apparatus as recited in claim 5 wherein channel pitch in the
base is between approximately 1 and 30 micrometers and a thickness
of the substrate is approximately 0.5 to 1.5 mm.
8. The apparatus as recited in claim 1, wherein channels of the
first and second groups have equal aspect ratios.
9. The apparatus as recited in claim 1, wherein channels of the
first and second groups have equal cross-sectional areas.
10. The apparatus as recited in claim 1, wherein at least one of
the channels has different cross-sectional areas at respective
different locations in the at least one channel.
11. The apparatus as recited in claim 1, wherein channels of the
first and second groups have cross-sectional areas that range
between approximately 30 square microns to 3000 square microns.
12. The apparatus as recited in claim 1, further comprising: first
and second housings disposed at respective edges of the base, each
housing hermetically sealing the manifolds disposed at respective
edges of the base.
13. The apparatus as recited in claim 12, wherein the first housing
has a first group of vias at a first height to fluidly connect the
first manifold of the first pair of manifolds to the first group of
channels and a second group of vias at a second height to fluidly
connect the first manifold of the second pair of manifolds to the
second group of channels.
14. The apparatus as recited in claim 13, wherein the second
housing has a first group of vias at the first height to fluidly
connect the second manifold of the first pair of manifolds to the
first group of channels and a second group of vias at the second
height to fluidly connect the second manifold of the second pair of
manifolds to the second group of channels.
15. The apparatus as recited in claim 1, further comprising first
and second fluid conduits connected to the first and second pair of
manifolds.
16. The apparatus as recited in claim 15, further comprising a pump
operable to flow a fluid through one or more of the conduits.
17. The apparatus as recited in claim 16, further comprising first
and second housings disposed at respective edges of the base, each
housing hermetically sealing the manifolds disposed at respective
edges of the base.
18. The apparatus of claim 16, further comprising a heat exchanger,
at least a portion of each of the first and second conduits in
thermal contact with the heat exchanger.
19. A method of managing heat in an integrated circuit comprising:
causing fluid to flow in a first direction from an inlet end to an
outlet end in a first plurality of channels formed in a base, the
channels being substantially parallel to a surface of the base and
running from a first to a second edge of the base, the first
direction being from the first to the second edge of the base; and
causing fluid to flow in a second direction from an inlet end to an
outlet end in a second plurality of channels formed in the base,
the second plurality of channels substantially parallel to the
surface of the base and running from the first to the second edge
of the base, the second direction being from the second to the
first edge of the base, and wherein the one or more channels of the
first group are substantially thermally non-blocking with respect
to the one or more channels of the second group in a direction
towards a heat source.
20. The method as recited in claim 19 further comprising, feeding
cold fluid from a first manifold disposed at the first edge of the
base to the inlet ends of the first plurality of channels; and
exhausting warmed fluid to a second manifold disposed at the second
edge of the base from the outlet ends of the first plurality of
channels; feeding cold fluid from a third manifold disposed at the
second edge of the base to the inlet ends of the second plurality
of channels; and exhausting warmed fluid to a fourth manifold
disposed at the first edge of the base from the outlet ends of the
second plurality of channel.
21. The method as recited in claim 19 wherein the base is a
substrate of the integrated circuit.
22. The method of claim 19, further comprising isolating the fluid
in the first plurality of channels from the fluid in the second
plurality of channels.
23. The method of claim 19, further comprising: causing the fluid
from the first plurality of channels to flow from the second
manifold into a first fluid conduit; and causing the fluid from the
second plurality of channels to flow from the fourth manifold into
a second fluid conduit.
24. The method of claim 23, further comprising: transferring heat
between the fluid in at least one of the first and second conduits
and a heat exchanger along the path of the at least one of the
conduits.
25. A process for making an apparatus, the process comprising:
disposing one manifold of a first pair of manifolds and one
manifold of a second pair of manifolds along a first edge of a
base, the base having a first and second group of channels
extending from a first to a second edge of the base; disposing a
second manifold of the first pair and a second manifold of the
second pair along a second edge of the base, the pairs of manifolds
in fluid communication with respective groups of channels; and
hermetically sealing the manifolds to the edges of the base along
which they are disposed, maintaining fluid communication between
first and second pairs of manifolds and respective groups of
channels.
26. The process as recited in claim 25, wherein the base is a back
side of a substrate of an integrated circuit.
27. The process as recited in claim 25, wherein the channels of the
first and second groups have equal aspect ratios.
28. The process as recited in claim 25, wherein the channels of the
first and second groups have equal cross-sectional areas.
29. The process as recited in claim 25, wherein channels of the
first and second groups have cross-sectional areas that range
between approximately 30 square microns to 3000 square microns.
Description
BACKGROUND
[0001] 1. Field of the Invention
[0002] This invention relates to cooling integrated circuits and
more particularly to microchannel coolers for integrated
circuits.
[0003] 2. Description of the Related Art
[0004] Much of the power consumed by a modern integrated circuit
(IC) during operation is dissipated as heat, increasing the
temperature of the IC and altering its properties. For example,
silicon switching speed is slower when hot. Additionally,
reliability is reduced as temperature increases. If the temperature
is sufficiently high, irreversible damage occurs. To remove heat as
quickly as possible, several approaches have been used in the art.
These generally involve mounting heat dissipaters, such as heat
sinks, near the IC package.
[0005] FIG. 1 shows a cross-sectional view of one such prior art
integrated circuit assembly 100. An IC 102 is mounted on a
substrate 104 using C4 bumps 106. The package lid 108 sits on the
substrate 104 and is thermally coupled to the IC 102 by a first
level thermal interface material (TIM) 110. A heat exchanger 112,
thermally coupled to the lid 108 by a second level TIM 114, removes
heat to the ambient, which may be a gas, e.g., air or dry nitrogen,
or a liquid, e.g., water or liquid nitrogen. The entire assembly
100 may be mounted to a circuit board (not shown) by pins 116 or
any other convenient mounting mechanism.
[0006] As can be seen, this integrated circuit assembly relies on
conduction through the thermal interface materials and the package
to remove heat from ICs. Since many ICs typically have hotspots,
i.e., they are not uniformly heated, that non-uniformity may be
transferred largely unchanged through the package to the heat
exchanger.
[0007] Referring to FIG. 2A, one approach contemplated in the prior
art to provide improved cooling is to run a cooling liquid through
channels 201 in the semiconductor as shown in FIG. 2A. A problem
with the approach shown in FIG. 2A is that as the cool water enters
one side 202 of the semiconductor and travels to the other, it
loses cooling capacity by absorbing heat from the semiconductor as
it travels. In that case, the other end 203 of the integrated
circuit will be left with a higher temperature.
[0008] One approach to address that problem, shown in FIG. 2B,
utilizes stacked channels 205 and 207 with cold water being
supplied from two sides of an integrated circuit. As shown in FIG.
2B, cold water is supplied to the channels 205 on the bottom of
front side 206 of the integrated circuit, and cold water is also
supplied to the top channels 207 on the far side 208 of the
integrated circuit. The cold water fed to channels 207 exits as
warm water on side 206. Similarly, the cold water supplied on side
206 exits as warm water on far side 208. Thus, in order to deal
with the problem associated with FIG. 2A (warm coolant concentrated
on one side of the semiconductor), cold water is fed from both
sides in FIG. 2B.
[0009] A vertical section close to the edge of side 208, and
looking into the IC, is shown in FIG. 2C and a vertical section
close to edge 206 is shown in FIG. 2D. A plan view of the
integrated circuit shows the top channel 207 cold on side 208 and
warm on side 206. Note that the transition shown as abrupt in FIG.
2E from cold to warm would, of course, be gradual.
[0010] The stacked channel approach shown in FIGS. 2B-2E suffers
from the fact that the deep set of channels 205, closest to the
heat source (i.e., the active semiconductor), shields the active
semiconductor from the second set of channels 207. Further, each
channel will have a "cold" end and then get warmer as the conduit
crosses to the other side. Thus, some parts of the device are
starved of coolant.
[0011] In view of the approaches described above, improved cooling
approaches are desirable to improve reliability and
performance.
SUMMARY
[0012] In one embodiment, an apparatus includes a plurality of
channels formed in a base, each channel having first and second
ends. The channels are substantially parallel to a surface of the
base and run from a first to a second edge of the base. The
apparatus includes a first pair of manifolds, each manifold of the
first pair having a plurality of branches and a plenum connected to
the branches. A first manifold of the first pair is disposed at the
first edge and a second manifold of the first pair disposed at the
second edge of the base. The first pair of manifolds are in fluid
communication with a first group of the channels. The apparatus
includes a second pair of manifolds, each manifold of the second
pair having a plurality of branches and a plenum connected to the
branches. A first manifold of the second pair is disposed at the
first edge and a second manifold of the second pair is disposed at
the second edge of the base. The second pair of manifolds are in
fluid communication with a second group of channels and isolated
from the first pair of manifolds and the first group of channels.
The one or more channels of the first group are substantially
thermally non-blocking with respect to the one or more channels of
the second group of channels in a direction towards a heat
source.
[0013] In an embodiment, the channels in the first and second group
are configured to carry fluid in opposite directions. In an
embodiment, the channels of the first group are interleaved with
channels of the second group.
[0014] In another embodiment, a method is provided that includes
causing fluid to flow in a first direction from an inlet end to an
outlet end in a first plurality of channels formed in a base, the
channels being substantially parallel to a surface of the base and
running from a first to a second edge of the base, the first
direction being from the first to the second edge of the base; and
causing fluid to flow in a second direction from an inlet end to an
outlet end in a second plurality of channels formed in the base,
the second plurality of channels substantially parallel to the
surface of the base and running from the first to the second edge
of the base, the second direction being from the second to the
first edge of the base, and wherein the one or more channels of the
first group are substantially thermally non-blocking with respect
to the one or more channels of the second group in a direction
towards a heat source.
[0015] In still another embodiment, a process for making an
apparatus is provided. The process includes disposing one manifold
of a first pair of manifolds and one manifold of a second pair of
manifolds along a first edge of a base, the base having a first and
second group of channels extending from a first to a second edge of
the base. A second manifold of the first pair and a second manifold
of the second pair are disposed along a second edge of the base,
the pairs of manifolds in fluid communication with respective
groups of channels. The manifolds are hermetically sealed to the
edges of the base along which they are disposed, maintaining fluid
communication between first and second pairs of manifolds and
respective groups of channels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The present invention may be better understood, and its
numerous objects, features, and advantages made apparent to those
skilled in the art by referencing the accompanying drawings. As is
customary in the art, sketches such as those shown in the figures
are not to scale, with some features exaggerated to better point
out relevant relationships between them.
[0017] FIG. 1 is a cross-sectional view of a typical integrated
circuit assembly.
[0018] FIG. 2A is a view of a prior art cooling approach.
[0019] FIG. 2B is a view of another prior art cooling approach.
[0020] FIGS. 2C and 2D are sectional views of the prior art
approach shown in FIG. 2B.
[0021] FIG. 2E is a plan view of the prior art approach shown in
FIG. 2B.
[0022] FIG. 3A illustrates a cross-sectional view of a system
according to an embodiment of the invention.
[0023] FIG. 3B illustrates a cross-sectional view of a system
according to an embodiment of the invention.
[0024] FIG. 4A is a perspective view of microchannels according to
an embodiment of the invention.
[0025] FIG. 4B is a cross-sectional view of the microchannels shown
in FIG. 4A.
[0026] FIG. 5A shows a plan view of microchannels and a sectional
view of housings according to an embodiment of the invention.
[0027] FIG. 5B shows a plan view of microchannels and a sectional
view of housings according to an embodiment of the invention.
[0028] FIG. 6A shows a cross-sectional of a manifold in a housing
for supplying or exhausting coolant to/from the channels.
[0029] FIG. 6B shows a cross-sectional of a manifold in a housing
for supplying or exhausting coolant to/from the channels.
[0030] FIG. 6C shows a plan view of the channels in a base for use
with the housing shown in FIG. 6E.
[0031] FIG. 6D shows a cross-section of a PCB housing used with the
base shown in FIG. 6C.
[0032] FIG. 6E shows a sectional view of the housing for use with
the base shown in FIG. 6C.
[0033] FIG. 7A shows a plan view of the channels in a base for use
with the housing shown in FIG. 7C.
[0034] FIG. 7B shows a cross section of a PCB housing for use with
the base shown in FIG. 7A.
[0035] FIG. 7C shows a sectional view of the housing for use with
the base shown in FIG. 7A.
[0036] FIG. 8 illustrates an embodiment of a base incorporating
microchannels according to an embodiment of the invention.
[0037] FIGS. 9A and 9B illustrate alternative embodiments of the
invention.
[0038] The use of the same reference symbols in different drawings
indicates similar or identical items.
DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0039] In order to address the limitations of the stacked channel
arrangement shown in FIGS. 2B-2E, and other prior art cooling
techniques, a counterflow microchannel approach is utilized in
various embodiments of the invention described herein. Before other
details of the counterflow architecture are examined, a high level
view of a system incorporating the counterflow architecture will be
examined. Accordingly, FIG. 3A shows a cross-sectional view of a
simplified IC assembly 200 according to an embodiment of the
invention. The embodiment illustrated in FIG. 3A includes a
microchannel device 220 that includes an integrated circuit as
described further herein. In the particular embodiment of FIG. 3A,
two coolant lines 222, 224 feed cold coolant and remove warm
coolant to/from the microchannel device 220. The coolant lines 222,
224, carry the warmed fluid to a heat exchanger 112, where the
fluid is cooled by exchange of heat with ambient. The cooled fluid
then returns through the coolant line 222, 224 into the
microchannel device 220 in a closed loop. The direction of the cold
feed and warm returns are indicated in the figure for each of the
coolant lines. In the embodiment of FIG. 3A, the fluid conduits
222, 224 pass through the exchange portion 113 (identified in FIG.
1) of the heat exchanger 112, here passing between or around the
fins 115 (identified in FIG. 1) and making thermal contact with
them.
[0040] In the embodiment of FIG. 3B, the fluid conduits 222, 224
pass through the body 111 (identified in FIG. 1) of the heat
exchanger 112, making thermal contact with it. Regardless of the
particular configuration employed, heat is exchanged between the
conduits 222, 224 and the heat dissipater 112, heating the heat
dissipator while cooling the fluid conduits 222, 224 and their
contents. Heat exchangers are well known in the art and take many
shapes, the particular shape chosen for convenient deployment in a
particular application.
[0041] As stated before, in order to address the limitations of the
stacked channel arrangement, a counterflow microchannel approach is
utilized in various embodiments of the invention described herein.
FIG. 4A is a perspective view of an embodiment of the invention in
which microchannels 330 and 350 are formed in a base 332. The
series of channels 330, 350 traverse the base between its edges.
Channels 330, 350 may be formed in or on the base by a number of
techniques, including lithographic procedures common in
semiconductor manufacturing, direct etching by ion beams or lasers,
scribing, and other methods. As shown in FIG. 4A, the channels are
formed on the surface of the base and are of different depths. In
an embodiment, as illustrated in FIG. 4A, channels 330 and 350 have
equal areas and aspect ratios, with one group of channels oriented
at a 90.degree. angle with respect to the other. Channels 330, 350
may have other cross sections, including circular, triangular,
trapezoidal, or any convenient shape, and the cross sections need
not be the same for both channels 330 and 350. Channels 330, 350
may be formed at the same level (same height in the base 330) or at
different levels (different heights in the base 332), and at any
height within the base 332, including on its top or bottom
surfaces. In the embodiment shown in FIG. 4A, at least a portion of
each of the channels are coplanar in a plane parallel to a surface
of the base. One key aspect of this embodiment shown in FIG. 4A is
that the channels are not blocked from the heat source by other
channels.
[0042] In an embodiment of the invention, the base 332 is a
substrate of a semiconductor device with the active area of the
semiconductor displaced from the location of the microchannels.
Thus, the microchannels are formed on the backside of the
substrate. In one embodiment, the substrate is silicon and the
integrated circuit may be formed by any of a number of well known
integrated circuit manufacturing techniques. In the embodiment of
the microchannels shown in FIG. 4A, adjacent microchannels are
assumed to carry coolant in opposite directions as explained more
fully herein.
[0043] Referring to FIG. 4B, illustrated is a sectional view of the
microchannels according to an embodiment of the invention. In an
embodiment such as shown in FIGS. 4A and 4B, the base 332 is
silicon, while in other embodiments, the base could be made of
glass, quartz, polymeric material, metal, or any of a number of
materials appropriate to the application. Furthermore, the base
need not be monolithic as shown in FIG. 3, but may be made up of
several layers, and channels may be formed between layers or atop
the final layer as depicted. As stated above, the base may be
formed integrally with the IC itself, for example, on the back of
the IC substrate. The base 332 is preferably formed of a material
resistant, over the lifetime of the device, to corrosion by the
fluid employed, although accommodations for other materials can be
made by those skilled in the art. Note that at least a portion of
each of the microchannels 330 and at least a portion of each of the
micro channels 350 in FIG. 4B are co-planar, in a plane parallel to
the surface of the base. In other embodiments, they may be fully
coplanar (see FIGS. 7A-7C).
[0044] Referring now to FIG. 5A, housings 334, 354 are shown to be
disposed at opposite edges of the base 332. The cross-sectional
view of the housings is in a plane parallel to the surface of the
base. At the particular depths shown, channels 330 are shown to
communicate with the interior of the housings 334, 354 through a
series of vias 336 through the inner housing walls 338, 339 at each
end of the channels 330, 350. Walls 345, 347 provide the sealing
layer for the vias 336. Although depicted in FIG. 3 as running
across the base 332 from one edge to the opposite edge in parallel
to each other, the channels 330, 350 may take other
non-intersecting paths in the plane of the assembly.
[0045] Referring now to FIG. 5B, a sectional view at a different
depth from FIG. 5A shows that channels 350 communicate with the
interior of the housings 334, 354 through a series of vias 356
through the inner housing walls 338, 339 at each end of the
channels 330, 350. Note that in this embodiment at this depth, the
vias 336 are not visible. Outer walls 358, 359 provide the sealing
layer for the vias 356.
[0046] Referring again to FIG. 4B, the cross-sectional view of the
base 332 is seen from the edge along line 4B of FIGS. 5A and 5B
showing the channels 330, 350. The cap 460 seals the channels 330,
350 that are formed on the surface of the base 332. Alternative
sealing mechanisms may be employed, for example, an organic
sealant, a TIM or adhesive, or a monolithically incorporated cap
layer. In the particular embodiment depicted in FIG. 4B, channels
330 and 350 have equal areas and aspect ratios, with one group of
channels oriented at a 90.degree. angle with respect to the other.
As stated earlier, channels 330, 350 may have other cross sections.
The cross sections and their areas may change throughout the length
of the channels 330, 350. It may be advantageous to alter the
channel shape throughout its length, for example, making the cross
section at the inlet side bigger than the cross section at the
outlet side. In an embodiment, in order to accomplish the different
cross sectional areas, constant depth is utilized for the channels
but the outlet side (hot) side is narrower than the inlet (cool)
side, thereby providing a smaller cross section at the outlet side
and a larger velocity of coolant at the hot end. The channels 330,
350 may have large or small cross-sectional areas, as appropriate
to the application. For example, the cross-sectional areas may
range from about 3 micrometers by about 10 micrometers up to about
30 micrometers by 100 micrometers. Thus, the cross-sectional areas
may range from about 30 micrometers up to about 3000 micrometers.
These particular ranges are exemplary. The aspect ratio of the
channels may also vary. For example, in various embodiments, the
aspect ratio may range from about 1:1.5 to about 1:10. Of course,
other aspect ratios may be used according to the particular
application.
[0047] The channels may be formed monolithically in the base 332 by
scribing, etching techniques such as those used for
micro-electro-mechanical structures (MEMS), use of a sacrificial
filler material such as in lost wax casting, growing layers over
embedded channels or other methods. Capping with a separate
material may also form the channels 330, 350. Channels 330 and 350
need not alternate in a one-to-one fashion as shown. For example,
two channels 330 may be interleaved between two channels 350, or
some other arrangement. However, in a preferred embodiment, the
channels 330 and 350 are interleaved. Further, the pitch (and
depth) of the channels is much less than the distance to the heat
source. In a typical high power microprocessor, the distance from
the microchannels to the heat source on the active side of the
semiconductor is determined by semiconductor thickness,
approximately 0.8 mm. More generally, the substrate may have a
thickness, e.g., of 0.5 to 1.5 mm, while the pitch of the channels
may range, e.g., from several micrometers to tens of micrometers.
Pitch is defined as the lateral size of the channels plus the gap
between them. Channel depth may have similar or smaller dimensions
than pitch. Having the pitch (and depth) of the channels be much
less than the distance to the heat source allows the heat source to
see the warm and cold adjacent channels as a dipole and provides
better heat management for the integrated circuit.
[0048] The housings 334 and 354 shown in FIGS. 5A and 5B may be
formed of multi-layer printed circuit board (PCB) material. FIGS.
6A-6B show separate layers of an embodiment of a housing 334 made,
in this case, of a multi-layer printed circuit board (PCB) material
462 supporting patterned traces of thick copper 464, 466. In FIG.
6A one layer of copper has been formed on a layer of PCB material
462 and patterned. Traces 464 form manifold 468. Manifold 468
includes branches 472 that supply coolant to (or receive coolant
from) channels 330 through vias 336. Manifold 468 also includes
plenum 470. The plenum 470 is the area common to and supplies (or
is supplied by) the branches 468. As used herein, the term manifold
may be used to refer to the multiple branch structure formed by
branches 468 and also to the overall system formed by the
combination of the multiple branch structure and the plenum. The
manifold and plenum formed by metal traces 464 allows for
confinement of liquid when the PCB layer with the metal traces is
capped by formation of the next layer of the housing 334. With the
capping of the manifold and plenum, liquid may enter the plenum 470
and then flow into any of the branches 472, and then flow through
the vias 336 into the channels 330. In this figure, liquid is
injected from the left, although the opposite configuration could
certainly be implemented. Assuming that manifold 468 and plenum 470
is formed in housing 334, another similar or identical manifold and
plenum would be formed in housing 354. Assuming that manifold 468,
used here in the broader sense to include the multiple branches 472
and plenum 470, is the cold feed side, then the manifold opposite
(again used in the broader sense) would be the warm exhaust
manifold. Assuming liquid is exhausted from the exhaust manifold
opposite the inlet manifold on the cold feed side after flowing
through the channels 330, only one open end is required, input or
exhaust, for each manifold of the pair. Thus, for example, the
manifold 468 in housing 334 is an input and the manifold opposite
in housing 354 would be an exhaust. The input of the manifold 468
would be coupled to a cold feed conduit 222 and the exhaust of the
opposite manifold would be coupled to the warm return (see FIG.
3A).
[0049] FIG. 6B depicts the layer of the housing 334 bearing the
traces 466 that form the manifold 474 including multiple branches
478 and a plenum 476 for liquid flowing through channels 350. Since
the manifold 468 shown in FIG. 6A was assumed to be a cold feed
manifold, manifold 474 would be a warm return. Each of the housings
334 and 354 include both a cold feed manifold and a warm return
manifold shown in FIGS. 6A and 6B. In FIG. 6B liquid is shown to be
exhausted from the plenum 476 to the right. Of course other
configurations are possible. Liquid may enter exit branches 478
through vias 356 after flowing through the channels 350. Coolant is
supplied to the channels 350 from a similarly constructed or
identical manifold in the opposite housing 454. The output of
manifold 474 is coupled to the warm exhaust manifold of conduit
224, while the input manifold opposite manifold 474 is coupled to
the cold feed portion of conduit 224 (see FIG. 3A).
[0050] Full circles in FIGS. 6A and 6B indicate the location of
vias 336, 356 to be cut (or drilled or etched, etc.) after all the
desired manifolds have been formed, and thus may not be visible at
intermediate stages of construction. The vias 336, 356 may also be
formed during construction of the housing 334. By confining liquid
to separate manifolds with vias communicating with only one group
of channels 330 or 350, each group of channels may be isolated from
the other group of channels and each group 336, 356 of vias from
each other. Furthermore, the two manifolds 468, 474 are separated
from each other. This allows isolation of, for example, cool
injected liquid from warmed returning liquid, allowing for cold
liquid to be supplied from each side providing for a counterflow
architecture.
[0051] FIG. 6C shows a plan view of the base with channels 330 and
350. FIG. 6D shows a cross section of the printed circuit board
forming the housing in FIG. 6E. FIG. 6E shows a plan view of the
housing for use with the channels in FIG. 6C, showing both the warm
water return manifold and the cold water feed manifold. Assuming
the cold feed is feeding into the paper, the cold feed manifold 474
is outside and the warm return manifold 468 is inside (closer to
the channels) in the view shown in FIG. 6E. On the opposite side of
the channels, the manifolds perform the opposite function (cold
feed or warm return) for the channel to which they are coupled. In
FIG. 6E, the position of the channels 330, 350 are indicated, with
the bottom of the channel indicated by a thicker black line. Note
that the channels would not normally be visible in the view shown
in FIG. 6E, but are shown to see the appropriate placement of the
channels with respect to the housing. Note that only the top vias
are shown in the cross section in FIG. 6D. Note also that an
appropriate water-proof adhesive should be used to attach the PCB
to the base. When attached, the channels are aligned with the vias.
In an embodiment, an O-ring (not shown) associated with a conduit
such as 222 (FIG. 3A) and a flange are used to feed/return water
from each PCB. A clamp may be used to hold the conduit/flange in
contact with the PCB.
[0052] In the example depicted in FIGS. 4B and 6A-6C, with
alternating shallow 350 and deep 330 channels, vias 356 and 336 may
be separated by depth. In the more general case, vias 336, 356 may
be separated, and so channels 330, 350 isolated by placement of the
branches 372, 378. Note that in FIGS. 6A, 6B, and 6E, layers of the
housings 334, 354 provide a seal for the vias 336, 356. Layers of
the PCB are also used as covers for the manifolds. The number of
layers and the material making up the housing is limited only by
practicality.
[0053] FIGS. 7A-7C illustrate an embodiment in which the vias 756
are at the same depth. As shown in FIG. 7A, a plan view of the base
shows that channels 730 have the same cross section from the top,
and may also have the same depth, and thus be identical channels.
FIG. 7B shows a cross section of a printed circuit board in which
the manifolds are disposed. Note that the vias 756 are all visible
in this view since they are of the same depth. FIG. 7C shows warm
and return manifolds coupled to vias 756 at the same height. The
manifolds 774 and 768 are shown as substantially identical but
isolated from each other by PCB layers such as shown in FIG.
7B.
[0054] Referring back to FIG. 5A, the counterflow architecture is
illustrated. Arrows 362 and 363 illustrate the opposite direction
of cold fluid flow for two adjacent channels 330 and 350. That
pattern may be repeated for all the channels. Referring to FIGS. 3A
and 3B, the device 220 includes, e.g., an integrated circuit with
microchannels in combination with PCBs on each side providing
intake and exhaust manifolds. Still referring to FIGS. 3A and 3B,
inner 222 and outer 224 fluid conduits may be connected to mutually
isolated pairs of manifolds (each including multiple branches and a
plenum) through the housings. For example, inner conduit 222 may
supply plenum 470 in manifold 468 in housing 334 and exhaust fluid
from another plenum in an identical manifold in housing 354, while
outer conduit 224 may exhaust fluid from plenum 476 in housing 334
and supply another plenum in an identical manifold in housing 354.
These conduits 222, 224 provide a closed loop through which a
coolant or other fluid may be circulated. When a greater pressure
drop or fluid flow rate is desired than can be provided by
convection alone, a pump 226, 228 may be interposed between outlets
and corresponding inlets. By providing a forced fluid flow, the
pump may overcome any extra resistance provided by the conduits.
Multiple pumps, each circulating fluid in one of the conduits, or a
single pump designed to provide counterflow to both fluids, may be
inserted into part of the fluid flow path. Further cooling power
may be provided by having a portion of the fluid path through one
or both conduits pass through a heat exchanger 112, either
literally through the body 111 of the heat exchanger 112, or
through an area very close to its body 111 or exchange 113 portion
(see FIGS. 3A and 3B). Warmed fluid entering the heat exchange area
transfers heat to the heat exchanger, returning to the inlet area
at a lower temperature. When combined with the microchannel device,
conduits, pump(s), and heat exchanger(s) may provide significant
cooling advantages for an IC.
[0055] Referring to FIG. 8, illustrated is an embodiment in which
the microchannel device is formed of a base 832 separate from the
integrated circuit 801. The channels 830, 850 are formed in the
base 832, which may be silicon or other materials described herein.
The base is then attached to the integrated circuit 801 by a
suitable adhesive. The integrated circuit substrate may serve as a
cover for the channels, or another cover may be utilized such as
described in association with FIG. 4B. Note that adhesive coupling
the semiconductor and the base may need to be sufficiently thin to
reduce thermal resistance.
[0056] Manifold configurations may be modified or constructed
differently to accommodate alternate fluid flow patterns. FIGS. 9A
and 9B show a manifold configuration in which cool fluid flows into
manifold 468 and into channel 330a and across the base to manifold
469. Note that in the discussion of FIGS. 9A and 9B, the channels
are identified by the same reference numerals, e.g., 330a, 350a,
etc., as the vias shown in the figures in communication with
respective channels. In manifold 469, channel 330a communicates
with channel 350a having a different direction of fluid flow.
Coolant flows from channel 330a to channel 350a and then back to
manifold 468, where it flows into channel 330b and through to
manifold 469 and so on. In this configuration, fluid may be
injected and exhausted through the same manifold, e.g., manifold
468, or injected into manifold 468 and exhausted from manifold 469
or vice versa. In some embodiments, no manifold is necessary, only
an inlet and an outlet, as when the channels are connected at their
ends or form a continuous path. Neither in this nor any other
configuration need the channels run in a straight line from one
edge of the base to the other, but rather may exhibit corners or
curves to change their direction, as desirable for the
application.
[0057] 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. Various
embodiments of techniques for managing thermal loads in integrated
circuits have been described. The description of the invention set
forth herein is illustrative, and is not intended to limit the
scope of the invention as set forth in the following claims. For
example, although the present invention has been described
primarily with reference to cooling an IC, it also may be used to
heat or maintain a constant temperature in an IC used at cryogenic
temperatures. Other variations and modifications of the embodiments
disclosed herein may be made based on the description set forth
herein, without departing from the scope of the invention as set
forth in the following claims.
* * * * *