U.S. patent application number 14/853927 was filed with the patent office on 2016-04-28 for flexible cooling line assembly.
The applicant listed for this patent is EBULLIENT, LLC. Invention is credited to Robert A. Buchanan, Brett A. Lindeman, Timothy A. Shedd.
Application Number | 20160116224 14/853927 |
Document ID | / |
Family ID | 55791713 |
Filed Date | 2016-04-28 |
United States Patent
Application |
20160116224 |
Kind Code |
A1 |
Shedd; Timothy A. ; et
al. |
April 28, 2016 |
FLEXIBLE COOLING LINE ASSEMBLY
Abstract
A flexible cooling line assembly, when fluidly connected to a
two-phase cooling apparatus, can provide device-level cooling to
one or more devices. The assembly can include a first section of
flexible, low-pressure tubing fluidly connected to an inlet port of
a heat sink module. The heat sink module can include an inlet
chamber fluidly connected to the inlet port and a plurality of
orifices fluidly connecting the inlet chamber to an outlet chamber.
The outlet chamber can be fluidly connected to an outlet port of
the module, and a second section of flexible, low-pressure tubing
can be fluidly connected to the outlet port. The plurality of
orifices can deliver a plurality of jet streams of coolant into the
outlet chamber and against a heat providing surface when the first
heat sink module is mounted to the heat providing surface and when
pressurized coolant is delivered to the inlet chamber.
Inventors: |
Shedd; Timothy A.;
(Middleton, WI) ; Lindeman; Brett A.; (Madison,
WI) ; Buchanan; Robert A.; (Madison, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
EBULLIENT, LLC |
Madison |
WI |
US |
|
|
Family ID: |
55791713 |
Appl. No.: |
14/853927 |
Filed: |
September 14, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14604727 |
Jan 25, 2015 |
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14853927 |
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14612276 |
Feb 2, 2015 |
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14604727 |
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14623524 |
Feb 17, 2015 |
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14612276 |
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14644211 |
Mar 11, 2015 |
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14623524 |
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14663465 |
Mar 20, 2015 |
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14644211 |
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14677833 |
Apr 2, 2015 |
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14663465 |
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14679026 |
Apr 6, 2015 |
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14677833 |
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14705972 |
May 7, 2015 |
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14679026 |
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14721532 |
May 26, 2015 |
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14705972 |
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14723388 |
May 27, 2015 |
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14721532 |
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14826822 |
Aug 14, 2015 |
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14723388 |
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14846758 |
Sep 5, 2015 |
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14826822 |
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62069301 |
Oct 27, 2014 |
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62072421 |
Oct 29, 2014 |
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62099200 |
Jan 1, 2015 |
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Current U.S.
Class: |
165/104.22 |
Current CPC
Class: |
F28F 9/0258 20130101;
F25B 23/006 20130101; F28D 15/00 20130101; F28F 13/02 20130101;
F28F 9/26 20130101; H05K 7/20327 20130101; F25B 41/003 20130101;
F28F 3/12 20130101 |
International
Class: |
F28D 15/00 20060101
F28D015/00 |
Claims
1. A hot-swappable, flexible cooling line assembly for use with a
two-phase cooling apparatus, the flexible cooling line assembly
comprising: a first quick-connect fitting comprising a first
non-spill shut-off valve and a first connection feature; a first
section of flexible tubing comprising a first end and a second end,
wherein the first end of the first section of tubing is fluidly
connected to the first connection feature of the first
quick-connect fitting; a first heat sink module comprising: a first
inlet port fluidly connected to a first inlet chamber; a first
plurality of orifices fluidly connecting the first inlet chamber to
a first outlet chamber; and a first outlet port fluidly connected
to the first outlet chamber, the second end of the first section of
flexible tubing being fluidly connected to the first inlet port; a
second section of flexible tubing comprising a first end and a
second end, wherein the first end of the second section of flexible
tubing is fluidly connected to the first outlet port of the first
heat sink module; a second heat sink module comprising: a second
inlet port fluidly connected to a second inlet chamber; a second
plurality of orifices fluidly connecting the second inlet chamber
to a second outlet chamber; and a second outlet port fluidly
connected to the second outlet chamber, the second end of the
second section of flexible tubing being fluidly connected to the
second inlet port; a third section of flexible tubing comprising a
first end and a second end, wherein the first end of the third
section of flexible tubing is fluidly connected to the second
outlet port of the second heat sink module; and a second
quick-connect fitting comprising a second non-spill shut-off valve
and a second connection feature fluidly connected to the second end
of the third section of flexible tubing.
2. The hot-swappable flexible cooling line assembly of claim 1,
further comprising: a first thermally conductive base member,
wherein the first heat sink module is mounted against a surface of
the first thermally conductive base member; a first sealing member
compressed between a bottom surface of the first heat sink module
and the surface of the first thermally conductive base member to
provide a first liquid-tight seal around a perimeter of the first
outlet chamber; a second thermally conductive base member, wherein
the second heat sink module is mounted against a surface of the
second thermally conductive base member; and a second sealing
member compressed between a bottom surface of the second heat sink
module and the surface of the second thermally conductive base
member to provide a second liquid-tight seal around a perimeter of
the second outlet chamber.
3. The hot-swappable flexible cooling line assembly of claim 1,
wherein the first section of flexible tubing has a maximum
operating pressure of less than about 35, 50, 75, or 100 psi rated
at 100 degrees C.
4. The hot-swappable flexible cooling line assembly of claim 1,
wherein the first section of flexible tubing has an outer diameter
less than about 0.3 in. and a minimum bend radius of less than or
equal to about 2.5 in.
5. The hot-swappable flexible cooling line assembly of claim 1,
wherein the first plurality of orifices have an average diameter of
about 0.001-0.020, 0.001-0.2, 0.001-0.150, 0.001-0.120,
0.001-0.005, 0.020-0.045, 0.030-0.050 in, or 0.040 in.
6. The hot-swappable flexible cooling line assembly of claim 2,
wherein the first plurality of orifices have an average jet height
of about 0.01-0.75, 0.05-0.5, 0.05-0.25, 0.020-0.25, 0.03-0.125, or
0.04-0.08 in., wherein jet height for each orifice is measured as a
shortest distance from an exit of an orifice to the surface of the
first thermally conductive base member.
7. The hot-swappable flexible cooling line assembly of claim 1,
wherein the first plurality of orifices have an average diameter of
D and an average length of L, and wherein L divided by D is greater
than or equal to one or about 1-10, 1-8, 1-6, 1-4, or 1-3.
8. The hot-swappable flexible cooling line assembly of claim 1,
further comprising a vapor quality sensor attached to the third
section of flexible tubing.
9. The hot-swappable flexible cooling line assembly of claim 9,
wherein the vapor quality sensor is an ultrasonic sensor capable of
detecting density variations between vapor coolant and liquid
coolant.
10. The hot-swappable flexible cooling line assembly of claim 2,
wherein an inner volume of the flexible cooling line assembly is
filled with dielectric coolant.
11. A modular cooling line assembly for a low pressure, two-phase
cooling apparatus, the cooling line assembly comprising: a first
fitting comprising a first connection feature; a first section of
flexible tubing comprising a first end and a second end, wherein
the first end of the first section of tubing is fluidly connected
to the first connection feature of the first fitting; a first heat
sink module comprising: a first inlet port fluidly connected to a
first inlet chamber; a first plurality of orifices fluidly
connecting the first inlet chamber to a first outlet chamber; and a
first outlet port fluidly connected to the first outlet chamber,
the second end of the first section of flexible tubing being
fluidly connected to the first inlet port; and a second section of
flexible tubing comprising a first end and a second end, wherein
the first end of the second section of flexible tubing is fluidly
connected to the outlet port of the first heat sink module.
12. The modular cooling line assembly of claim 11, further
comprising a second fitting comprising a second connection feature,
the second end of the second section of flexible tubing fluidly
connected to the second connection feature.
13. The modular cooling line assembly of claim 11, further
comprising: a second heat sink module comprising: a second inlet
port fluidly connected to a second inlet chamber; a second
plurality of orifices fluidly connecting the second inlet chamber
to a second outlet chamber; and a second outlet port fluidly
connected to the second outlet chamber, the second end of the
second section of flexible tubing being fluidly connected to the
second inlet port; a third section of flexible tubing comprising a
first end and a second end, wherein the first end of the third
section of flexible tubing is fluidly connected to the second
outlet port of the second heat sink module; and a second fitting
comprising a second connection feature fluidly connected to the
second end of the third section of flexible tubing.
14. The modular cooling line assembly of claim 11 wherein the first
fitting is a quick-connect fitting comprising a non-spill shut-off
valve.
15. The modular cooling line assembly of claim 11, wherein the
first inlet chamber is formed within the first heat sink module,
the first outlet chamber is formed within the heat sink module, the
first outlet chamber having an open portion, the open portion
configured to be enclosed by a heat providing surface when the
first heat sink module is installed on the heat providing surface;
and a dividing member disposed between the first inlet chamber and
the first outlet chamber, the first plurality of orifices formed in
the dividing member, the first plurality of orifices extending from
a top surface of the dividing member to a bottom surface of the
dividing member, the first plurality of orifices configured to
deliver a plurality of jet streams of coolant into the first outlet
chamber and against the heat providing surface when the first heat
sink module is installed on the heat providing surface and when
pressurized coolant is provided to the first inlet chamber.
16. The modular cooling line assembly of claim 11, wherein the
first section of flexible tubing comprises nylon or fluorinated
ethylene propylene tubing with a maximum operating pressure of less
than about 35, 50, 75, or 100 psi rated at 100 degrees C.
17. The modular cooling line assembly of claim 11, wherein the
first plurality of orifices have an average diameter of about
0.001-0.020, 0.001-0.2, 0.001-0.150, 0.001-0.120, 0.001-0.005,
0.020-0.045, 0.030-0.050 in, or 0.040 in.
18. The modular cooling line assembly of claim 11, further
comprising: a thermally conductive base member, wherein the first
heat sink module is mounted against a surface of the thermally
conductive base member; a sealing member compressed between a
bottom surface of the first heat sink module and the surface of the
thermally conductive base member to provide a liquid-tight seal
around a perimeter of the first outlet chamber, wherein the first
inlet chamber is formed within the first heat sink module, the
first outlet chamber is formed within the heat sink module, the
first outlet chamber having an open portion, the open portion
enclosed by the surface of the thermally conductive base member;
and a dividing member disposed between the first inlet chamber and
the first outlet chamber within the first heat sink module, the
first plurality of orifices formed in the dividing member, the
first plurality of orifices extending from a top surface of the
dividing member to a bottom surface of the dividing member, the
first plurality of orifices configured to deliver a plurality of
jet streams of coolant into the first outlet chamber and against
the surface of the thermally conductive base member when
pressurized coolant is provided to the first inlet chamber.
19. The modular cooling line assembly of claim 18, wherein the
first plurality of orifices have an average jet height of about
0.01-0.75, 0.05-0.5, 0.05-0.25, 0.020-0.25, 0.03-0.125, or
0.04-0.08 in., and wherein jet height for each orifice is measured
as a shortest distance from an exit of an orifice proximate the
bottom surface of the dividing member to the surface of the first
thermally conductive base member.
20. A flexible cooling line assembly for a cooling apparatus, the
flexible cooling line assembly comprising: a first section of
flexible tubing comprising a first end and a second end; a heat
sink module mounted to a surface of a thermally conductive base
member, the heat sink module comprising: an inlet chamber formed
within the heat sink module and fluidly connected to an inlet port;
an outlet chamber formed within the heat sink module and fluidly
connected to an outlet port, the outlet chamber having an open
portion, the open portion enclosed by the surface of the thermally
conductive base member; and a dividing member disposed between the
inlet chamber and the outlet chamber, the dividing member
comprising a first plurality of orifices formed in the dividing
member, the first plurality of orifices extending from a top
surface of the dividing member to a bottom surface of the dividing
member and fluidly connecting the inlet chamber to the outlet
chamber, the first plurality of orifices configured to deliver a
plurality of jet streams of coolant into the outlet chamber and
against the surface of the thermally conductive base member when
pressurized coolant is provided to the inlet chamber, the second
end of the first section of flexible tubing being fluidly connected
to the first inlet port; and a second section of flexible tubing
comprising a first end and a second end, wherein the first end of
the second section of flexible tubing is fluidly connected to the
outlet port of the heat sink module.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 14/604,727 filed Jan. 25, 2015; U.S. patent
application Ser. No. 14/612,276 filed on Feb. 2, 2015; U.S. patent
application Ser. No. 14/623,524 filed Feb. 17, 2015; U.S. patent
application Ser. No. 14/644,211 filed Mar. 11, 2015; U.S. patent
application Ser. No. 14/663,465 filed on Mar. 20, 2015; U.S. patent
application Ser. No. 14/677,833 filed Apr. 2, 2015; U.S. patent
application Ser. No. 14/679,026 filed on Apr. 6, 2015; U.S. patent
application Ser. No. 14/705,972 filed on May 7, 2015; U.S. patent
application Ser. No. 14/721,532 filed on May 26, 2015; U.S. patent
application Ser. No. 14/723,388 filed May 27, 2015; U.S. patent
application Ser. No. 14/826,822 filed on Aug. 14, 2015; U.S. patent
application Ser. No. 14/846,758 filed on Sep. 5, 2015 and claims
the benefit of U.S. Provisional Patent Application No. 62/069,301
filed Oct. 27, 2014; U.S. Provisional Patent Application No.
62/072,421 filed Oct. 29, 2014; and U.S. Provisional Patent
Application No. 62/099,200 filed Jan. 1, 2015, each of which is
hereby incorporated by reference in its entirety as if fully set
forth in this description.
FIELD
[0002] This disclosure relates to cooling systems and subsystems
for cooling one or more heat sources, such as one or more heat
sources associated with an electrical, mechanical, chemical, or
electromechanical device or process.
BACKGROUND
[0003] Modern data centers house thousands of servers, each having
two or more heat-generating microprocessors. Microprocessors can
easily produce more than 40 thermal watts per square centimeter,
and future microprocessors are expected to produce even higher heat
fluxes as semiconductor technology continues to progress.
Collectively, the amount of heat generated by all servers in a data
center is substantial. Unfortunately, removing this heat from the
data center using conventional air conditioning systems is costly
and inefficient. Installing air conditioning in a data center
requires significant upfront capital expenditures on large computer
room air conditioning (CRAC) units, air handling equipment, and
related ducting, as well as ongoing operating expenditures to
service and maintain the CRAC units. Moreover, CRAC units suffer
from poor thermodynamic efficiency, which translates to high
monthly utility costs for data center operators. To reduce the cost
of operating data centers, and thereby reduce the cost of cloud
computing services reliant on data centers, there is a strong need
to cool servers within data centers more efficiently.
[0004] According to the U.S. Department of Energy, nearly three
percent of all electricity used in the United States is devoted to
powering data centers and computer facilities. Approximately half
of this electricity goes toward power conditioning and cooling.
Increasing the efficiency of cooling systems for data centers and
computer facilities would lead to dramatic savings in energy
nationwide. More efficient cooling systems are also needed in
transportation systems due to increasing adoption of hybrid and
electric vehicles that rely on complex electrical components,
including batteries, inverters, and electric motors, which produce
significant amounts of heat that must be effectively dissipated.
Cooling systems capable of more efficiently cooling these
electrical components would translate to increased range and
utility for these vehicles.
[0005] Presently, the majority of computers (e.g. servers and
personal computers) in residential and commercial settings are
cooled using forced air cooling systems in which room air is
forced, by one or more fans, over finned heat sinks mounted on
microprocessors, power supplies, or other electronic devices. The
heat sinks add mass and cost to the computers and place mechanical
stress on electronic components to which they are mounted. If a
computer is subject to vibration, such as vibration caused by a fan
mounted in the computer, a heat sink mounted on top of a
microprocessor can oscillate in response to the vibration and can
fatigue the electrical connections that attach the microprocessor
to the motherboard of the computer.
[0006] Another downside of air cooling systems is that cooling fans
commonly operate at high speeds and can be quite noisy. When many
computers are collocated, such as in a data center or computer
room, the collective noise produced by the computer fans can
require service personnel to wear hearing protection. As air passes
over electronic devices in the computers, the air, which is at a
lower temperature than the hot surfaces of the electronic devices,
absorbs heat from the electronic devices, thereby cooling the
devices. These air cooling systems are inherently limited in terms
of performance and efficiency due to the low specific heat of air,
which is much lower than the specific heat of water and other
coolants. For example, dry air at 20.degree. C. and 1 bar, has a
specific heat of about 1,007 J/(kg-K), whereas water at 20.degree.
C. has a specific heat of about 4,181 J/(kg-K). Due to air's low
specific heat and low density, high flow rates are required to
ensure adequate cooling of even relatively small heat loads.
[0007] Electronic components within a typical server chassis can
produce a thermal load of about 500 watts. The amount of airflow
required to cool the components can be calculated with the
following equation:
flo{dot over (w)}.sub.air=Q/c.sub.p.times.r.times..DELTA.T
where fl{dot over (o)}w.sub.air is air flow rate, Q is heat
transferred, c.sub.p is the specific heat of air, r is density of
the air, and .DELTA.T is the change in temperature between the air
entering the server chassis and air exiting the server chassis.
Where the thermal load of the server is 500 W and the maximum
allowable .DELTA.T is about 30 degrees, the server chassis will
require about 53 cubic feet per minute (cfm) of air flow. For an
installation of 20 servers, which is common in computer rooms of
small businesses and academic institutions, over 1,000 cfm of air
flow is required to cool the servers. Achieving adequate cooling
capacity in this scenario requires two air conditioning units sized
for a typical U.S. home as well as an appropriately sized air
handler and ducting to deliver cool air to the room.
[0008] Modern data centers, which can have tens of thousands of
servers, must be equipped with many CRAC units designed to cool and
circulate large amounts of air. The CRAC units are large and
expensive and must be professionally installed and often require
substantial modifications to the facility, including installation
of structural supports, custom air ducting, custom plumbing, and
electrical wiring. After installation, CRAC units require frequent
preventative maintenance in an attempt to avoid unplanned downtime.
And simply delivering large amounts of cool air to the data center
will not ensure adequate cooling of the servers. Special care must
be taken to deliver cool air to the servers without the cool air
first mixing with warm air exhausting from the servers. This can
require installation of special airflow management products, such a
raised floors, air curtains, and specially designed server
enclosures, to assist with air containment. These products can
significantly increase the build-out cost of a data center per
square foot. Inevitably, these products do not succeed at isolating
cold air from warm air, they simply reduce mixing of hot and cold
air and thereby provide marginal efficiency improvements.
Therefore, to ensure that sensitive components within the servers
do not overheat, most data centers are forced to increase flow
rates of cool air well above theoretical values as well as decrease
the set point temperature of the room. The result is higher power
consumption by the CRAC units and air handlers, leading to higher
cooling costs for the data center.
[0009] Many electronic devices operate less efficiently as their
temperature increases. As one example, a typical microprocessor
operates less efficiently as its junction temperature increases.
FIG. 64 shows a plot of power consumption in watts versus junction
temperature. The bottom curve shows static power consumption of a
microprocessor and the top curves show total power consumption for
switching speeds of 1.6 GHz and 2.4 GHz, respectively. Total power
consumption includes both static power consumption and dynamic
power consumption, which varies with switching frequency. As shown
in FIG. 64, as the temperature of the microprocessor increases, it
consumes more power to provide the same performance. In air cooling
systems, it is common for fully utilized microprocessors to operate
at or near their maximum rated temperature, resulting in poor
operating efficiency. In the example shown in FIG. 64, the
microprocessor uses over 35% more power when operating at 95
degrees C. than when operating at 45 degrees C. To conserve energy,
it is therefore desirable to provide a cooling system that will
allow the microprocessor to operate consistently at lower
temperatures. Providing a consistently lower operating temperature
for the microprocessor can also extend its useful life and can
avoid unnecessary throttling (dynamic frequency scaling) or
downtime of the computer due to an unsafe junction temperature.
[0010] Operating speeds of next generation microprocessors will
continue to increase, as will heat fluxes (defined as heat load per
unit area) produced by those next generation microprocessors.
Conventional air cooling systems will soon be incapable of
effectively and efficiently cooling these next generation
microprocessors. Therefore, it is desirable to provide a new
cooling system that is significantly more effective and efficient
than existing air cooling systems and is capable of managing high
heat fluxes that will be produced by next generation
microprocessors.
[0011] Pumped liquid cooling systems can provide improved thermal
performance over conventional air cooling systems. Pumped liquid
cooling systems typically include the following items connected by
tubing: a heat sink attached to the microprocessor, a liquid-to-air
heat exchanger, and a pump that circulates liquid coolant through
the system. As the liquid coolant passes through channels in the
heat sink, heat from the microprocessor is transferred through the
thermally conductive heat sink to the coolant, thereby increasing
the temperature of the coolant and transferring heat away from the
microprocessor. The heat sink is typically designed to maximize
heat transfer by maximizing the surface area of the channels
through which the liquid passes. In some examples, the heat sink
can be a micro-channel heat sink that utilizes fine fin channels
through which the liquid coolant flows. The heated liquid coolant
exiting the heat sink is then circulated through a liquid-to-air
heat exchanger where the heat is expelled to the surrounding air to
the reduce the temperature of the liquid coolant before it
circulates back to the pump for another cycle.
[0012] Use of closed liquid cooling systems is beginning to migrate
from high performance computers to personal computers.
Unfortunately, existing liquid cooling systems have performance
constraints that will prevent them from effectively cooling next
generation microprocessors. This is because liquid cooling systems
rely solely on transferring sensible heat by increasing the
temperature of a liquid coolant as it passes through a heat sink.
The amount of heat that can be transferred is a function of, among
other factors, the thermal conductivity of the fluid and the flow
rate of the fluid. Dielectric fluids do not have sufficient thermal
conductivities to be used in liquid cooling systems. Instead, water
or a water-glycol mixture is commonly used due its significantly
higher thermal conductivity. Unfortunately, if a leak develops in a
liquid cooling system that uses water or a water-glycol mixture,
the water will destroy the server and potentially an entire rack of
servers. With the price of a single server being thousands of
dollars or even tens of thousands of dollars, many data center
operators are simply unwilling to accept the risk of loss presented
by water-based liquid cooling systems.
[0013] While more effective than air cooling, transferring heat by
sensible heating requires significant flow rates of liquid coolant,
and achieving high flow rates often necessitates high fluid
pressures. Consequently, a liquid cooling system designed to cool a
modern microprocessor can require a large pump, or a series of
small pumps positioned throughout the liquid cooling system, to
ensure an adequate liquid coolant pressure and flow rate. Operating
large pumps, or a series of small pumps, uses a significant amount
of energy and diminishes the efficiency of the cooling system.
Moreover, using a series of small pumps increases the probability
of the cooling system experiencing a mechanical failure, which
translates to unwanted facility downtime.
[0014] Although liquid cooling systems have proven adequate at
cooling modern microprocessors, they will be unable to adequately
cool next generation microprocessors while maintaining practical
physical dimensions and specifications. For instance, to cool a
next generation microprocessor, liquid cooling systems will require
very high flow rates (e.g. of water), which will require large,
heavy duty cooling lines (e.g. greater than 3/4'' outer diameter),
such as reinforced rubber cooling lines or sweated copper tubing,
that will be difficult to route in any practical manner into and
out of a server housing. If installed in a server, these large
plumbing lines will block access to electrical components within
the server, thereby frustrating maintenance of the server. These
large plumbing lines will also prevent drawers on a server rack
from opening and closing as intended, thereby preventing the server
from being easily accessed and further frustrating maintenance of
the server. As mentioned above, water poses a catastrophic risk to
servers, and increasing the pressure and flow rates of water into
and out of servers only increases this risk. Consequently,
increasing the capabilities of existing liquid cooling systems to
meet the cooling requirements of next generation microprocessors is
simply not a practical or viable option. Without further innovation
in the area of cooling systems, the implementation of
next-generation microprocessors will be hampered.
[0015] As noted above, liquid cooling systems commonly rely on
flowing liquid water through channels in finned heat sinks. The
heat sinks are often indirectly coupled to a heat source via a
metal base plate that is mounted on the heat source using thermal
paste, such as solder thermal interface material (STIM) or polymer
thermal interface material (PTIM), and/or a direct bond adhesive.
While this approach can be more effective than air cooling, the
intervening materials between the water and the heat source induce
significant thermal resistance, which reduces heat transfer rates
and the overall efficiency of the cooling system. The intervening
materials also add cost and time to manufacturing and installation
processes, constitute additional points of failure, and create
potential disposal issues. Finally, the intervening materials
render the system unable to adapt to local hot spots on a heat
source. The net effect of these performance limitations is that the
liquid cooling system must be designed to accommodate the maximum
anticipated heat load of one or more localized hot spots on the
surface of the heat source (e.g. to adequately cool one hot core of
a multicore processor), resulting in additional cost and complexity
of the entire liquid cooling system.
[0016] Unlike water, dielectric coolants can be placed in direct
contact with electronic devices and not harm them. Unfortunately,
dielectric coolants can have a lower specific heat than water, so
they are not well suited for use in single-phase pumped liquid
cooling systems. For instance, some dielectric coolants, such as
certain hydrofluoroethers have a specific heat of about 1,300
J/(kg-K), whereas water has a specific heat of about 4,181
J/(kg-K). This means that that cooling a microprocessor by sensibly
warming a flow of dielectric coolant will require a flow rate about
four times higher than a flow rate of water used to cool an
identical microprocessor by sensibly warming the flow of water.
This higher flow rate requires more pump power, which translates to
lower cooling system efficiency.
[0017] As an alternative to pumped liquid systems, dielectric
coolants can be used in immersion cooling systems. Immersion
cooling is an aggressive form of liquid cooling where an entire
electronic device (e.g. a server) is submerged in a vat of
dielectric coolant (e.g. HFE-7000 or mineral oil). Unfortunately,
immersion cooling vats are large, costly, and heavy, especially
when filled with dielectric coolant, which can have a density
significantly higher than water. Existing vats hold upwards of 250
gallons of coolant and can weigh more than 8,000 pounds when filled
with coolant. Typically, a room must be specially engineered to
accommodate the immersion cooling vat, and containment systems need
to be specially designed and installed in the room as a precaution
against vat failure. When using 250 gallons of coolant, the cost of
the coolant becomes a significant capital expenditure. Certain
coolants, such as mineral oil, can act as solvents and over time
can remove certain identifying information from motherboards and
from other server components. For instance, product labels (e.g.
stickers containing serial numbers and bar codes) and other
markings (e.g. screen printed values and model numbers on
capacitors and other devices) are prone to dissolve and wash off
due to a continuous flow of coolant over all surfaces of the
server. As the labels and dyes wash off the servers, the coolant in
the vat can become contaminated and may need to be replaced,
resulting in an additional expense and downtime. Another downside
of immersion cooling is that servers cannot be serviced immediately
after being withdrawn from the vat. Typically, the server must be
removed from the vat and permitted to drip dry for a period of time
(e.g. 24 hours) before a professional can service the server.
During this drying period, the server is exposed to contaminants in
the air, and the presence of mineral oil on the server may attract
and trap contaminants on sensitive circuitry of the server, which
is undesirable.
[0018] Another cooling approach, known as spray cooling or spray
evaporative cooling, relies on atomized sprays. In this approach,
atomized liquid coolant is sprayed, through air or vapor, directly
onto an electronic device. As a result, small droplets impinge a
heated surface of the device and coalesce to form a thin liquid
film on the heated surface. Heat is then transferred from the
heated surface to the liquid film either by sensible heating of the
bulk liquid or by latent heating, as a fraction of the liquid film
transitions to vapor. Spray cooling is a very efficient way to
remove high heat fluxes from small surfaces. Unfortunately, the
margin for error in spray cooling is very narrow, and the onset of
dry out and critical heat flux is a constant concern that can have
catastrophic consequences. Critical heat flux is a condition where
evaporation of coolant from the heated surface forms a vapor layer
that prevents atomized liquid from reaching and cooling the
surface, often resulting in run-away device temperatures and rapid
failure. Great care must be taken to ensure uniform coverage of the
spray on the heated surface and adequate drainage of fluid from the
heated surface. Although achievable in static laboratory settings,
mainstream adoption of spray cooling has been hampered by several
factors. First, spray cooling requires a significant working volume
to enable atomized sprays to form, which results in non-compact
cooling components, making it impractical for packaging in most
commercial products. Second, atomizing liquid coolant requires a
significant amount of pressure upstream of the atomizer to generate
an appropriate pressure drop at the atomizer-air interface to
enable atomized sprays to form. Maintaining this amount of pressure
within the system consumes a significant amount of pump or
compressor energy. Third, high flow rates of atomized sprays are
required to prevent dry out or critical heat flux from occurring.
In the end, it has proven difficult to design a practical,
reliable, and compact spray cooling system, despite a large amount
of time and effort that has been expended to do so.
[0019] In view of the foregoing discussion, efficient, scalable,
high-performing methods and apparatuses are needed for cooling
electronic devices that produce high heat fluxes, such as
processors and power electronics.
SUMMARY
[0020] This disclosure presents flexible cooling lines assemblies
for cooling systems capable of cooling one or more heat sources,
such as one or more heat sources associated with an electrical,
mechanical, chemical, or electromechanical device or process.
[0021] In one example, a hot-swappable cooling line assembly can be
adapted to fluidly connect to and disconnect from a two-phase
cooling apparatus. The cooling line assembly can include a first
quick-connect fitting having a first non-spill shut-off valve and a
first connection feature. The cooling line assembly can include a
first section of flexible tubing having a first end and a second
end. The first end of the first section of tubing can be fluidly
connected to the first connection feature of the first
quick-connect fitting. The cooling line assembly can include a
first heat sink module having a first inlet port fluidly connected
to a first inlet chamber, a first plurality of orifices fluidly
connecting the first inlet chamber to a first outlet chamber, and a
first outlet port fluidly connected to the first outlet chamber.
The second end of the first section of flexible tubing can be
fluidly connected to the first inlet port. The cooling line
assembly can include a second section of flexible tubing comprising
a first end and a second end. A first end of the second section of
flexible tubing can be fluidly connected to the first outlet port
of the first heat sink module. The cooling line assembly can
include a second heat sink module having a second inlet port
fluidly connected to a second inlet chamber, a second plurality of
orifices fluidly connecting the second inlet chamber to a second
outlet chamber, and a second outlet port fluidly connected to the
second outlet chamber. The second end of the second section of
flexible tubing can be fluidly connected to the second inlet port.
The cooling line assembly can include a third section of flexible
tubing having a first end and a second end. The first end of the
third section of flexible tubing can be fluidly connected to the
second outlet port of the second heat sink module. The cooling line
assembly can include a second quick-connect fitting having a second
non-spill shut-off valve and a second connection feature fluidly
connected to the second end of the third section of flexible
tubing.
[0022] The cooling line assembly can include a first thermally
conductive base member. The first heat sink module can be mounted
against a surface of the first thermally conductive base member. A
first sealing member can be disposed and compressed between a
bottom surface of the first heat sink module and the surface of the
first thermally conductive base member to provide a first
liquid-tight seal around a perimeter of the first outlet
chamber.
[0023] The cooling line assembly can include a second thermally
conductive base member. The second heat sink module can be mounted
against a surface of the second thermally conductive base member. A
second sealing member can be disposed and compressed between a
bottom surface of the second heat sink module and the surface of
the second thermally conductive base member to provide a second
liquid-tight seal around a perimeter of the second outlet
chamber.
[0024] The first section of flexible tubing can have a maximum
operating pressure of less than about 35, 50 or 75 psi rated at 100
degrees C. The first section of flexible tubing can have an outer
diameter less about 0.3 in. and a minimum bend radius of less than
or equal to 2.5 in. The second section of flexible tubing can have
a maximum operating pressure of less than about 35, 50 or 75 psi
rated at 100 degrees C. The second section of flexible tubing can
have an outer diameter less about 0.3 in. and a minimum bend radius
of less than or equal to 2.5 in. The third section of flexible
tubing can have a maximum operating pressure of less than about 35,
50 or 75 psi rated at 100 degrees C. The third section of flexible
tubing can have an outer diameter less about 0.3 in. and a minimum
bend radius of less than or equal to 2.5 in.
[0025] The first plurality of orifices in the first heat sink
module can have an average diameter of about 0.001-0.020,
0.001-0.2, 0.001-0.150, 0.001-0.120, 0.001-0.005, 0.020-0.045,
0.030-0.050 in, or 0.040 in. A second plurality of orifices in the
second heat sink module can have an average diameter of about
0.001-0.020, 0.001-0.2, 0.001-0.150, 0.001-0.120, 0.001-0.005,
0.020-0.045, 0.030-0.050 in, or 0.040 in.
[0026] The first plurality of orifices can have an average jet
height of about 0.01-0.75, 0.05-0.5, 0.05-0.25, 0.020-0.25,
0.03-0.125, or 0.04-0.08 in., where each jet height is measured as
a shortest distance from an exit of an orifice to the surface of
the first thermally conductive base member. The second plurality of
orifices can have an average jet height of about 0.01-0.75,
0.05-0.5, 0.05-0.25, 0.020-0.25, 0.03-0.125, or 0.04-0.08 in.,
where each jet height is measured as a shortest distance from an
exit of an orifice to the surface of the second thermally
conductive base member.
[0027] The first plurality of orifices can have an average diameter
of D.sub.1 and an average length of L.sub.1. L.sub.1 divided by
D.sub.1 can be greater than or equal to one or about 1-10, 1-8,
1-6, 1-4, or 1-3. The second plurality of orifices can have an
average diameter of D.sub.2 and an average length of L.sub.2.
L.sub.2 divided by D.sub.2 can be greater than or equal to one or
about 1-10, 1-8, 1-6, 1-4, or 1-3.
[0028] The first connection feature can be a first barbed fitting
configured to engage with an interior cylindrical surface of the
first end of the first section of flexible tubing. The second
connection feature can be a second barbed fitting configured to
engage with an interior cylindrical surface of the second end of
the third section of flexible tubing.
[0029] The cooling line assembly can include a vapor quality
sensor. The vapor quality sensor can be an ultrasonic sensor
capable of detecting density variations between vapor coolant and
liquid coolant. The vapor quality sensor can be attached to the
first section of flexible tubing, second section of flexible
tubing, or third section of flexible tubing. The vapor quality
sensor can be integrated into the first fitting, second fitting,
first heat sink module, or second heat sink module.
[0030] The cooling line assembly can have an inner volume including
inner volumes of the sections of flexible tubing, heat sink
modules, and fittings. The inner volume of the flexible cooling
line assembly can be filled with dielectric coolant. The dielectric
coolant can be a hydrofluorether, such as Novec 7000, or a
pentafluoropropane, such as R-245fa. The inner volume of the
flexible cooling line assembly can be filled with a compressible
gas. The compressible gas can be nitrogen or argon. The inner
volume of the flexible cooling line assembly can be filled with a
mixture of dielectric coolant and compressible gas, such as a
mixture of hydrofluoroether and nitrogen.
[0031] In another example, a modular cooling line assembly can be
adapted to fluidly connect to a low pressure, two-phase cooling
apparatus. The cooling line assembly can include a first fitting
having a first connection feature. The first fitting can be a
threaded fitting, compression fitting, or a quick-connect fitting
with a non-spill shut-off valve. The cooling line assembly can
include a first section of flexible tubing having a first end and a
second end. The first end of the first section of tubing can be
fluidly connected to the first connection feature of the first
fitting. The first connection feature can be a first barbed fitting
configured to engage with an interior cylindrical surface of the
first end of the first section of flexible tubing. A first heat
sink module can include a first inlet port fluidly connected to a
first inlet chamber, a first plurality of orifices fluidly
connecting the first inlet chamber to a first outlet chamber, and a
first outlet port fluidly connected to the first outlet chamber.
The first plurality of orifices can have an average diameter of
about 0.001-0.020, 0.001-0.2, 0.001-0.150, 0.001-0.120,
0.001-0.005, 0.020-0.045, 0.030-0.050 in, or 0.040 in. The second
end of the first section of flexible tubing can be fluidly
connected to the first inlet port. The cooling line assembly can
include a second section of flexible tubing having a first end and
a second end. A first end of the second section of flexible tubing
can be fluidly connected to the outlet port of the first heat sink
module.
[0032] The cooling line assembly can include a second fitting
having a second connection feature. The second end of the second
section of flexible tubing can be fluidly connected to the second
connection feature. Alternately, the cooling line assembly can
include a second heat sink module having a second inlet port
fluidly connected to a second inlet chamber, a second plurality of
orifices fluidly connecting the second inlet chamber to a second
outlet chamber, and a second outlet port fluidly connected to the
second outlet chamber. The second end of the second section of
flexible tubing can be fluidly connected to the second inlet port.
The cooling line assembly can include a third section of flexible
tubing having a first end and a second end. The first end of the
third section of flexible tubing can be fluidly connected to the
second outlet port of the second heat sink module. The cooling line
assembly can include a second fitting having a second connection
feature fluidly connected to the second end of the third section of
flexible tubing. The second fitting can be a threaded fitting,
compression fitting, or a quick-connect fitting with a non-spill
shut-off valve.
[0033] The first inlet chamber and the first outlet chamber can be
formed within the first heat sink module. The outlet chamber can
have an open portion configured to be enclosed by a heat-providing
surface when the first heat sink module is installed on the
heat-providing surface. The first heat sink module can include a
dividing member disposed between the inlet chamber and the outlet
chamber. The first plurality of orifices can be formed in the
dividing member. The first plurality of orifices can extend from a
top surface of the dividing member to a bottom surface of the
dividing member. The first plurality of orifices can be configured
to deliver a plurality of jet streams of coolant into the first
outlet chamber and against the heat-providing surface when the
first heat sink module is installed on the first heat-providing
surface and when pressurized coolant is provided to the first inlet
chamber.
[0034] The first section of flexible tubing can be made of nylon or
fluorinated ethylene propylene tubing. The first section of
flexible tubing can have a maximum operating pressure of less than
about 35, 50, or 75 psi rated at 100 degrees C. The second section
of flexible tubing can be made of nylon or fluorinated ethylene
propylene tubing. The second section of flexible tubing can have a
maximum operating pressure of less than about 35, 50, or 75 psi
rated at 100 degrees C. The third section of flexible tubing can be
made of nylon or fluorinated ethylene propylene tubing. The third
section of flexible tubing can have a maximum operating pressure of
less than about 35, 50, or 75 psi rated at 100 degrees C.
[0035] The cooling line assembly can include a first thermally
conductive base member. The first heat sink module can be mounted
against a surface of the first thermally conductive base member. A
first sealing member can be disposed and compressed between a
bottom surface of the first heat sink module and the surface of the
first thermally conductive base member to provide a first
liquid-tight seal around a perimeter of the first outlet chamber.
The first inlet chamber can be formed within the first heat sink
module. The first outlet chamber can be formed within the heat sink
module. The outlet chamber can have an open portion. The open
portion can be enclosed by the surface of the thermally conductive
base member. The first heat sink module can include a dividing
member disposed between the first inlet chamber and the first
outlet chamber within the heat sink module. The first plurality of
orifices can be formed in the dividing member. The first plurality
of orifices can extend from a top surface of the dividing member to
a bottom surface of the dividing member. The first plurality of
orifices can be configured to deliver a plurality of jet streams of
coolant into the first outlet chamber and against the surface of
the first thermally conductive base member when pressurized coolant
is provided to the first inlet chamber.
[0036] The first plurality of orifices can have an average jet
height of about 0.01-0.75, 0.05-0.5, 0.05-0.25, 0.020-0.25,
0.03-0.125, or 0.04-0.08 in. Jet height for each orifice can be
measured as a shortest distance from an exit of an orifice
proximate the bottom surface of the dividing member to the surface
of the first thermally conductive base member.
[0037] In yet another example, a cooling line assembly can be
adapted to fluidly connect to a cooling apparatus. The cooling line
assembly can include a first section of flexible tubing having a
first end and a second end. The cooling line assembly can include a
heat sink module mounted to a surface of a thermally conductive
base member. The heat sink module can include an inlet port fluidly
connected to an inlet chamber formed within the heat sink module
and an outlet chamber formed within the heat sink module. The
outlet chamber can be fluidly connected to an outlet port. The
outlet chamber can have an open portion that is enclosed by the
surface of the thermally conductive base member when the heat sink
module is mounted to the thermally conductive base member. The heat
sink module can include a dividing member disposed between the
inlet chamber and the outlet chamber. The dividing member can
include a first plurality of orifices formed in the dividing
member. The first plurality of orifices can extend from a top
surface of the dividing member to a bottom surface of the dividing
member. The first plurality of orifices can be configured to
deliver a plurality of jet streams of coolant into the outlet
chamber and against the surface of the thermally conductive base
member when pressurized coolant is provided to the inlet chamber.
The second end of the first section of flexible tubing can be
fluidly connected to the first inlet port. The cooling line
assembly can include a second section of flexible tubing having a
first end and a second end. The first end of the second section of
flexible tubing can be fluidly connected to the outlet port of the
heat sink module.
[0038] Additional objects and features of the invention are
introduced below in the Detailed Description and shown in the
drawings. While multiple embodiments are disclosed, still other
embodiments will become apparent to those skilled in the art from
the following Detailed Description, which shows and describes
illustrative embodiments. As will be realized, the disclosed
embodiments are susceptible to modifications in various aspects,
all without departing from the scope of the present disclosure.
Accordingly, the drawings and detailed description are to be
regarded as illustrative in nature and not restrictive.
[0039] This Summary is provided to introduce a selection of
concepts in a simplified form that are further described in the
Detailed Description below. This Summary is not intended to
identify key features or essential features of the claimed subject
matter, nor is it intended that this Summary be used to limit the
scope of the claimed subject matter. Furthermore, the claimed
subject matter is not limited to implementations that solve any or
all disadvantages noted in any part of this disclosure.
BRIEF DESCRIPTIONS OF DRAWINGS
[0040] FIG. 1 shows a front perspective view of a cooling apparatus
installed on a plurality of servers arranged in eight racks in a
data center.
[0041] FIG. 2A shows a rear view of the cooling apparatus of FIG.
1.
[0042] FIG. 2B shows a detailed view of a portion of the cooling
apparatus of FIG. 2A, where the pump, reservoir, heat exchanger,
manifolds of the primary cooling loop, and sections of flexible
tubing connecting parallel cooling lines to the manifolds are
visible.
[0043] FIG. 3 shows a left side view of the cooling apparatus of
FIG. 1, where the pump, reservoir, heat exchanger, valve, first
bypass, a portion of the primary cooling loop, and sections of
flexible tubing connecting parallel cooling lines to the inlet and
outlet manifolds are visible.
[0044] FIG. 4 shows an inlet manifold and an outlet manifold of the
cooling apparatus and sections of flexible tubing with
quick-connect fittings connecting parallel cooling lines to the
inlet and outlet manifolds.
[0045] FIG. 5 shows a top perspective view of a server with its lid
removed and a portion of a cooling apparatus installed within the
server, the cooling apparatus having two heat sink modules mounted
on vertically-oriented processors within the server, the heat sink
modules arranged in a series configuration and fluidly connected
with sections of flexible tubing to transport coolant from an
outlet port of a first heat sink module to an inlet port of a
second heat sink module.
[0046] FIG. 6 shows a top view of a server with its lid removed and
a portion of a cooling apparatus installed within the server, the
cooling apparatus including two heat sink modules mounted on
horizontally-oriented processors within the server, the heat sink
modules arranged in a series configuration and held down with
mounting brackets and fluidly connected with a section of flexible
tubing to transport coolant from an outlet port of a first heat
sink module to an inlet port of a second heat sink module.
[0047] FIG. 7 shows a cooling assembly including a heat sink
module, a first section of flexible tubing fluidly connected to an
inlet port of the heat sink module, and a second section of
flexible tubing fluidly connected to an outlet port of the heat
sink module.
[0048] FIG. 8 shows a plot of power consumption versus time for a
computer room with forty active dual-processor servers initially
cooled by a CRAC and then cooled by the CRAC and a cooling
apparatus as described herein, where the cooling apparatus provides
substantial reductions in overall power consumption despite being
installed on just ten of the forty servers in the computer
room.
[0049] FIG. 9 shows a front perspective view of a redundant cooling
apparatus installed on eight racks of servers in a data center
where the redundant cooling apparatus includes a first independent
cooling system as shown in FIG. 1 and a second independent cooling
system as shown in FIG. 1.
[0050] FIG. 10 shows a rear view of the redundant cooling apparatus
of FIG. 9.
[0051] FIG. 11A shows a schematic of a cooling apparatus having a
primary cooling loop, a first bypass, and a second bypass, where
the primary cooling loop includes a reservoir, a pump, and a heat
sink module mounted on a heat-generating surface, the first bypass
including a first valve upstream of a heat exchanger, and a second
bypass including a second valve configured to control a pressure
differential between an inlet port and an outlet port of the heat
sink module.
[0052] FIG. 11B shows the schematic of FIG. 11A with the primary
cooling loop identified by dashed lines, the primary cooling loop
including a reservoir, a pump, and a heat sink module mounted on a
heat source.
[0053] FIG. 11C shows the schematic of FIG. 11A with the first
bypass identified by dashed lines, the first bypass including a
valve and a heat exchanger.
[0054] FIG. 11D shows the schematic of FIG. 11A with the second
bypass identified by dashed lines, the second bypass including a
valve.
[0055] FIG. 12A shows a schematic of a cooling apparatus having a
primary cooling loop, a first bypass, and a second bypass, the
primary cooling loop including a reservoir, a pump, and one heat
sink module mounted on a heat source, the first bypass including a
first valve located downstream of a heat exchanger, and the second
bypass including a second valve.
[0056] FIG. 12B shows a schematic of a cooling apparatus having
primary cooling loop, a first bypass, and a second bypass, the
primary cooling loop including two pumps arranged in parallel for
redundancy in case one pump fails, the first bypass including a
first valve located upstream of a heat exchanger, and the second
bypass including a second valve.
[0057] FIG. 12C shows a schematic of a cooling apparatus having a
three-way valve at a junction between a primary cooling loop and a
bypass, the primary cooling loop including a reservoir, a pump, a
heat sink module mounted on a heat source, and the three-way valve,
and the bypass including a heat exchanger.
[0058] FIG. 12D shows a schematic of a cooling apparatus having a
three-way valve at a junction between a primary cooling loop and a
bypass, the primary cooling loop including a reservoir, a pump, and
a heat sink module on a heat source, and the bypass including a
heat exchanger.
[0059] FIG. 12E shows a schematic of a cooling apparatus including
a bypass and a primary cooling loop, the bypass including a heat
exchanger and a valve, and the primary cooling loop including a
reservoir, a pump, and a heat sink module with an internal bypass
containing a valve.
[0060] FIG. 12F shows a schematic of a cooling apparatus having a
primary cooling loop and a bypass, the primary cooling loop
including a reservoir, pump, and heat sink module, and the bypass
including a valve.
[0061] FIG. 12G shows a schematic of a cooling apparatus with a
primary cooling loop including a reservoir, a pump, and a heat sink
module with an internal bypass containing a valve.
[0062] FIG. 12H shows a schematic of a cooling apparatus including
a pump, a reservoir, and a heat sink module that is configured to
mount on a heat source or be mounted in thermal communication with
a heat source.
[0063] FIG. 12I shows a schematic of a cooling apparatus including
a pump, such as a variable speed pump, and a heat sink module
configured to mount on a heat source or be mounted in thermal
communication with a heat source.
[0064] FIG. 12J shows a schematic of a cooling apparatus with a
primary cooling loop, a first bypass, and a second bypass, where
the primary cooling loop includes a first pump, a reservoir, and a
heat sink module mounted on a heat source, the first bypass
including a second pump and a heat exchanger, and the second bypass
including a valve.
[0065] FIG. 12K shows a schematic of a cooling apparatus with a
primary cooling loop, a first bypass, and a second bypass, where
the primary cooling loop includes a first pump, a reservoir, and a
heat sink module mounted on a heat source, the first bypass
includes a valve and a heat exchanger, and the second bypass
includes a second pump.
[0066] FIG. 12L shows a schematic of a cooling apparatus with a
primary cooling loop, a first bypass, and a second bypass, where
the primary cooling loop includes a first pump, a reservoir, and a
heat sink module mounted on a heat source, the first bypass
including a second pump and a heat exchanger, and the second bypass
including a third pump.
[0067] FIG. 12M shows a schematic of a cooling apparatus with a
primary cooling loop, a first bypass, and a second bypass, where
the primary cooling loop includes a reservoir, a pump, and a heat
sink module mounted on a heat source, the first bypass includes a
first heat exchanger and a first valve, and the second bypass
includes a second heat exchanger and a second valve.
[0068] FIG. 12N shows a schematic of a cooling apparatus having a
primary cooling loop, a first bypass, and a second bypass, where
the primary cooling loop includes a reservoir, a pump, and heat
sink module mounted on a heat, source, the first bypass includes
first valve and a heat exchanger, the second bypass includes a
second vale, and the first bypass and second bypass merge upstream
of the reservoir.
[0069] FIG. 12O shows a schematic of a cooling apparatus having a
primary cooling loop, a first bypass, and a second bypass, where
the primary cooling loop includes a reservoir, a pump, and a heat
sink module mounted on a heat source, the first bypass includes a
first valve and a heat exchanger, and the second bypass includes a
second valve, where the first bypass and second bypass merge
upstream of the heat exchanger in the first bypass.
[0070] FIG. 12P shows a schematic of a cooling apparatus having a
primary cooling loop, a first bypass, and a second bypass, where
the primary cooling loop includes a reservoir, redundant parallel
pumps with shut-off valves, and a heat sink module mounted on a
heat source, the second bypass includes a valve, and the first
bypass includes a heat exchanger that can be a dry cooler.
[0071] FIG. 12Q shows a schematic of a cooling apparatus having a
primary cooling loop, a first bypass, and a second bypass, where
the primary cooling loop includes a reservoir, redundant parallel
pumps with shut-off valves, and a heat sink module mounted on a
heat source, and the first bypass includes a heat exchanger that
can be a dry cooler.
[0072] FIG. 12R shows a schematic of a preferred cooling apparatus
having a primary cooling loop, a first bypass, and a second bypass,
where the first bypass includes a liquid-to-liquid heat exchanger
fluidly connected to an external heat exchanger located outside of
a room where the cooling apparatus is located, the external heat
exchanger being connected to the heat exchanger by an external heat
rejection loop having a pump configured to circulate external
cooling fluid, such as a water-glycol mixture, through the external
heat rejection loop.
[0073] FIG. 12S shows a schematic of a cooling apparatus having a
primary cooling loop, a first bypass, and a second bypass, where
the first bypass includes a first heat exchanger, and where the
primary cooling loop includes two series-connected heat sink
modules with a second heat exchanger fluidly connected between the
heat sink modules to reduce quality of the flow to avoid formation
of slug flow in the primary cooling loop between the
series-connected heat sink modules.
[0074] FIG. 12T shows a schematic of a cooling apparatus configured
to cool two racks of servers, the cooling apparatus including an
inlet manifold and an outlet manifold for each rack of servers,
where a plurality of heat sink modules are fluidly connected in
series and parallel arrangements between each inlet and outlet
manifold to cool processors within the servers.
[0075] FIG. 13 shows a schematic of a cooling apparatus including a
filter located between a reservoir and a pump in a primary cooling
loop.
[0076] FIG. 14A shows a schematic of a cooling apparatus having a
primary cooling loop, a first bypass, and a second bypass, the
primary cooling loop including a reservoir, a pump, and three
series-connected heat sink modules, the first bypass including a
first valve and a heat exchanger, and the second bypass including a
second valve.
[0077] FIG. 14B shows a representation of coolant flowing through
three heat sink modules connected in series by lengths of flexible
tubing, similar to the configurations shown in FIGS. 14A and 15,
and shows corresponding plots of saturation temperature, liquid
coolant temperature, pressure, and quality (x) versus distance,
where quality increases, pressure decreases, liquid coolant
temperature decreases, and T.sub.sat decreases through the second
and third series-connected heat sink modules.
[0078] FIG. 14C shows a representation of coolant flowing through
three heat sink modules connected in series by lengths of flexible
tubing, similar to FIG. 14B, except that the coolant does not reach
its saturation temperature until the second heat sink module and is
therefore liquid coolant until it transitions to two-phase bubbly
flow within the second heat sink module.
[0079] FIG. 15 shows a portion of a primary cooling loop of a
cooling apparatus, where the cooling loop includes three
series-connected heat sink modules mounted on three surfaces to be
cooled and connected by sections of flexible, low-pressure tubing
where a single-phase liquid coolant is provided to a first heat
sink module, and due to heat transfer within the first module,
two-phase bubbly flow is transported from the first module to the
second module, and due to heat transfer within the second module,
higher quality two-phase bubbly flow is transported from the second
module to the third module, and due to heat transfer within the
third module, even higher quality two-phase bubbly flow is
transported out of the third module.
[0080] FIG. 16 shows a schematic of a cooling apparatus having a
primary cooling loop, a first bypass, and a second bypass, where
the primary cooling line includes a reservoir, a pump, and three
parallel cooling lines each having three series-connected heat sink
modules, the first bypass including a first valve and a heat
exchanger, and the second bypass including a second valve.
[0081] FIG. 17 shows a schematic of a redundant cooling apparatus
having a redundant heat sink module mounted on a surface to be
cooled, the redundant heat sink module having a first independent
coolant pathway fluidly connected to a first independent cooling
system similar to the cooling system shown in FIG. 11A and a second
independent coolant pathway fluidly connected to a second
independent cooling system similar to the cooling system shown in
11A.
[0082] FIG. 18 shows a schematic of a redundant cooling apparatus
having a first independent cooling apparatus and a second
independent cooling apparatus, where each of the independent
cooling apparatuses has two parallel cooling lines each fluidly
connected to three series-connected redundant heat sink modules,
where each redundant heat sink module has a first independent
coolant pathway fluidly connected to the first independent cooling
apparatus and a second independent coolant pathway fluidly
connected to the second independent cooling apparatus.
[0083] FIG. 19 shows a top view of a redundant cooling apparatus
installed in a data center having twenty racks of servers, the
redundant cooling system having a first independent cooling
apparatus and a second independent cooling apparatus, both
connected to heat exchangers located inside of the room where the
servers are located, the fluid distribution tubing of the first
independent cooling apparatus depicted with dashed lines and the
fluid distribution tubing of the second independent cooling
apparatus depicted with solid lines.
[0084] FIG. 20 shows a top view of a redundant cooling apparatus
installed in a data center having twenty racks of servers, the
redundant cooling system having a first independent cooling
apparatus and a second independent cooling apparatus, both
connected to heat exchangers located outside of the room where the
data center is located, the fluid distribution tubing of the first
independent cooling apparatus depicted with dashed lines and the
fluid distribution tubing of the second independent cooling
apparatus depicted with solid lines.
[0085] FIG. 21 shows a top perspective view of a compact heat sink
module for cooling a heat source, the heat sink module having an
inlet port and an outlet port.
[0086] FIG. 22 shows a top view of a heat sink module in FIG. 21,
the heat sink module further including a first compression fitting
installed on an inlet port of the heat sink module, a second
compression fitting installed on an outlet port of the heat sink
module, and a plurality of fasteners arranged near a perimeter of
the heat sink module according to a mounting hole pattern for
affixing the heat sink module to a heat-providing surface.
[0087] FIG. 23 shows a bottom perspective view of the heat sink
module of FIG. 21 showing an inlet port, outlet port, outlet
chamber, mounting holes, dividing member, and a plurality of
orifices in the dividing member, as well as a sealing member
installed within a continuous channel circumscribing the outlet
chamber of the heat sink module.
[0088] FIG. 24 shows a bottom view of the heat sink module of FIG.
21 showing an array of orifices having staggered columns and
staggered rows to prevent flow stagnation regions on a surface to
be cooled.
[0089] FIG. 25 shows a side cross-sectional view of the heat sink
module of FIG. 24 taken along section B-B and showing an inlet
port, an inlet passage, an inlet chamber, a plurality of orifices,
a dividing member, and an outlet chamber within the heat sink
module.
[0090] FIG. 26 shows a side cross-sectional view of the heat sink
module of FIG. 24 taken along section B-B with the heat sink module
mounted on a thermally conductive base member and showing central
axes of several orifices, jet heights, and bubble formation within
the outlet chamber proximate the surface to be cooled of the
thermally conductive base member where a portion of the liquid
coolant changes to vapor.
[0091] FIG. 27 shows a side cross-sectional view of the heat sink
module of FIG. 24 taken along section B-B with the heat sink module
mounted directly on a computer processor located on a circuit board
and showing central axes of several orifices, the heat sink module
capable of mounting directly on a lid of a processor and providing
impinging jet streams of coolant against the lid or mounting
directly on a processor without a lid and providing
direct-to-silicon cooling where jet streams of coolant impinge a
silicon surface of the processor.
[0092] FIG. 28 shows a side cross-sectional view of the heat sink
module of FIG. 24 taken along section B-B with the heat sink module
mounted on a thermally conductive base member that is bonded to a
processor by a layer of thermal interface material, the
microprocessor being electrically connected to a motherboard.
[0093] FIG. 29 shows a side cross-sectional view of the heat sink
module of FIG. 24 taken along section A-A and showing an outlet
port, an outlet passage, an outlet chamber, a dividing member, and
a plurality of orifices within the heat sink module.
[0094] FIG. 30 shows a side cross-sectional view of the heat sink
module of FIG. 24 taken along section A-A, with the heat sink
module mounted on a thermally conductive base member and sealed by
a sealing member, the figure showing bubbles forming within the
outlet chamber proximate a heated surface of the conductive base
member where a portion of the coolant changes from liquid phase to
vapor phase upon interacting with the heated surface thereby
forming two-phase bubbly flow, which exits the heat sink module
through the outlet port.
[0095] FIG. 31 shows a cross-sectional top view of the heat sink
module of FIG. 21 taken along section C-C shown in FIG. 25, the
cross-section passing horizontally through the dividing member of
the heat sink module to expose an array of orifices within the heat
sink module, the orifices in the array being arranged according to
staggered columns and staggered rows to prevent flow stagnation
regions on a surface to be cooled.
[0096] FIG. 32 shows a top view of a surface to be cooled within an
outlet chamber of a heat sink module of FIG. 21 taken along section
D-D shown in FIG. 30, where an array of jet streams originating
from the array of orifices in the heat sink module are impinging
non-perpendicularly on the surface to be cooled, thereby creating a
directional flow of coolant from left to right across the surface
to be cooled, the directional flow filling the outlet chamber and
traveling toward and exiting from an outlet port of the heat sink
module.
[0097] FIG. 33 shows a bottom view of a heat sink module having a
first plurality of orifices and a second plurality of orifices, the
second plurality of orifices being configured to deliver a
plurality of anti-pooling jet streams into the outlet chamber to
promote directional flow within the outlet chamber and to prevent
pooling on the surface to be cooled near a rear wall of the outlet
chamber.
[0098] FIG. 34 shows a side cross-sectional view of the heat sink
module of FIG. 33 taken along section B-B, the side view showing an
inlet port, an inlet passage, an inlet chamber, a plurality of
orifices, an outlet chamber, and an anti-pooling orifice within the
heat sink module.
[0099] FIG. 35 shows a detailed view of a portion of the heat sink
module of FIG. 34 highlighting an orifice with length (L), diameter
(D), and jet height and highlighting the anti-pooling orifice that
extends from the inlet chamber to a rear wall of the outlet chamber
and is configured to deliver an anti-pooling jet stream proximate a
rear wall of the outlet chamber to prevent pooling on the surface
to be cooled.
[0100] FIG. 36 shows a side cross-sectional view of the heat sink
module of FIG. 33 taken along section B-B, with the heat sink
module sealed against a thermally conductive base member and
showing central axes of a plurality of orifices and an anti-pooling
orifice located near a rear wall of the outlet chamber.
[0101] FIG. 37 shows a side cross-sectional view of the heat sink
module of FIG. 33 taken along section A-A and showing an outlet
port, an outlet passage, an inlet chamber, an outlet chamber, a
plurality of orifices, and an anti-pooling orifice.
[0102] FIG. 38 shows a side cross-sectional view of the heat sink
module of FIG. 33 taken along section A-A, with the heat sink
module sealed against a thermally conductive base member, the
figure showing coolant being introduced to an outlet chamber as a
plurality of jet streams of coolant, a portion of liquid coolant
changing phase upon absorbing heat from the surface to be cooled
thereby forming a directional flow of two-phase bubbly flow that
exits the heat sink module through an outlet port.
[0103] FIG. 39 shows a top view of a heat sink module of FIG.
33.
[0104] FIG. 40 shows a side cross-sectional view of the heat sink
module of FIG. 39 taken along section B-B and showing the location
of section C-C passing through an inlet chamber and the location of
section D-D passing through an outlet chamber.
[0105] FIG. 41 shows a front view of the heat sink module of FIG.
33 showing an upwardly angled inlet port and an upwardly angle
outlet port.
[0106] FIG. 42 shows a left side view of the heat sink module of
FIG. 33 showing an outlet port and an inlet port arranged at an
angle of .alpha. with respect to a mounting surface of the heat
sink module, the angle configured to permit ease of assembly within
a crowded server housing or other constrained installation.
[0107] FIG. 43 shows a top cross-sectional view of the heat sink
module of FIG. 39 taken along section C-C shown in FIG. 42, the top
view showing the inlet port, inlet passage, inlet chamber, top
surface of the dividing member, and inlets of the plurality of
orifices and plurality of anti-pooling orifices.
[0108] FIG. 44 shows a cross-sectional bottom view of the heat sink
module of FIG. 39 taken along section D-D shown in FIG. 42, the
bottom view showing the outlet port, outlet passage, outlet
chamber, bottom surface of the dividing member, and outlets of the
plurality of orifices and plurality of anti-pooling orifices.
[0109] FIG. 45 shows a bottom view of a heat sink module having a
plurality of boiling-inducing members extending from the dividing
member into the outlet chamber.
[0110] FIG. 46 shows a side cross-sectional view of the heat sink
module of FIG. 45 taken along section B-B, the side view showing an
inlet port, an inlet passage, an inlet chamber, a plurality of
orifices, a dividing member, and a plurality of boiling-inducing
members extending from the dividing member into the outlet
chamber.
[0111] FIG. 47 shows a side cross-sectional view of the heat sink
module of FIG. 45 taken along section B-B with the heat sink module
mounted on a thermally conductive base member and showing central
axes of the plurality of orifices.
[0112] FIG. 48 shows a detailed view of a portion of the heat sink
module shown in FIG. 46, the detailed view showing three boiling
inducing members extending from a bottom surface of the dividing
member into the outlet chamber and an orifice extending from the
inlet chamber to the outlet chamber, a flow clearance being
provided between a tip of each boiling-inducing member and a
surface to be cooled.
[0113] FIG. 49 shows a side cross-sectional view of the heat sink
module of FIG. 45 taken along section A-A, the side view showing an
outlet port, an outlet passage, an inlet chamber, an outlet
chamber, a plurality of orifices, an anti-pooling orifice, a
plurality of boiling-inducing members, and a dividing member.
[0114] FIG. 50 shows a side cross-sectional view of the heat sink
module of FIG. 45 taken along section A-A, the heat sink module
being mounted on a thermally conductive base member, the figure
showing central axes of the plurality of orifices and an
anti-pooling orifice.
[0115] FIG. 51A shows a top perspective view of a redundant heat
sink module having a first independent coolant pathway and a second
independent coolant pathway.
[0116] FIG. 51B shows a top view of the redundant heat sink module
of FIG. 51A, where the first independent coolant pathway and the
second independent coolant pathway are represented by dashed lines,
where the first independent coolant pathway passes through a first
region near a middle of the module, and where the second
independent coolant pathway passes through a second region beyond a
perimeter of the first region.
[0117] FIG. 51C shows a top view of the redundant heat sink module
of FIG. 51A with compression fittings installed on the inlet and
outlet ports.
[0118] FIG. 51D shows a bottom view of the redundant heat sink
module of FIG. 51A, where the first independent coolant pathway
includes an array of orifices arranged in a first region located
near a middle of the heat sink module, and where the second
independent coolant pathway includes an array of orifices arranged
in a second region circumscribing the first region, and where a
first sealing member is configured to provide a liquid-tight seal
between the first and second independent coolant pathways.
[0119] FIG. 51E shows a top view of the heat sink module of FIG.
51A.
[0120] FIG. 51F shows a cross-sectional side view of the redundant
heat sink module of FIG. 51A taken along section A-A shown in FIG.
51E, the figure showing a first inlet port, a first inlet passage,
a first inlet chamber, a first outlet chamber, a first plurality of
orifices, a portion of a second outlet chamber, and a second outlet
port.
[0121] FIG. 51G shows a side cross-sectional side view of the
redundant heat sink module of FIG. 51A taken along section B-B
shown in FIG. 51E, the figure showing a second inlet port, a second
inlet passage, one orifice of a second plurality of orifices, a
first plurality of orifices, one anti-pooling orifice of a first
plurality of anti-pooling orifices, a first outlet chamber, a
portion of a second outlet chamber, and a first outlet port.
[0122] FIG. 51H shows a side view of the redundant heat sink module
of FIG. 51A showing upwardly angled ports configured to ease
installation in a crowded server housing or other constrained
installation.
[0123] FIG. 51I shows a cross-sectional rear view of the redundant
heat sink module of FIG. 51A taken along section C-C shown in FIG.
51H, the figure showing a first inlet chamber, a first outlet
chamber, and a first plurality of orifices associated with a first
independent coolant pathway and a second inlet chamber, a second
outlet chamber, and a second plurality of orifices associated with
a second independent coolant pathway.
[0124] FIG. 51J shows a top view of the redundant heat sink module
of FIG. 51A.
[0125] FIG. 51K shows a side cross-sectional view of the redundant
heat sink module of FIG. 51A taken along section D-D shown in FIG.
51J, the figure showing a significant portion of the first
independent coolant pathway.
[0126] FIG. 51L shows a top view of the redundant heat sink module
of FIG. 51A.
[0127] FIG. 51M shows a side cross-section view of the redundant
heat sink module of FIG. 51A taken along section E-E of FIG. 51L,
the figure showing a significant portion of the second independent
coolant pathway.
[0128] FIG. 51N is a top view of the redundant heat sink module of
FIG. 51A and shows flow vectors in a first independent coolant
pathway and flow vectors in a second independent coolant
pathway.
[0129] FIG. 51O is a top view of the redundant heat sink module of
FIG. 51A and shows a first independent coolant pathway having a
first inlet port and a first outlet port and a second independent
coolant pathway having a second inlet port and a second outlet
port, where coolant enters the first inlet port as liquid flow and
exits the first outlet port as two-phase bubbly flow, and where
coolant enters the second inlet port as liquid flow and exits the
second outlet port as two-phase bubbly flow.
[0130] FIG. 51P is a top view of the redundant heat sink module of
FIG. 51A and shows a first coolant pathway having a first inlet
port and a first outlet port and a second coolant pathway having a
second inlet port and a second outlet port, where coolant enters
the first inlet port as liquid flow and exits the first outlet port
as liquid flow, and where coolant enters the second inlet port as
liquid flow and exits the second outlet port as two-phase bubbly
flow.
[0131] FIG. 51Q is a top view of the redundant heat sink module of
FIG. 51A and shows a first coolant pathway having a first inlet
port and a first outlet port and a second coolant pathway having a
second inlet port and a second outlet port, where coolant enters
the first inlet port as liquid flow and exits the first outlet port
as two-phase bubbly flow, and where coolant enters the second inlet
port as liquid flow and exits the second outlet port as liquid
flow.
[0132] FIG. 52A shows two redundant heat sink modules mounted on a
thermally conductive base member, where two sink modules are
provided for redundancy and/or increased heat transfer
capability.
[0133] FIG. 52B shows two heat sink modules mounted on a thermally
conductive base member, where two sink modules are provided for
redundancy and/or increased heat transfer capability.
[0134] FIG. 53 shows a top perspective view of a redundant heat
sink module having side-by-side independent coolant pathways.
[0135] FIG. 54 shows a bottom perspective view of a redundant heat
sink module mounted to a planar, thermally conductive base member
with fasteners.
[0136] FIG. 55 shows a top perspective view of a thermally
conductive base member having a surface to be cooled and an array
of boiling-inducing members extending from the surface to be
cooled, the array of boiling-inducing members configured to fit
within an inner perimeter of an outlet chamber of a heat sink
module when the heat sink module is mounted on the thermally
conductive base member.
[0137] FIG. 56 shows a top perspective view of a motherboard of a
server including microprocessors and a plurality of vertically
arranged memory modules that are parallel and offset, where a heat
sink module can be mounted on top of each microprocessor.
[0138] FIG. 57 shows a top perspective view of a server including a
plurality of vertically arranged memory modules that are parallel
and offset.
[0139] FIG. 58 shows two-phase flow regimes, including (a) bubbly
flow with a first number density of bubbles, (b) bubbly flow with a
second number density of bubbles that is greater than the first
number density of bubbles, (c) slug flow, (d) churn flow, and (e)
annular flow.
[0140] FIG. 59A shows a flow regime map for a steam-water system
with .rho..sub.liquid*j.sub.liquid.sup.2 on the x-axis and
.rho..sub.vapor*j.sub.vapor.sup.2 on the y-axis.
[0141] FIG. 59B shows two-phase flow regimes for coolant plotted on
void fraction versus mass flux axes.
[0142] FIG. 60 shows a flow boiling curve for water where heat
transfer rate is plotted as a function of excess temperature.
[0143] FIG. 61 shows a boiling curve for water at one atmosphere
and shows an onset of nucleate boiling, an inflection point, the
point of critical heat flux, and the Leidenfrost point.
[0144] FIG. 62 shows possible orifice configurations for a heat
sink module, including (a) a regular rectangular jet array, (b) a
regular hexagonal jet array with staggered columns and staggered
rows, and (c) a circular jet array.
[0145] FIG. 63 shows a top view of a heated surface covered by
coolant, the coolant having regions of vapor coolant and wetted
regions of liquid coolant in contact with the heated surface, where
a three-phase contact line length is measured as a sum of all
curves where liquid coolant, vapor coolant, and the heated surface
are in mutual contact on the heated surface.
[0146] FIG. 64 shows a plot of power consumption versus junction
temperature for a processor at a static condition and at dynamic
conditions with switching speeds of 1.6 GHz and 2.4 GHz.
[0147] FIG. 65 shows a heat sink module with an insertable orifice
plate installed within a module body, where a sealing member is
provided between the insertable orifice plate and the module
body.
[0148] FIG. 66 shows a side cross-sectional view of a motherboard
having a first microprocessor, a second microprocessor, a first
finned heat sink arranged on top of the first microprocessor, a
second finned heat sink arranged on top of the second
microprocessor, and a cooling apparatus, where the cooling
apparatus includes a heat sink module mounted on a thermally
conductive member that extends from the first finned heat sink to
the second heat sink module.
[0149] FIG. 67 shows a side cross-sectional view of a motherboard
having a first microprocessor, a second microprocessor, and a
cooling system, where the cooling system includes a heat sink
module mounted on a thermally conductive member that extends from
the first microprocessor to the second microprocessor.
[0150] FIG. 68 shows a schematic of a preferred cooling apparatus
having a primary cooling loop, a bypass, and a heat rejection loop,
where the primary cooling loop includes a reservoir, a pump, and a
heat sink module, the bypass includes a valve, and the heat
rejection loop includes a pump and a heat exchanger connected to
the reservoir.
[0151] FIG. 69 shows a schematic of a redundant cooling apparatus
having a first cooling apparatus, a second cooling apparatus, and a
heat rejection loop having a pump and a heat exchanger, where the
first cooling apparatus, the second cooling apparatus, and the heat
rejection loop are fluidly connected to a common reservoir.
[0152] FIG. 70 shows a schematic of a redundant cooling apparatus
having a redundant heat sink module mounted on a heat source, the
redundant heat sink module having a first independent fluid pathway
fluidly connected to a first cooling apparatus and a second
independent fluid pathway fluidly connected to a second cooling
apparatus, the first and second cooling apparatuses sharing a
common reservoir but having independent heat exchangers.
[0153] FIG. 71 shows a schematic of a cooling apparatus having a
primary cooling loop and a bypass, where the primary cooling loop
includes a pump, a heat exchanger, a heat sink module mounted on a
heat source, and a reservoir, and the bypass includes a valve
configured to control a pressure differential between an inlet port
and an outlet port of the heat sink module.
[0154] FIG. 72 shows a schematic of a cooling apparatus having a
primary cooling loop and a bypass, where the primary cooling loop
includes redundant, parallel pumps with check valves, a reservoir,
a heat exchanger, a heat sink module mounted on a heat source, and
the bypass includes a valve configured to control a pressure
differential between an inlet port and an outlet port of the heat
sink module.
[0155] FIG. 73 shows a cross-sectional view of a first heat sink
module fluidly connected to a second heat sink module by a section
of flexible tubing, where single-phase flow delivered to an inlet
chamber of the first heat sink module becomes two-phase bubbly flow
within an outlet chamber of the first heat sink module due to heat
being transferred from a first surface to be cooled to the flow,
where flexible tubing transports the two-phase bubbly flow from an
outlet port of the first heat sink module to an inlet port of a
second heat sink module, where the two-phase bubbly flow is
delivered to an inlet chamber of the second heat sink module and
passes as a plurality of jet streams through a plurality of
orifices within the second heat sink module, the jet streams
configured to impinge against a second surface to be cooled and
absorb heat from the second surface to be cooled.
[0156] FIG. 74 shows a portable cooling device that includes a
plurality of heat sink modules mounted on a portable layer, the
portable layer being conformable to a contoured heated surface or
rigid and including one or more inlet connections and one or more
outlet connections that can be connected to a cooling apparatus
that delivers a flow of pressurized coolant to the portable cooling
device to permit cooling of the heated surface through latent
heating of the coolant within the plurality of heat sink
modules.
[0157] FIG. 75 shows a schematic of a preferred cooling apparatus
having a primary cooling loop, a first bypass, and a second bypass,
where the first bypass includes a liquid-to-liquid heat exchanger
fluidly connected to an external heat exchanger located outside of
a room where the cooling apparatus is located, the external heat
exchanger being connected to the heat exchanger by an external heat
rejection loop having a pump configured to circulate external
cooling fluid, such as a water-glycol mixture, through the external
heat rejection loop, the external heat exchanger being an
air-to-liquid heat exchanger.
[0158] FIG. 76 shows a schematic of a cooling apparatus having a
primary cooling loop, a first bypass, and a second bypass, where
the first bypass includes a liquid-to-liquid heat exchanger fluidly
connected to a heat rejection loop, the heat rejection loop being a
supply of chilled water from a building in which the cooling
apparatus is installed.
[0159] FIG. 77 shows a schematic of a preferred cooling apparatus
having a primary cooling loop, a first bypass, and a second bypass,
where the first bypass includes a liquid-to-liquid heat exchanger
fluidly connected to an external heat exchanger located outside of
a room where the cooling apparatus is located, the external heat
exchanger being connected to the heat exchanger by an external heat
rejection loop having a pump configured to circulate external
cooling fluid, such as a water-glycol mixture, through the external
heat rejection loop, the external heat exchanger being an
liquid-to-liquid heat exchanger being connected to a supply of
chilled water from a building in which the cooling apparatus is
installed.
[0160] FIG. 78 shows a schematic of a cooling apparatus that is
configured to allow cooling lines to be added or removed
(hot-swapped) during operation of the cooling apparatus without
causing unstable two-phase flow in the cooling apparatus.
[0161] FIG. 79 shows a schematic of a cooling apparatus having an
inlet manifold, an outlet manifold, a valve fluidly connected
between the inlet manifold and the outlet manifold, and thirty
cooling lines extending from the inlet manifold to the outlet
manifold.
[0162] FIG. 80 shows a schematic of a cooling apparatus having a
first inlet manifold, a first outlet manifold, and a first set of
thirty cooling lines associated with a first server rack, the
cooling apparatus also having a second inlet manifold, a second
outlet manifold, and a second set of thirty cooling lines
associated with a second server rack, where a fluid distribution
unit provides a flow of coolant to the first and second inlet
manifolds, the fluid distribution unit including a pump and a
reservoir.
[0163] FIG. 81 shows a representation of a preferred cooling
apparatus having a flow of single-phase liquid coolant being pumped
from a pump outlet, a flow of subcooled single-phase liquid coolant
passing through a first bypass containing a heat exchanger and a
first valve, a flow of single-phase liquid coolant passing through
a second bypass containing a second valve, a flow of single-phase
liquid coolant passing through a cooling line into a heat sink
module and exiting the heat sink module as two-phase bubbly flow
due to heat transfer from a heat-providing surface to the coolant,
a mixed flow of single-phase liquid coolant and two-phase bubbly
flow passing through a return line to a reservoir, where vapor in
the two-phase bubbly flow is condensed back to liquid in the return
line due to heat transfer from the two-phase bubbly flow to the
single-phase liquid coolant resulting in sensible heating of the
single-phase liquid coolant.
[0164] FIG. 82 shows a representation of a cooling apparatus having
a flow of single-phase liquid coolant being withdrawn from a
reservoir and pumped from a pump outlet, a flow of single-phase
liquid coolant passing through a bypass containing a valve, a flow
of single-phase liquid coolant passing through a cooling line into
a heat sink module and exiting the heat sink module as two-phase
bubbly flow due to heat transfer from a heat-providing surface to
the coolant, a mixed flow of single-phase liquid coolant and
two-phase bubbly flow passing through a return line to the
reservoir, where vapor in the two-phase bubbly flow is condensed
back to liquid in the return line and in the reservoir due to heat
transfer from the two-phase bubbly flow to subcooled liquid coolant
in the reservoir.
[0165] FIG. 83 shows a representation of a cooling apparatus having
a flow of single-phase liquid coolant being withdrawn from a
reservoir pumped from a pump outlet, a flow of subcooled
single-phase liquid coolant passing through a bypass containing a
heat exchanger and a first valve, a flow of single-phase liquid
coolant passing through a cooling line into a heat sink module and
exiting the heat sink module as two-phase bubbly flow due to heat
transfer from a heat-providing surface to the coolant, mixing of
the two-phase bubbly flow and the flow of subcooled single-phase
liquid coolant in the reservoir, where vapor in the two-phase
bubbly flow is condensed back to liquid in the reservoir due to
heat transfer from the two-phase bubbly flow to the subcooled
single-phase liquid coolant.
[0166] FIG. 84 shows a top perspective view of two series-connected
heat sink modules installed on top of microprocessors within a
server housing, each heat sink module held in place by a mounting
bracket secured to mounting holes in the motherboard using threaded
fasteners, the heat sink modules being fluidly connected with
flexible tubing.
[0167] FIG. 85 shows a top view of a heat sink module mounted on a
microprocessor in a server, the heat sink module being secured to a
motherboard of the server by an S-shaped bracket that permits
variable positioning of the heat sink module on a top surface of
the microprocessor for ease of routing sections of flexible tubing
that transport coolant to and from the heat sink module.
[0168] FIG. 86 shows a top perspective view of a heat sink module
mounted on top of a microprocessor of a motherboard with an
S-shaped bracket prior to installation of flexible cooling lines to
and from an inlet port and an outlet port, respectively, of the
heat sink module.
[0169] FIG. 87 shows a top view of the motherboard of FIG. 86.
[0170] FIG. 88 shows an enlarged top perspective view of the
motherboard of FIG. 86 showing the heat sink module mounted on top
of the microprocessor.
[0171] FIG. 89 shows an enlarged top view of the motherboard of
FIG. 86 showing the heat sink module mounted on top of the
processor.
[0172] FIG. 90 shows a top view of a heat sink module mounted on a
thermally conductive base member with an S-shaped mounting bracket
with slotted mounting holes.
[0173] FIG. 91 shows a top view of a heat sink module with an
S-shaped mounting bracket with slotted mounting holes.
[0174] FIG. 92 shows a front perspective view of a fluid
distribution unit of a cooling apparatus, the fluid distribution
unit having redundant pumps with automatic failover circuitry, a
reservoir, and a bypass with a valve and a heat exchanger, the heat
exchanger configured to connect to an external heat rejection
loop.
[0175] FIG. 93 shows a right side view of the fluid distribution
unit of FIG. 92.
[0176] FIG. 94 shows a front view of the fluid distribution unit of
FIG. 92.
[0177] FIG. 95 shows an exploded view of the fluid distribution
unit of FIG. 92.
[0178] FIG. 96 shows an exploded view of the pump and shut-off
valves of the fluid distribution unit of FIG. 92.
[0179] FIG. 97 shows the heat exchanger from the fluid distribution
unit of FIG. 92, the heat exchanger having a first isolated fluid
pathway for transporting a dielectric coolant from a first bypass
of the cooling apparatus and a second isolated fluid pathway for
transporting a glycol-water mixture from an external heat rejection
loop, the first and second isolated fluid pathways being in thermal
communication within the heat exchanger.
[0180] FIG. 98 shows a top perspective view of two series-connected
heat sink modules installed on top of operating processors within a
server, where subcooled single-phase liquid coolant is delivered to
a first heat sink module wherein it absorbs sensible heat causing
the temperature of the coolant to rise, and where the single-phase
liquid coolant is then transported from the first module to the
second heat sink module where it absorbs additional sensible heat
unit it reaches its saturation temperature and thereafter absorbs
latent heat resulting in formation of two-phase bubbly flow that
can be transported out of the server.
[0181] FIG. 99 shows a top perspective view of two series-connected
heat sink modules installed on top of operating processors within a
server, where single-phase liquid coolant is delivered to the first
heat sink module where it absorbs sensible heat until it reaches
its saturation temperature and thereafter absorbs latent heat
resulting in formation of two-phase bubbly flow having a first
quality, and where the two-phase bubbly flow having a first quality
is then transported to a second heat sink module where it absorbs
additional latent heat resulting in additional bubble formation,
thereby changing the two-phase bubbly flow to a second quality
greater than the first quality.
[0182] FIG. 100 shows a front perspective view of a manifold
assembly for use with a cooling apparatus, the manifold assembling
including an inlet chamber, an outlet chamber, thirty quick-connect
fittings fluidly connected to the inlet chamber, thirty
quick-connect fittings fluidly connected to the outlet chamber, a
bypass fluidly connecting the inlet chamber to the outlet chamber,
and a valve disposed in the bypass.
[0183] FIG. 101 shows a left side view of the manifold assembly of
FIG. 100.
[0184] FIG. 102 shows the manifold assembly of FIG. 100 mounted to
a server rack with two mounting brackets.
[0185] FIG. 103 shows a rear view of a manifold assembly with a
valve, where fluid passageways are depicted with dashed lines.
[0186] FIG. 104 shows a rear view of a manifold assembly having a
valve and separate inlet and outlet manifolds, where fluid
passageways are depicted with dashed lines.
[0187] FIG. 105 shows a rear view of a manifold assembly including
an integrated valve in an internal bypass of a manifold, where
fluid passageways are depicted with dashed lines.
[0188] FIG. 106 shows a front perspective view of a manifold
assembly for use with a cooling apparatus, the manifold assembling
including an inlet chamber, an outlet chamber, seven quick-connect
fittings fluidly connected to the inlet chamber, seven
quick-connect fittings fluidly connected to the outlet chamber, a
bypass fluidly connecting the inlet chamber to the outlet chamber,
and a valve disposed in the bypass.
[0189] FIG. 107 shows a quick connect fitting having a barbed end
and a coupler body configured to receive a coupler insert.
[0190] FIG. 108 shows a quick connect fitting having a threaded end
and a coupler insert configured to mate with the coupler body shown
in FIG. 107.
[0191] FIG. 109 shows a quick connect fitting having a threaded end
and a coupler body configured to receive a coupler insert.
[0192] FIG. 110 shows a quick connect fitting having a barbed end
and a coupler insert configured to mate with the coupler body shown
in FIG. 109, the coupler insert having an O-ring seal.
[0193] FIG. 111 shows front perspective view of a differential
pressure bypass valve.
[0194] FIG. 112 shows a front cross-sectional view of the
differential pressure bypass valve of FIG. 111 exposing a valve
inlet, a valve outlet, a bypass circuit fluidly connecting the
valve inlet to the valve outlet, a valve plug, a spring, and a
control knob.
[0195] FIG. 113 shows a quick-connect cooling line assembly for a
cooling apparatus, where the cooling line assembly include three
heat sink modules fluidly connected in series by sections of
flexible tubing, where an inlet section of tubing and an outlet
section of tubing each include a quick-connect fitting as shown in
FIG. 107 to allow the cooling line assembly to be rapidly connected
to and disconnected from the manifold assembly as shown in FIG. 100
or 106.
[0196] FIG. 114 shows a quick-connect cooling line assembly for a
cooling apparatus, where the cooling line assembly includes three
heat sink modules fluidly connected in series by sections of
flexible tubing, where an inlet section of tubing and an outlet
section of tubing each include a quick-connect fitting as shown in
FIG. 107 to allow the cooling line assembly to be rapidly connected
to and disconnected from a manifold assembly.
[0197] FIG. 115 shows a schematic of a cooling apparatus having a
primary cooling loop and a heat rejection loop, where the primary
cooling loop includes a first pump and a bypass, where the heat
rejection loop includes a second pump and a heat exchanger, where
the primary cooling loop and the heat rejection loop are both
fluidly connected to a common reservoir that resides in a fluid
distribution unit housed within a computer, such as a server or
personal computer.
[0198] FIG. 116 shows a portion of the cooling apparatus of FIG.
115 installed in a computer with two processors, where heat sink
modules are mounted on the processors and heat from the processors
is absorbed into a pumped coolant and rejected via a liquid-to-air
heat exchanger fluidly connected to the cooling apparatus.
[0199] FIG. 117 shows a schematic of a preferred cooling apparatus
having a primary cooling loop and a heat rejection loop, where the
primary cooling loop includes a first pump, a manifold, a bypass,
and a plurality of cooling line assemblies each routed through one
server, where the heat rejection loop includes a second pump and a
heat exchanger, where the primary cooling loop and the heat
rejection loop are both fluidly connected to a common reservoir
that resides in a fluid distribution unit housed within a server
rack.
[0200] FIG. 118 shows a top, front perspective view of a
rack-mountable fluid distribution unit, suitable for use with the
cooling apparatus of FIG. 117, the fluid distribution unit having a
primary cooling loop and a heat rejection loop, where the primary
cooling loop includes a first pump fluidly connected to a
reservoir, where the heat rejection loop includes a second pump and
a heat exchanger fluidly connected to the reservoir, and where the
pumps and the reservoir are mounted to a support structure.
[0201] FIG. 119 shows a top, rear perspective view of the fluid
distribution unit of FIG. 118.
[0202] FIG. 120 shows a right side view of the fluid distribution
unit of FIG. 118 without the support structure.
[0203] FIG. 121 shows a left side view of the fluid distribution
unit of FIG. 118 without the support structure.
[0204] FIG. 122 shows a top view of the fluid distribution unit of
FIG. 118 without the support structure.
[0205] FIG. 123 shows a bottom view of the fluid distribution unit
of FIG. 118 without the support structure.
[0206] FIG. 124 shows a front view of the fluid distribution unit
of FIG. 118 without the support structure.
[0207] FIG. 125 shows a left side perspective view of the fluid
distribution unit of FIG. 118 without the support structure.
[0208] FIG. 126 shows a fluid distribution unit having a primary
cooling loop and a heat rejection loop, the primary cooling loop
including a first pump and a manifold assembly of FIG. 105, the
heat rejection loop including a second pump upstream of a heat
exchanger.
[0209] FIG. 127 shows a fluid distribution unit having a primary
cooling loop and a heat rejection loop, the primary cooling loop
including a first pump and a manifold assembly of FIG. 105, the
heat rejection loop including a second pump downstream of a heat
exchanger.
[0210] FIG. 128 shows the fluid distribution unit of FIG. 118 being
installed into the server rack with manifold assembly of FIG.
102.
[0211] FIG. 129 shows a schematic of a cooling apparatus having a
primary cooling loop and a heat rejection loop, where the primary
cooling loop includes a first pump, a manifold, a bypass, and a
plurality of cooling line assemblies each routed through one or
more servers, where the heat rejection loop includes a second pump
and a heat exchanger, where the primary cooling loop and the heat
rejection loop are both fluidly connected to a common reservoir
that resides in a fluid distribution unit housed within a server
rack.
[0212] FIG. 130 shows a schematic of a cooling apparatus having a
primary cooling loop and a heat rejection loop, the primary cooling
loop including a first pump fluidly connected to a reservoir and
fluidly connected to one or more heat sink modules, the heat
rejection loop including a second pump fluidly connected to a heat
exchanger and the reservoir.
[0213] FIG. 131 shows a schematic of a modular cooling apparatus
having a primary cooling loop and a heat rejection loop, the
primary cooling loop including a first pump fluidly connected to a
reservoir and fluidly connected three modular cooling line
assemblies similar to the one shown in FIG. 132, the heat rejection
loop including a second pump and a heat exchanger fluidly connected
to the reservoir.
[0214] FIG. 132 shows a modular cooling line assembly including a
heat sink module with an inlet port and an outlet port, a first
section of flexible tubing having a first end connected to an inlet
fitting and a second end connected to the inlet port, and a second
section of flexible tubing having a first end connected to the
outlet port and a second end connected to an outlet fitting.
[0215] FIG. 133 shows a modular cooling line assembly including a
first heat sink module with an inlet port and an outlet port, a
first section of flexible tubing having a first end connected to an
inlet fitting and a second end connected to the inlet port of the
first heat sink module, a second heat sink module with an inlet
port and an outlet port, a second section of flexible tubing
connecting the outlet port of the first heat sink module to the
inlet port of the second heat sink module, and a third section of
flexible tubing having a first end connected to the outlet port of
the second heat sink module and a second end connected to an outlet
fitting.
[0216] FIG. 134 shows a schematic of a modular cooling apparatus
having a primary cooling loop and a heat rejection loop, the
primary cooling loop including a first pump fluidly connected to a
reservoir and fluidly connected to three series-connected modular
cooling line assemblies, the first modular cooling line assembly
having two heat sink modules, the second modular cooling line
assembly having two heat sink modules, and the third modular
cooling line assembly having four heat sink modules, the heat
rejection loop including a second pump and a heat exchanger fluidly
connected to the reservoir.
[0217] FIG. 135 shows a schematic of a modular cooling apparatus
having a primary cooling loop and a heat rejection loop, the
primary cooling loop including a first pair of redundant pumps
fluidly connected to a reservoir and fluidly connected to three
series-connected modular cooling line assemblies, the first modular
cooling line assembly having two heat sink modules, the second
modular cooling line assembly having two heat sink modules, and the
third modular cooling line assembly having four heat sink modules,
the heat rejection loop including a second pair of redundant pumps
and a heat exchanger fluidly connected to the reservoir.
[0218] FIG. 136 shows a schematic of a redundant cooling apparatus
having a first cooling apparatus and a second cooling apparatus,
the first cooling apparatus including a first primary cooling loop
and a first heat rejection loop, the first primary cooling loop
including a first pump fluidly connected to a first reservoir and
two series-connected redundant heat sink modules, the first heat
rejection loop including a second pump fluidly connected to a first
heat exchanger and the first reservoir, the second cooling
apparatus having a second cooling loop and a second heat rejection
loop, the second primary cooling loop including a third pump
fluidly connected to a second reservoir and the two
series-connected heat sink modules, the second heat rejection loop
including a fourth pump fluidly connected to a second heat
exchanger and the second reservoir.
[0219] FIG. 137 shows a schematic of a cooling apparatus having a
primary cooling loop and a heat rejection loop, the primary cooling
loop including a first pump fluidly connected to a reservoir and
fluidly connected to three series-connected heat sink modules and a
series-connected memory cooler, the heat rejection loop including a
second pump fluidly connected to a heat exchanger and the
reservoir.
[0220] FIG. 138 shows a schematic of a cooling apparatus having a
primary cooling loop and a heat rejection loop, the primary cooling
loop including a first pump fluidly connected to a reservoir and
fluidly connected to three series-connected heat sink modules and a
series-connected memory cooler, the heat rejection loop including a
second pump fluidly connected to a heat exchanger and the
reservoir.
[0221] FIG. 139 shows a cooling apparatus with a fluid distribution
unit having a primary cooling loop and a heat rejection loop, the
primary cooling loop including a first pump and the manifold
assembly of FIG. 105 fluidly connected to a reservoir, the heat
rejection loop including a second pump upstream of a heat exchanger
fluidly connected to the reservoir, the cooling apparatus including
a plurality of cooling line assemblies fluidly attached to the
manifold assembly, each cooling line assembly including sections of
flexible tubing fluidly connected to at least one heat sink module
on a surface to be cooled.
[0222] FIG. 140A shows a block diagram for an electronic control
system connected to one or more sensors, an antenna, a network, and
a power source.
[0223] FIG. 140B shows a block diagram for an electronic control
system connected to one or more sensors, a network, an antenna, one
or more variable speed drives, one or more valves, one or more
coolant heaters, one or more fire suppression fire sprinklers, and
a power source.
[0224] FIG. 141A shows a top perspective view of a heat sink
assembly including a heat sink module mounted to a
thermally-conductive base member and a mounting bracket configured
to secure the heat sink module against a surface to be cooled while
permitting rotation of the heat sink module relative to the
mounting bracket for ease of installation.
[0225] FIG. 141B shows an exploded perspective view of the heat
sink assembly of FIG. 141A.
[0226] FIG. 142A shows a side cross-sectional view of the heat sink
assembly of FIG. 141A taken along section A-A, the mounting bracket
having a first bevel in contact with a second bevel of the
thermally-conductive base member, together the first and second
bevels preventing lateral movement of the thermally-conductive base
member relative to the mounting bracket while permitting rotation
of the thermally-conductive base member.
[0227] FIG. 142B shows an alternative embodiment of FIG. 142A, the
mounting bracket having a first step feature in contact with a
second step feature of the thermally-conductive base member,
together the first and second step features preventing lateral
movement of the thermally-conductive base member relative to the
mounting bracket while permitting rotation of the
thermally-conductive base member.
[0228] FIG. 143 shows a top view of a cooling line assembly with
two series-connected heat sink module assemblies as show in FIG.
141A connected with flexible tubing that extends to quick-connect
fittings.
[0229] FIG. 144 shows a top view of a cooling line assembly with
two series-connected heat sink module assemblies as show in FIG.
141A connected with flexible tubing and connectors.
[0230] FIG. 145 shows a bottom view of a cooling line assembly with
two heat sink modules, each mounted on a thermally-conductive base
member, the modules fluidly connected in series with flexible
tubing and connectors.
[0231] FIG. 146 shows a top view of a cooling line assembly with
two series-connected heat sink modules mounted on processors within
a server.
[0232] FIG. 147 shows blade servers mounted in a server rack, where
two of the blade servers are fluidly connected to a manifold
assembly of the cooling apparatus of FIG. 148 by a pair of cooling
line assemblies with quick-connect fittings.
[0233] FIG. 148 shows a fluid distribution unit of FIG. 125 mounted
to a base member of a server rack and fluidly connected to a
manifold assembly, the server rack populated with a plurality of
blade servers.
[0234] FIG. 149 shows a front perspective view of the blade server
of FIG. 151 with access holes provided in a front face of the
server to permit routing of the sections of inlet and outlet
tubing.
[0235] FIG. 150 shows a server rack populated with blade servers
and having two vertically-mounted manifold assemblies for
redundancy, where the first manifold assembly is in the process of
being fluidly connected to each blade server with a cooling line
assembly, and where the second manifold has not yet been connected
to any of the blade servers.
[0236] FIG. 151 shows a top view of a hot-swappable blade server
with its lid removed and a cooling line assembly routed into and
out of the blade server through a front face plate, the cooling
line assembly having two series-connected heat sink module
assemblies, each mounted on a processor of the server, the cooling
line assembly a first section of flexible tubing extending from a
first quick-connect fitting to an inlet port of a first heat sink
module, a second section of flexible tubing extending from an
outlet port of the first heat sink module to an inlet port of a
second heat sink module, and a third section of flexible tubing
extending from an outlet port of the second heat sink module to a
second quick-connect fitting.
[0237] FIG. 152 shows a sparsely-populated server rack with air
gaps provided between adjacent servers to permit air flow between
servers to provide adequate cooling with traditional air
conditioning.
[0238] FIG. 153 shows four densely-populated server racks without
air gaps between adjacent servers and suitable for cooling with the
two-phase cooling apparatuses shown and described herein.
[0239] FIG. 154 shows a graphics card with a GPU having an exposed
silicon surface.
[0240] FIG. 155 shows a heat sink module mounted directly against
the exposed silicon surface of the GPU of FIG. 154 to provide
direct-to-silicon cooling as shown in FIG. 27.
[0241] FIG. 156 shows a mounting bracket installed over the heat
sink module of FIG. 155 and secured to the graphics card by
fasteners that compress a sealing member between the silicon
surface and the heat sink module to provide a liquid-tight seal
circumscribing an outlet chamber of the heat sink module, the heat
sink module forming part of a cooling line assembly.
DETAILED DESCRIPTION
[0242] The cooling apparatuses 1 (cooling systems) and methods
described herein are suitable for a wide variety of applications,
ranging from cooling electrical devices to cooling mechanical
devices to cooling chemical reactions and/or related devices and
processes. Examples of electrical devices that can be effectively
cooled with the cooling apparatuses 1 and methods include densely
packed servers in data centers, computers in distributed computing
clusters, workstations in office buildings, medical imaging
devices, electronic communications equipment in cellular networks,
insulated-gate bipolar transistors (IGBTs), solar panels, gaming
consoles, personal computers, home appliances, high-power diode
laser arrays, light emitting diode (LED) arrays, theater lighting
systems, video projectors, directed-energy weapons, solar panels,
current sources, and electric vehicle components (e.g. battery
packs, inverters, electric motors, display screens, and power
electronics). Examples of mechanical devices that can be
effectively cooled with the cooling apparatuses 1 and methods
include turbines, internal combustion engines, turbochargers,
after-treatment components, and braking systems. Examples of
chemical processes that can be effectively cooled with the cooling
apparatuses 1 include condensation processes involving rotary
evaporators or reflux distillation condensers.
[0243] Compared to competing air or single-phase liquid cooling
systems, the cooling apparatuses 1 and methods described herein are
more efficient, more reliable, safer, less expensive, and have
lower operating noise. The cooling apparatuses 1 described herein
are suitable for retrofit on existing server designs and can be
incorporated into new server or processor designs. Due to their
high efficiency, modularity, flexibility, quick-connections, small
size, and hot-swappability, the cooling apparatuses 1 described
herein redefine design constraints that have until now hampered the
development of new electronic devices. By replacing traditional
cooling methods with a more compact and higher performing solution,
the cooling apparatuses 1 described herein allow the size of
electronic device housings to be significantly reduced while
maintaining or even improving device performance by maintaining the
device at consistent operating temperatures.
[0244] In the case of servers 400 arranged in server racks 410, the
cooling apparatus 1 described herein allows servers 400 to be
arranged in close proximity to neighboring servers in the same rack
410, as shown in FIGS. 1-3 and 153. FIG. 153 shows four
densely-populated server racks 410 cooled by the two-phase cooling
apparatus 1 described herein. Unlike the air-cooled example shown
in FIG. 152 where air gaps are needed between adjacent servers to
allow for adequate air flow, the example shown in FIG. 153 does not
require air gaps. Consequently, more servers 400 can be installed
and cooled per square foot of floor space in a data center 425. In
addition, a fluid distribution unit 10 of the cooling apparatus 1
has a relatively small footprint of about 7 square feet, whereas a
CRAC unit that it displaces may have a footprint of over 42 square
feet. Installing the cooling apparatus 1 described herein instead
of a CRAC unit frees up enough floor space to accommodate at least
five additional racks 410 of densely-populated server racks
410.
[0245] The cooling apparatus 1 described herein can be deployed in
computer rooms and in large-scale data center applications. In
other applications, the cooling apparatus 1 can be made in smaller
sizes suitable for incorporation in automobiles, aircraft, and
other vehicles, which may require cooling of batteries, inverters,
and other electronic devices. In still other applications, the
cooling apparatus 1 can be miniaturized for use in laptop and
tablet computers and in handheld mobile electronic devices. In such
examples, coolant passageways for transporting dielectric coolant
50 to a heat sink module 100 can be formed directly on a circuit
board of the mobile device by any suitable manufacturing process,
such as 3D printing. Similarly, heat sink modules 100 can be formed
directly on a processor, memory module, or other electronic
component of the mobile device by, for example, 3D printing.
[0246] Using the methods described herein, a high-efficiency
cooling apparatus 1 for a wide variety of applications can be
rapidly designed, optimized, manufactured, and installed. In some
examples, additive-manufacturing processes can be used to rapidly
manufacture heat sink modules 100 that permit consistent cooling of
multiple device surfaces 12, even when those devices have
non-uniform heat distributions on their surfaces, such as surfaces
of multi-core microprocessors.
[0247] Due to their small size and flexible connections, the
components described herein can be discretely packaged in many
existing machines and devices that require efficient and reliable
cooling of surfaces that produce high heat fluxes. For example, the
cooling apparatuses 1 described herein can be discretely packaged
in personal computers, servers, mobile electronic devices, or other
electronic devices to cool memory modules and processors, such as
computer processing units (CPUs), graphic processing units (GPUs),
application-specific integrated circuits (ASICs),
application-specific instruction set processor (ASIPs), physics
processing unit (PPUs), digital signal processor (DSPs), image
processors, coprocessors, network processors, audio processors,
multi-core processors, and front end processors. The cooling
apparatuses 1 described herein can also be packaged in vehicles to
cool battery packs, inverters, electric motors, in-dash
entertainment and navigation systems, display screens, and power
electronics and in medical imaging devices to cool power supplies
and other electronic components.
[0248] In some applications, heat rejected from the cooling
apparatus 1 can be used to provide comfort heating or preheating of
other fluids. In buildings, heat rejected from the cooling
apparatus 1 can be used to preheat water to offset or eliminate the
need for separate facility water heaters or to heat office space.
Rejected heat can also be used for deicing of adjacent sidewalks
and parking lots. In vehicles, heat rejected from the cooling
apparatus can be used to warm occupant seats and steering wheels
and can preheat mechanical components, such as cylinder heads and
engine blocks to reduce cold start emissions. In vehicles, heat
rejected from the cooling apparatus 1 can be used to warm vehicle
transmission fluid and engine oil to decrease fluid viscosity and
improve mechanical efficiency.
[0249] In data center applications, the cooling apparatuses 1 and
methods described herein can provide local, efficient cooling of
critical system components and, where the data center 425 is
located in an office building, can allow the ambient temperature of
the office building to remain at a temperature that is comfortable
for human occupants, while still permitting effective cooling of
critical system components. Presently, competing air cooling
systems use room air within an office building to cool critical
system components by employing small fans to blow air across finned
surfaces of system components. As the system components (e.g.
microprocessors) are more highly utilized, they begin to generate
more heat. To provide additional cooling, there are only two
options in an air cooling system. First, the mass flow rate of air
across the components can be increased to increase the heat
transfer rate, or second, the temperature of the room air can be
reduced to provide a larger temperature differential between the
room air and the component temperature, thereby increasing the heat
transfer rate. Initially, fans speeds can be increased to provide
higher flow rates of room air, which in turn provides higher heat
transfer rates. However, at some point, maximum fan speeds will be
attained, at which point the flow rate of room air can no longer be
increased. At this point, if critical system components demand
additional cooling (e.g. to prevent overheating or failure), the
only option in competing air cooling systems is to decrease the
temperature of the room air by delivering larger volumetric flow
rates of cool air from an air conditioning unit to the room to
reduce the room temperature. This approach is highly inefficient
and ultimately results in discomfort for human occupants of the
office building, since larger volumetric flow rates of cool air
eventually cause the air temperature within the building to reach
an uncomfortably cool temperature, which can diminish worker
productivity.
Experimental Data
[0250] FIG. 8 shows a plot of experimental data showing power
consumed versus time to cool a computer room 425 having forty
active dual-processor servers 400. The left portion of the plot,
extending from about 15 to 390 minutes, shows power consumed by a
CRAC tasked with cooling the computer room 425. From about 15 to
190 minutes, the servers 400 were fully utilized, and from about
240 to 360 minutes, the servers were at idle state. At about 390
minutes, the cooling apparatus 1 was activated to assist the CRAC
with cooling the servers 400. However, the heat sink modules 100
connected to the cooling apparatus 1 were only installed on
microprocessors in 25% of the servers (ten of forty servers).
Nevertheless, a dramatic reduction in power consumption was
recorded. From 390 to 590 minutes, the cooling apparatus 1
conserved about 1.5 kW of power compared to the baseline idle state
cooled by the CRAC only, and from about 625 to 840 minutes, the
cooling apparatus 1 conserved about 2 kW of power compared to the
baseline fully utilized state cooled by the CRAC only. The
reduction in power consumption measured in this experiment is
expected to scale as more servers in the computer room are
connected to the cooling apparatus 1. Consequently, if heat sink
modules 100 of the cooling apparatus 1 were installed on
microprocessors 415 of all forty servers 400, reductions in power
consumption of about 6 kW (i.e. 55%) and 8 kW (i.e. 67%) compared
to the baseline idle and baseline fully utilized states,
respectively, are expected. Reductions in power consumption of this
magnitude can translate to significant savings in annual operating
expenses for computer room and data center operators.
[0251] Experimental tests have demonstrated that significantly
higher heat transfer rates are achievable with the cooling
apparatus 1 than with existing single-phase pumped liquid systems.
This higher heat transfer rate can be attributed, at least in part,
to establishing conditions in an outlet chamber 150 of the heat
sink module 100 that promote boiling of the coolant proximate the
surface to be cooled 12. Experimental tests have confirmed that the
heat sink module 100 shown in FIG. 21 is capable of dissipating a
heat load of about 500 thermal watts, and the redundant heat sink
module 700 shown in FIG. 51A is capable of dissipating a heat load
of about 800 thermal watts.
[0252] During testing, a heat sink module 100 was provided that
contained a plurality of orifices 155 configured to provide
impinging jets streams 16 of coolant 50 directed against a surface
to be cooled 12, as shown in FIG. 26. In a first test, the pressure
in the outlet chamber 150 of the heat sink module 100 was set to
establish a saturation temperature of about 95.degree. C. for the
coolant. In a second test, the pressure in the outlet chamber 150
of the heat sink module 100 was set to establish a saturation
temperature of about 74.degree. C. for the coolant. The saturation
temperature of about 74.degree. C. was chosen to substantially
match the mean temperature of the heated surface (i.e. surface to
be cooled 12) in the test. The same flow rate of coolant was used
for each test. During the second test, bubbles 275 were generated
in the outlet chamber 150 with the coolant having the lower
saturation temperature. Such a phase change did not occur in the
outlet chamber 150 with coolant having the higher saturation
temperature in the first test. Overall, the heat transfer
performance increased by 80% with the lower saturation temperature
(i.e. the second test) where bubbles were generated compared to the
higher saturation temperature (i.e. the first test) where bubbles
were not generated.
[0253] One benefit of the cooling technology described herein is
the ability to efficiently cool local hot spots on a
heat-generating device 12 (e.g. hot spots on microprocessors 415).
For example, if just one core of a given microprocessor 415 is more
heavily utilized than other cores in the same processor, and a
plurality of jet streams of coolant are directed at the surface of
the microprocessor, more evaporation will occur proximate the hot
core, thereby increasing the local heat transfer rate proximate the
hot core relative to the cooler cores, and thereby self-regulating
to maintain the entire surface 12 of the microprocessor at a more
uniform temperature than is possible with purely single-phase
cooling systems that are incapable of self-regulating. Because the
cooling apparatus 1 is capable of self-regulating to cool local hot
spots (e.g. by providing local increases in heat transfer rates
through evaporation), the entire cooling system can be operated at
lower flow rate and pressure, which conserves energy, and still
handle fluctuations in processor temperature caused by variations
in utilization. This is in sharp contrast to existing liquid
cooling systems that are not capable of self-regulating to cool
local hot spots and must therefore be operated at much higher flow
rates and pressures to ensure adequate cooling of hot spots, for
example, on microprocessors. In other words, existing liquid
cooling systems must operate continuously at a setting that is
designed to handle a peak heat load to ensure the system is capable
of handling the peak heat load if it occurs. As a result, when the
microprocessor is not being heavily utilized, which is quite often,
existing systems operate at a pressure and flow rate that are
considerably above where they would otherwise need to operate to
handle a non-peak heat load. This approach needlessly consumes a
significant amount of excess energy, and is therefore
undesirable.
Two-Phase Flow
[0254] In some aspects, the cooling apparatuses 1 described herein
can be configured to cool a heat-generating surface 12 by directing
jet streams 16 of coolant against the surface 12 and by flowing
coolant 50 over the surface 12, as shown in FIGS. 26 and 30. The
terms "heat-generating surface," "surface to be cooled," "surface
of the device," "heat source," "heated surface," "heat providing
surface," "device surface," "component surface," and
"heat-producing surface" are used herein to describe any surface 12
of a component or device that is at a temperature above ambient
temperature, whether due to heat produced by or within the
component or device or due to heat transferred to the component or
device from some other component or device that is in thermal
communication with the surface 12. Within some components of the
cooling apparatus 1, at least a portion of the coolant 50 can
undergo a phase change from a liquid to a vapor in response to
absorbing heat from the surface 12 of the device. The phase change
can result in the coolant 50 transitioning from a single-phase
liquid flow to two-phase bubbly flow or from a two-phase bubbly
flow having a first number density of vapor bubbles to two-phase
bubbly flow having a second number density of vapor bubbles, where
the second number density is higher than the first number density.
By initiating boiling proximate the surface 12 being cooled, and
taking advantage of the highly-effective heat transfer mechanisms
associated therewith, the cooling apparatuses 1 and methods
described herein can deliver heat transfer rates that far exceed
heat transfer rates attainable with traditional single-phase liquid
cooling or air cooling systems. By providing dramatically increased
heat transfer rates, the cooling apparatus 1 described herein is
able to cool devices far more efficiently than any other existing
cooling apparatus, which translates to significantly lower power
consumption by the cooling apparatus 1 and lower utility bills.
Where the cooling apparatus 1 is used in a large scale cooling
application, such as a data center, and replaces a conventional air
conditioning system, the cooling apparatus can result in
significant savings on utility bills for a data center
operator.
[0255] When a heat-generating surface 12 exceeds the saturation
temperature of the coolant 50, boiling of the coolant proximate
(i.e. at or near) the heat-generating surface occurs. This can
occur whether the bulk fluid temperature of the coolant 50 is at or
below its saturation temperature. If the bulk fluid temperature is
below the saturation temperature of the coolant 50, boiling is
referred to as "local boiling" or "subcooled boiling." If the bulk
fluid temperature of the coolant is equal to the saturation
temperature, then "bulk boiling" is said to occur. Bubbles formed
proximate the heat-generating surface 12 depart the surface 12 and
are transported by the bulk fluid, creating a flow of liquid fluid
with bubbles distributed therein, known as two-phase bubbly flow.
Depending on the degree of subcooling, as the bubbly flow passes
through tubing, some or all of the bubbles in the bubbly flow may
condense and collapse as mixing of the fluid and bubbles occurs. As
bubbles collapse back to liquid, the bulk fluid temperature rises.
In saturated or bulk boiling, where the bulk fluid temperature is
near the saturation temperature, the bubbles 275 distributed in the
fluid may not collapse as the bubbly flow passes through tubing and
as mixing of the fluid and bubbles occurs.
[0256] Two-phase flow can be defined based on a volume fraction of
vapor present in the flow, where the volume fraction of vapor in
the flow (.alpha..sub.vapor) plus the volume fraction of liquid
(.alpha..sub.liquid) in the flow is equal to one
(.alpha..sub.vapor+.alpha..sub.liquid=1). The volume fraction of
vapor (.alpha..sub.vapor) is commonly referred to as "void
fraction" even though the vapor volume is filled with low density
gas and no true voids exist in the flow. The volume fraction within
a tube, such as a section of flexible tubing 225 between two
series-connected heat sink modules 100, can be calculated using the
following equation:
.alpha..sub.vapor=A.sub.vapor/A.sub.x
where A.sub.x is the total cross-sectional flow area at point x in
the tube, and A.sub.vapor is the cross-sectional area occupied by
vapor at point x in the tube. The volumetric flux of vapor
(j.sub.vapor) in a flow 51, also known as the "superficial
velocity" of the vapor, can be calculated using the following
equation:
j.sub.vapor=(v.sub.vapor.times.A.sub.vapor)/A.sub.x=.alpha..sub.vapor.ti-
mes.v.sub.vapor
where v.sub.vapor is the velocity of vapor in the tube. In some
instances, the velocity of vapor (v.sub.vapor) and the velocity of
the liquid (v.sub.liquid) in the flow may not be equal. This
inequality in velocities can be described as a slip ratio and
calculated using the following equation:
S=v.sub.vapor/v.sub.liquid
Where the vapor velocity (v.sub.vapor) and the liquid velocity
(v.sub.liquid) in the flow are equal, the slip ratio (S) is one.
The flow quality is the flow fraction of vapor and is always
between zero and one. Flow quality (x) is defined as:
x={dot over (m)}.sub.vapor/{dot over (m)}={dot over
(m)}.sub.vapor/({dot over (m)}.sub.vapor+{dot over
(m)}.sub.liquid)
where {dot over (m)}.sub.vapor is the mass flow rate of vapor in
the tube, {dot over (m)}.sub.liquid is the mass flow rate of liquid
in the tube, and m is the total mass flow rate in the tube ({dot
over (m)}={dot over (m)}.sub.vapor+{dot over (m)}.sub.liquid). The
mass flow rate of liquid is defined as:
{dot over
(m)}.sub.liquid=.rho..sub.liquid.times.v.sub.liquid.times.A.sub.liquid
where .rho..sub.liquid is the density of the liquid, and
A.sub.liquid is the cross-sectional area occupied by liquid at
point x in the tube. Similarly, the mass flow rate of vapor is
defined as:
{dot over
(m)}.sub.vapor=.rho..sub.vapor.times.v.sub.vapor.times.A.sub.vapor
where .rho..sub.vapor is the density of the vapor. The distribution
of vapor in a two-phase flow of coolant 50, such as a two-phase
flow of coolant within a heat sink module 100 mounted on a
heat-generating surface 12, affects both the heat transfer
properties and the flow properties of the coolant 50. These
properties are discussed in greater detail below.
[0257] A number of flow patterns or "flow regimes" have been
observed experimentally by viewing flows of two-phase liquid-vapor
mixtures passing through transparent tubes. While the number and
characteristics of specific flow regimes are somewhat subjective,
four principal flow regimes are almost universally accepted. These
flow regimes are shown in FIG. 58 and include (1) bubbly flow, (2)
slug flow, (3) churn flow, and (4) annular flow. FIG. 58(a) shows
bubbly flow having a first number density of bubbles, and FIG.
58(b) shows bubbly flow having a second number density of bubbles
where the second number density is greater than the first number
density of FIG. 58(a). FIG. 58(c) shows slug flow. FIG. 58(d) shows
churn or churn-turbulent flow. FIG. 58(e) shows annular flow.
Beyond annular flow, the flow will transition through wispy-annular
flow before eventually reaching single-phase vapor flow.
[0258] Bubbly flow is generally characterized as individually
dispersed bubbles 275 transported in a continuous liquid phase.
Slug flow is generally characterized as large bullet-shaped bubbles
separated by liquid plugs. Churn flow is generally characterized as
vapor flowing in a chaotic manner through liquid, where the vapor
is generally concentrated near the center of the tube, and the
liquid is displaced toward the wall of the tube. Annular flow is
generally characterized as vapor forming a continuous core down the
center of the tube and a liquid film flowing along the wall of the
tube.
[0259] To predict existence of a particular flow regime, or a
transition from one flow regime to another, requires the
above-mentioned visually observed flow regimes to be quantified in
terms of measurable (or computed) quantities. This is normally
accomplished through the use of a flow regime map. An example of a
flow regime map is provided in FIG. 59A. The flow regime map shown
in FIG. 59A is valid for steam-water systems and shows
.rho..sub.vapor*j.sub.vapor.sup.2 on the x-axis and
.rho..sub.vapor*j.sub.vapor.sup.2 on the y-axis. A similar flow
regime map can be created for a dielectric coolant 50, such as a
hydrofluorocarbon or hydrofluorether, flowing over a
heat-generating surface 12 within a heat sink module 100 or flowing
within a flexible section of tubing 225, as described herein.
[0260] FIG. 59B shows the four two-phase flow regimes, including
bubbly flow, slug flow, churn flow, and annular flow, plotted on
void fraction versus mass flux axes. To maintain stability within
the cooling apparatus during operation, it can be desirable to
maintain single-phase liquid flow, bubbly flow, or a combination
thereof throughout the apparatus. Experimental testing confirmed
that bubbly flow does not result in flow instabilities within the
cooling apparatus 1. To remain comfortably within the bubbly flow
regime, it can be desirable to maintain the coolant below a
predetermined void fraction and/or above a predetermined mass flux.
The desired predetermined void fraction and predetermined mass flux
can depend on several factors, including the configuration of the
cooling apparatus 1 (e.g. components and layout), the type of
coolant 50 being used, the coolant pressure within the apparatus,
and the temperature of the surface to be cooled 12. In some
examples, the void fraction of the coolant exiting the heat sink
module 100 can be about 0-0.5, 0-0.4, 0-0.3, 0-0.2, or 0-0.1. In
some examples, the mass flux of the coolant flowing through a heat
sink module 100 can be about 10-2,000, 500-1,000, 750-1,500,
1,000-2,500, 2,250-2,500, 2,000-2,700, or greater than 2,700
kg/m2-s. As shown in FIG. 59B, as the void fraction increases (e.g.
from about 0.3-0.5), the mass flux of the coolant 50 must also
increase to avoid transitioning from bubbly flow to slug or churn
flow at an outlet of the heat sink module 100 in the flexible
tubing 225.
[0261] FIG. 60 shows a flow boiling curve where heat transfer rate
is plotted as a function of "excess temperature" (T.sub.e). Excess
temperature is the difference between the actual temperature of the
surface to be cooled 12 and the fluid saturation temperature
(T.sub.e=T.sub.surface-T.sub.sat). The curve is divided into 5
regions (a, b, c, d, and e), each corresponding to certain heat
transfer mechanisms.
[0262] In region (a) of FIG. 60, a minimum criterion for boiling is
that the temperature of the heat-generating surface 12 exceeds the
local saturation temperature of the coolant (T.sub.sat). In other
words, some degree of excess temperature (T.sub.e) is required for
boiling to occur. In region (a), the excess temperature may be
insufficient to support bubble formation and growth. Therefore,
heat transfer may occur primarily by single-phase convection in
region (a).
[0263] In region (b) of FIG. 60, bubbles begin forming at
nucleation sites on the heat-generating surface 12. These
nucleation sites are generally associated with crevices or pits on
the heat-generating surface 12 in which non-dissolved gas or vapor
accumulates and results in bubble formation. As the bubbles grow
and depart from the surface 12, they carry latent heat away from
the surface and produce turbulence and mixing that increases the
heat transfer rate. Boiling under these conditions is referred to
as nucleate boiling. In region (b), heat transfer is a complicated
mixture of single-phase forced convection and nucleate boiling.
This region is often called the mixed boiling or "partial nucleate
boiling region." As the temperature of the heat-generating surface
12 increases, the percentage of surface area that is subject to
nucleate boiling also increases until bubble formation occupies the
entire heat-generating surface 12.
[0264] In region (c) of FIG. 60, bubble density increases rapidly
as the surface temperature increases further beyond the saturation
temperature (T.sub.sat). In this region, heat transfer can be
dominated by bubble growth and departure from the surface 12.
Formation and departure of these bubbles 275 can transport large
amounts of latent heat away from the surface 12 and greatly
increase fluid turbulence and mixing in the vicinity of the
heat-generating surface 12. As a result, heat transfer can become
independent of bulk fluid conditions such as flow velocity and
temperature. Heat transfer in this region is know as "fully
developed nucleate boiling" and is characterized by a substantial
increase in heat transfer rate in response to only moderate
increases in surface 12 temperature. However, there is a limit to
the maximum rate of heat transfer that is attainable with fully
developed nucleate boiling. At some point, the bubble density at
the heat generating surface 12 cannot be increased any further.
This point is know as the critical heat flux ("CHF") and is denoted
as c* in FIG. 60. One theory is that at point c*, the bubble
density becomes so high that the bubbles 275 actually impede the
flow of liquid back to the surface 12, since bubbles in close
proximity tend to coalesce, forming insulating vapor patches that
effectively block the liquid coolant from reaching the
heat-generating surface 12 and thereby prevent the liquid coolant
from extracting latent heat, for example, by undergoing a phase
change (i.e. boiling) at the surface 12.
[0265] It may be possible to delay the onset of critical heat flux
by employing the cooling apparatuses 1 and methods described herein
(e.g. heat sink modules capable of providing jet stream 16
impingement) that increase the heat transfer rate from the heated
surface 12, thereby allowing the cooling apparatus 1 to safely and
effectively cool a heat generating surface 12 that is at a
temperature well above the saturation temperature of the coolant
(e.g. about 20-30 degrees C. above T.sub.sat) without reaching or
exceeding critical heat flux. In some examples, delaying the onset
of critical heat flux, and thereby increasing the heat transfer
rate of the cooling apparatus 1 to previously unattainable rates,
can be achieved by increasing the three-phase contact line 58
length, as described herein (see e.g. FIG. 63 and related
description), by using the methods and components (e.g. heat sink
modules 100) described herein, which can provide a plurality of jet
stream 16 impinging against a heated surface 12 where the jets are
positioned at a predetermined jet height 18 away from the heated
surface 12. To delay the onset of critical heat flux (and thereby
allow the cooling apparatus 1 to operate safely and effectively in
region (c) shown in FIG. 60), a mass flow rate 51, jet height 18,
orifice 155 diameter, coolant temperature, and coolant pressure can
be selected from the ranges described herein to provide a plurality
of jet streams 16 that impinge the surface to be cooled 12 and
effectively increase the three-phase contact line 58 length
proximate the surface to be cooled 12. Although the cooling
apparatus 1 can operate extremely well in regions (a) and (b), the
efficiency of the cooling apparatus 1 may be highest when operating
in region (c).
[0266] As the temperature of the surface 12 increases beyond the
temperature associated with critical heat flux, the heat transfer
rate actually begins to decrease, as shown in region (d) of FIG.
60. Further increases in the surface 12 temperature simply result
in a higher percentage of the surface 12 being covered by
insulating vapor patches. These insulating vapor patches reduce the
area available for liquid to vapor phase change (i.e. boiling).
Therefore, despite the surface temperature (T.sub.surface)
continuing to increase, the overall heat transfer rate actually
decreases, as shown in region (d) of FIG. 60. This region is
referred to as the partial film or "transition film boiling
region." Reaching or exceeding the temperature associated with
critical heat flux can be undesirable, since performance can
decrease and become unpredictable. Moreover, due to rapid
production of vapor proximate the surface to be cooled 12, the
two-phase flow in the cooling apparatus 1 can increase in quality
and transition from bubbly flow to slug, churn, or annular flow,
which can result in undesirable pressure surges within the system
due to a volume fraction of vapor exceeding a stable working range.
It is therefore desirable to operate in regions (a), (b), or (c),
below the onset of critical heat flux at point c*. Where the
cooling apparatus 1 includes a vapor quality sensor 880 near an
outlet port 110 of the heat sink module 100, as shown in FIG. 74,
the cooling apparatus is capable of operating beyond the onset of
critical heat flux at point c*, and even up to the Leidenfrost
point. In this arrangement, the vapor quality sensor 880 provides
feedback to an electronic control unit 850 that can rapidly control
the pressure and flow rate of coolant 50 though the heat sink
module 100. For instance, if the vapor quality sensor 880 provides
a signal to the electronic control unit 850 that is above a
predetermined threshold, indicating a vapor quality that is beyond
a maximum allowable vapor quality, the electronic control unit can
instruct the pump 20 to increase mass flow rate of coolant through
the heat sink module, either by increasing the pressure, velocity,
or both of the flowing coolant. In some examples, the flow quality
(x) sensor 880 can be an annular shaped sensor that fits over an
outer circumference of the flexible tubing 225 (see FIG. 74) and
provides a signal to the electronic control unit 850 wirelessly or
through a cable 852. In some examples, the flow quality (x) sensor
880 can be an ultrasonic sensor capable of detecting density
variations between vapor coolant and liquid coolant.
[0267] In region (e) of FIG. 60, a vapor layer covers the
heat-generating surface 12. In this region, heat transfer occurs by
conduction and convection through the vapor layer with evaporation
occurring at the interface between the vapor layer and the liquid
coolant. This region is known as the "stable film boiling region."
Similar to region (d), region (e) is may not be suitable for stable
operation of the cooling apparatus 1 due to significant vapor
formation resulting in slug, churn, or annular flow.
[0268] FIG. 61 shows a flow boiling curve for water at 1 atm, where
heat flux is plotted as a function of excess temperature. As noted
above, excess temperature is the difference between the actual
temperature of the surface to be cooled 12 and the fluid saturation
temperature (T.sub.e=T.sub.surface-T.sub.sat). The curve of FIG. 61
shows the onset of nucleate boiling, the point of critical heat
flux, and the Leidenfrost point. Between the critical heat flux
point and the Leidenfrost point is a transition boiling region
where the coolant vaporizes almost immediately on contact with the
heated surface 12. The resulting vapor suspends the liquid coolant
on a layer of vapor within the outlet chamber 150 and prevents any
further direct contact between the liquid coolant and the heated
surface 12. Since vapor coolant has a much lower thermal
conductivity than liquid coolant, further heat transfer between the
heated surface 12 and the liquid coolant is slowed down
dramatically, as shown by the downward slope of the plot between
CHF and the Leidenfrost point. Beyond the Leidenfrost point,
radiation effects become significant, as radiation from the heated
surface 12 transfers heat through the vapor layer to the liquid
coolant suspended above the vapor layer, and the heat flux again
increases.
Coolant
[0269] As used herein, the general term "coolant" refers to any
fluid capable of undergoing a phase change from liquid to vapor or
vice versa at or near the operating temperatures and pressures of
the cooling apparatuses 1. The term "coolant" can refer to fluid in
liquid phase, vapor phase, or mixtures thereof (e.g. two-phase
bubbly flow). A variety of coolants 50 can be selected for use in
the cooling apparatus 1 based on cost, level of optimization
desired, desired operating pressure, boiling point, and existing
safety regulations that govern installation (e.g. such as
regulations set forth in ASHRAE Standard 15 relating to permissible
quantities of coolant per volume of occupied building space).
[0270] Selection of the coolant 50 for the cooling apparatus 1 can
be influenced by desired dielectric properties of the coolant, a
desired boiling point of the coolant, and compatibility with
polymer materials used to manufacture the heat sink module 100 and
the flexible tubing 225 of the apparatus 1. For instance, the
coolant 50 may be selected to ensure little or no permeability
through system components (e.g. heat sink modules 100 and flexible
tubing 225) and no damage to any system components (e.g. to ensure
that pump 20 or quick-connect seals are not damaged or compromised
by the coolant 50).
[0271] Water is readily abundant and inexpensive. Although the
cooling apparatuses 1 described herein can be configured to operate
with water as a coolant, water has certain traits that make it less
desirable than other coolant options. For instance, water does not
change phase at a low temperature (such as 40-50.degree. C.)
without operating at very low pressures, which can be difficult to
maintain in a relatively inexpensive cooling apparatus that
includes at least some standard fittings and system components
(e.g. gear pumps, valves, valves, and flexible tubing). In
addition, water as a coolant requires a number of additives (e.g.
corrosion inhibitors and mold inhibitors) and can absorb a range of
materials from surfaces of system components it contacts. As water
changes phase, these materials can precipitate out of solution,
causing fouling or other issues within system components. Fouling
is undesirable, since it can reduce system performance by
effectively increasing the thermal resistance of certain components
that are tasked with expelling heat from the system (e.g. heat
exchanger 40) or tasked with absorbing heat into the system from
devices being cooled by the system (e.g. copper base plate 430).
The above-mentioned challenges can be overcome with appropriate
filtration and fittings, which adds cost to the system. However,
water is a highly effective heat transfer medium, so where
increased heat transfer rates are required, and where the risk of
failure of the electronic components is acceptable if a leak
develops, the additional cost and complexity associated with using
water as the coolant may be justified. But in most practical
situations, such as cooling servers 400 in data centers, the risk
of loss is not acceptable due to the high cost of servers, so water
should be avoided as a coolant.
[0272] In some examples, it can be preferable to use a dielectric
fluid, such as a hydrofluorocarbon (HFC) or a hydrofluoroether
(HFE) instead of water as a coolant 50 in the cooling apparatus 1.
Unlike water, dielectric coolants 50 can be used in direct contact
with electronic devices, such as CPUs, memory modules, and power
inverters without shorting electrical connections of the devices.
Therefore, if a leak develops in the cooling apparatus and coolant
drips onto an electrical device, there is no risk of damage to the
electrical device. In some examples of the cooling apparatus 1, the
dielectric coolant 50 can be delivered directly (e.g. by way of one
or more jet streams 16) onto one or more surfaces of the electronic
device (e.g. one or more surfaces of a microprocessor 415), thereby
eliminating the need for commonly-used thermal interface materials
(e.g. copper base plates 430 and thermal bonding materials) between
the flowing coolant 50 and the electronic device and can thereby
eliminate thermal resistances associated with those thermal
interface materials, thereby enhancing performance and overall
efficiency of the cooling apparatus 1.
[0273] Non-limiting examples of dielectric coolants 50 include
1,1,1,3,3-pentafluoropropane (known as R-245fa), hydrofluoroether
(HFE), 1-methoxyheptafluoropropane (known as HFE-7000),
methoxy-nonafluorobutane (known as HFE-7100). One version of
R-245fa is commercially available as GENETRON 245fa from Honeywell
International Inc. headquartered in Morristown, N.J. HFE-7000 and
HFE-7100 (as well as HFE-7200, HFE-7300, HFE-7500, HFE-7500, and
HFE-7600) are commercially available as NOVEC Engineered Fluids
from 3M Company headquartered in Mapleton, Minn. FC-40, FC-43,
FC-72, FC-84, FC-770, FC-3283, and FC-3284 are commercially
available as FLUOROINERT Electronic Liquids also from 3M
Company.
[0274] GENETRON 245fa is a pentafluoropropane and has a boiling
point of 58.8 degrees F. (.about.14.9 degrees C.) at 1 atm, a
molecular weight of 134.0, a critical temperature of 309.3 degrees
F., a critical pressure of 529.5 psia, a saturated liquid density
of 82.7 lb/ft3 at 86 degrees F., a specific heat of liquid of 0.32
Btu/lb-deg F at 86 degrees F., and a specific heat of vapor of 0.22
btu/lb-deg F at 1 atm and 86 degrees F. GENETRON 245fa has a Safety
Group Classification of A1 under ANSI/ASHRAE Standard 36-1992. For
cooling a processor 415 that has a preferred operating core
temperature of about 60-70 degrees C., GENETRON 245fa can be
provided at a pressure greater than atmospheric pressure to
increase its saturation temperature to about 25-35, 30-40, or 35-50
degrees C. to ensure the bulk of the coolant remains in liquid
phase at it passes through the heat sink module 100. For flow rates
of about 0.25-1.25 liters per minute of subcooled GENETRON 245fa
through the heat sink module 100, the rate of boiling can depend on
the processor utilization level. For instance, when the processor
415 is idling, the subcooled GENETRON 245fa may experience no local
boiling, and when the processor is fully utilized, the subcooled
GENETRON 245fa may experience vigorous local boiling and bubble 275
generation.
[0275] NOVEC 7000 has a boiling point of 34 degrees C., a molecular
weight of 200 g/mol, a critical temperature of 165 degrees C., a
critical pressure of 2.48 MPa, a vapor pressure of 65 kPa, a heat
of vaporization of 142 kJ/kg, a liquid density of 1400 kg/m3, a
specific heat of 1300 J/kg-K, a thermal conductivity of 0.075
W/m-K, and a dielectric strength of about 40 kV for a 0.1 inch gap.
For cooling a processor 415 that has a preferred operating core
temperature of about 60-70 degrees C., NOVEC 7000 works well. For
flow rates of about 0.25-1.25 liters per minute of subcooled NOVEC
7000 through the cooling line, where the subcooled NOVEC 7000 is
delivered to the heat sink module 100 at a pressure of about 15 psi
and a temperature of about 25 degrees C., local boiling of the
coolant may occur proximate the surface to be cooled. The rate of
boiling can depend on the processor utilization level. For
instance, when the processor is idling, the NOVEC 7000 may
experience no local boiling, and when the processor is fully
utilized, the NOVEC may experience vigorous local boiling and
bubble 275 generation.
[0276] NOVEC 7100 has a boiling point of 61 degrees C., a molecular
weight of 250 g/mol, a critical temperature of 195 degrees C., a
critical pressure of 2.23 MPa, a vapor pressure of 27 kPa, a heat
of vaporization of 112 kJ/kg, a liquid density of 1510 kg/m3, a
specific heat of 1183 J/kg-K, a thermal conductivity of 0.069
W/m-K, and a dielectric strength of about 40 kV for a 0.1 inch gap.
NOVEC 7100 works well for certain electronic devices, such as power
electronic devices that produce high heat loads and can operate
safely at temperatures above about 80 degrees C.
[0277] NOVEC 649 Engineered Fluid is also available from 3M
Company. It is a fluoroketone fluid (C.sub.6-fluoroketone) with a
low Global Warming Potential (GWP). It has a boiling point of 49
degrees C., a thermal conductivity of 0.059, a molecular weight of
316 g/mol, a critical temperature of 169 degrees C., a critical
pressure of 1.88 MPa, a vapor pressure of 40 kPa, a heat of
vaporization of 88 kJ/kg, and a liquid density of 1600 kg/m3.
[0278] In some examples, the coolant 50 can be a combination of
dielectric fluids described above. For instance, the coolant 50 can
include a combination of R-245fa and HFE-7000 or a combination of
R-245fa and HFE-7100. In one example, the coolant 50 can include
about 1-5, 1-10, 5-20, 10-20, 15-30, or 25-50 percent R-245fa by
volume with the remainder being HFE-7000. In another example, the
coolant 50 can include about 1-5, 1-10, 5-20, 10-20, 15-30, or
25-50 percent R-245fa by volume with the remainder being
HFE-7100.
[0279] Combining two or more types of dielectric fluids to form a
coolant mixture for use in the cooling apparatus 1 can be desirable
for several reasons. First, certain fluids, such a R-245fa may be
regulated in ways that restrict the volume of fluid that can be
used in an occupied building, such as an office building. Since
R-245fa has been shown to perform well in the cooling apparatus 1,
it may be desirable to use as much R-245fa as legally permitted in
the cooling apparatus 1, and if additional coolant volume is
required, to use an unregulated coolant, such as HFE-7000 or
HFE-7100, to increase the total coolant volume within the cooling
apparatus 1 to reach a desired coolant volume.
[0280] Second, combining dielectric coolants can allow a coolant
mixture with a desired boiling point to be formulated. R-245fa has
a boiling point of about 15 degrees C. at 1 atm, and HFE-7000 has a
boiling point of about 34 degrees C. at 1 atm. In some examples,
neither of these boiling points may be optimal for use in a
particular application. By combining R-245fa and HFE-7000, a
coolant mixture can be created that behaves as if its boiling point
were somewhere between 15 and 34 degrees C., depending on the
mixture ratio. The ability to create a coolant mixture with a
specific boiling point can be highly desirable for custom tailoring
the coolant mixture for a specific application depending on a
desired operating temperature of the surface to be cooled 12.
Cooling Apparatus
[0281] FIG. 1 shows a front perspective view of a cooling apparatus
1 installed on a plurality of racks 410 of servers 400 in a data
center or computer room 425. The racks 410 of servers 400 are
arranged in a row with a pump 20, reservoir 200, and other system
components arranged near the left side of the row of racks 410. One
or more tubes extend along the length of the row of racks 410 and
fluidly connect servers 400 within each rack 410 to the cooling
apparatus 1, thereby allowing heat-generating components 12 (e.g.
processors) within each server to be cooled by the cooling
apparatus 1. As used herein, the term "fluidly connected" refers to
two components that are arranged in such a manner that a fluid can
travel from a first component to a second component either directly
or indirectly (e.g., through one or more other components, such as
piping or fittings).
[0282] In addition to cooling microprocessors in servers, the
cooling apparatus can be configured to cool a wide variety of other
devices. In some examples, the cooling apparatus 1 can be
configured to cool one or more heat-producing surfaces 12
associated with batteries, electric motors, control systems, power
electronics, chemistry equipment (e.g. rotary evaporators or reflux
distillation condensers), or machines or mechanical devices (e.g.
turbines, internal combustion engines, radiators, braking
components, turbochargers, engine intake manifolds, plasma cutters,
drills, oil and gas exploratory and recovery equipment, water jet
cutters, welding systems, or computer numerical control (CNC) mills
or lathes).
[0283] FIG. 2A shows a rear view of the cooling apparatus 1, and
FIG. 2B shows a detailed rear view of a right portion of the
cooling apparatus shown in FIG. 2A. In this example, the cooling
apparatus 1 can include a plurality of components and
sub-assemblies fluidly connected to provide a cooling apparatus 1
that is capable of locally cooling one or more heat-producing
surfaces 12 (e.g. flat surfaces, curved surfaces, or complex
surfaces), such as surfaces associated with CPUs, memory modules,
and motherboards located within the server housings.
[0284] FIG. 3 shows a left side view of the cooling apparatus 1 of
FIG. 1. Portions of a primary cooling loop 300 are visible in FIG.
3, including a pump 20, reservoir 200, drain/fill location 245,
shut-off valve 250, pressure gauge 255, inlet manifold 210, and
return line 230. Portions of a first bypass 305 are also visible in
FIG. 3, including a valve 60 and heat exchanger 40. As shown in
FIG. 3, the primary cooling loop 300 and the first bypass 305 can
be fluidly connected to the reservoir 200.
[0285] FIGS. 92-95 show a cooling apparatus 1 with redundant pumps
(20-1, 20-2), shut-off valves 250, a tubular reservoir 200, and a
first bypass 305. The first bypass 305 can include a valve 60 and a
heat exchanger 40, as shown in FIG. 93. The valve 60 can be a
differential pressure bypass valve as shown in FIGS. 111-112. The
heat exchanger 40 can include two independent fluid pathways, as
shown in FIG. 97. A first independent fluid pathway can transport a
first bypass flow 51-1 of coolant 50, and a second independent
fluid pathway can transport a flow 42 of external cooling fluid,
such as a water-glycol mixture from an external heat rejection loop
43. The coolant 50 in the first independent pathway can be at a
higher temperature than the external cooling fluid in the second
independent pathway. Heat transfer from the coolant 50 to the
external cooling fluid can cause a decrease in the coolant
temperature and an increase in the external cooling fluid
temperature. The external heat rejection loop 43 can reject heat
absorbed from the coolant 50 to a location outside of the data
center 425 or distributed computing facility where the cooling
apparatus 1 is located.
[0286] In some examples, the heat exchanger 40 can be a heat
liquid-to-air heat exchanger as described in U.S. patent
application Ser. No. 14/833,087, titled "Heat Exchanger with
Helical Passageways" and filed on Aug. 22, 2015; and U.S. patent
application Ser. No. 14/833,092, titled "Heat Exchanger with
Interconnected Fluid Transfer Members" and filed on Aug. 22, 2015,
each of which is hereby incorporated by reference in its
entirety.
[0287] FIG. 115 shows a variation of the cooling apparatus 1
presented in FIG. 68. The schematic in FIG. 115 shows a cooling
apparatus 1 with a primary cooling loop 300 and a heat rejection
loop 43 that are both fluidly connected to a common reservoir 200.
The primary cooling loop 300 includes a first pump 20-1 that
circulates coolant from the reservoir 200, through the primary
cooling loop, and back to the reservoir. Of the coolant flow 51
provided by the first pump 20-1, a first portion 51-1 of the
coolant flow passes through a cooling line 303 and a second portion
51-2 of the coolant flow passes through a bypass 305 containing a
valve 60, such as a differential pressure bypass valve. The valve
60 can control a differential pressure between an inlet and an
outlet of the cooling line 303, thereby allowing a pressure
differential between an inlet and outlet chambers (145, 150) of the
heat sink module 100 to be established and controlled to promote
formation of two-phase flow within the heat sink modules 100 and
thereby achieve significantly higher heat absorption rates than
would be possible with only sensible heating of a single-phase
liquid. The cooling apparatus 1 in FIG. 115 includes a heat
rejection loop 43 that serves to reject heat from the coolant. Heat
rejection is accomplished by pumping coolant from the reservoir 200
using a second pump 20-2, flowing the coolant through a heat
exchanger 40 to reject heat, and returning the coolant to the
reservoir at a lower temperature than when it entered the heat
rejection loop 43. In FIG. 115, the primary cooling loop 300
includes one cooling line 303 fluidly connecting two heat sink
modules 100. In other examples, as shown in FIG. 117, the cooling
apparatus 1 can have more than one cooling line 303, each having
one or more heat sink modules.
[0288] FIG. 116 shows an example of the cooling apparatus 1 of FIG.
115 installed in a computer, such as a personal computer,
high-performance gaming computer, or server. In the example shown
in FIG. 116, the heat exchanger is located within the computer
housing and is connected to a computer fan 26. The computer in FIG.
116 includes two processors 415, each with a heat sink module 100
mounted thereon. In other examples, additional heat sink modules
100 can be fluidly connected in series with the two heat sink
modules to provide cooling of other components, such as one or more
CPUs, GPUs, or memory modules 420. In this example, the heat
exchanger 40 can be a traditional liquid-to-air heat exchanger or
can be the heat exchanger presented in U.S. patent application Ser.
Nos. 14/833,087 and 14/833,092.
[0289] FIG. 117 shows a schematic for a compact cooling apparatus 1
integrated with a server rack 410. The cooling apparatus 1 includes
a fluid distribution unit 10 that is fluidly connected to a
manifold assembly 680. The fluid distribution unit 10 can be housed
in an enclosure and can slide into the server rack 410 similar to
the way a server 400 slides into the server rack. The fluid
distribution unit 10 can be housed in an enclosure to protect
components of the fluid distribution unit and to reduce noise. For
instance, the enclosure can include acoustic foam or other sound
deadening materials on inner surfaces of the enclosure to reduce
noise resulting from operating pumps (20-1, 20-2). To improve
serviceability of the cooling system and to reduce the duration of
downtime if a pump or other component fails, the fluid distribution
unit can be swappable without tools. As shown in FIG. 117, the
fluid distribution can fluidly connect to the remainder of the
cooling apparatus by a pair of quick-connect couplers. In the event
of a component failure, the couplers can be disconnected by hand
and the fluid distribution unit 10 can be withdrawn from the rack
410 and replaced with a functional unit. This ease of
serviceability allows an IT professional to service the cooling
apparatus instead of requiring a facility professional.
[0290] As shown in FIGS. 92-95, the fluid distribution unit 10 of
the cooling apparatus 1 can be mounted on a moveable stand 49 that
allows the unit to be easily moved in a data center 425 when, for
example, the layout of the data center changes to accommodate an
increase or a decrease in the number of server racks 410. The fluid
distribution unit 10 can include the pump or pumps 20, reservoir
200, and heat exchanger 40. The moveable stand 49 of the fluid
distribution unit 10 can have a width and a depth similar to a
server rack 410, thereby allowing the moveable stand 49 to fit in
any area suitable for a server rack. For example, the moveable
stand 49 can have a width of about 20-36 inches and a depth of
about 35-45 inches. In some examples, the fluid distribution unit
10 can be mounted within a server rack 411, which can be moveable.
For larger cooling systems 1 (e.g. systems capable of cooling about
125-1,000 servers or more), the fluid distribution unit 10 may take
up all or most of an inner volume of the server rack 411. For
smaller cooling systems 1, (e.g. system capable of cooling 5-36
servers), the fluid distribution unit 10 may occupy a 4U or 6U slot
within a 42U server rack, where U stands for units that can be
installed in the server rack. The size of electronic equipment,
such as servers and network switches, can vary, but servers
commonly have a 1U form factor, meaning they occupy one unit slot
in the rack 411. For a fluid distribution unit 10 that has a 4U or
6U form factor, meaning it occupies 4 or 6 unit slots,
respectively, it can be desirable to enclose the fluid distribution
unit in a housing that easily slides into and out of the server
rack 411 chassis. This can allow the fluid distribution unit 10 to
be compatible with a wide variety of commercially available server
racks 411 and can allow for easy servicing or adjustment of
components within the fluid distribution unit, such as the pump 20
or valve 60. In many instances, it can be desirable for data center
operators to maintain one or more spare fluid distribution units 10
onsite. If an issue is encountered with an operating fluid
distribution unit 10, it can simple be removed and replaced with a
properly operating fluid distribution unit by a robot or unskilled
worker. This approach can greatly reduce downtime and can eliminate
the expense of having a skilled service professional constantly
onsite at the data center to handle urgent maintenance issues.
Rather, the faulty fluid distribution unit 10 can be serviced
during a regularly scheduled service visit to the data center by
the skilled service professional, or the faulty fluid distribution
unit 10 can be shipped to a service shop to eliminate travel
expenses for the skilled service professional to personally visit
the data center.
[0291] In some data centers, it can be desirable to minimize noise
from cooling systems so that employees do not have to wear hearing
protection. In the cooling apparatus 1 described herein, the pump
20 is the only component of the cooling apparatus that produces
noise. In some instances, it may be desirable to place the fluid
distribution unit 10 in a separate room to isolate pump noise from
the data center floor where the racks 410 of servers 400 are
located. The fluid distribution unit 10 can be located up to 50
feet away from servers it is actively cooling, so locating the
fluid distribution unit in a separate room is feasible. Where a
data center has a large number of servers that requires multiple
cooling apparatuses to provide cooling, the fluid distribution
units 10 for all of the cooling apparatuses may be located in the
same room or gallery to isolate pump noise.
[0292] FIGS. 11A-14, 16-20, 68-72, and 75-83 present a variety of
configurations for the cooling apparatus 1. Depending on its
configuration, the cooling apparatus 1 can include a plurality of
fluidly connected components, including one or more pumps 20, one
or more reservoirs 200, one or more heat exchangers 40, one or more
inlet manifolds 205, one or more outlet manifolds 210, one or more
valves 60, one or more sections of flexible tubing 225, and one or
more heat sink modules 100 mounted on, or placed in thermal
communication with, one or more surfaces to be cooled 12.
[0293] FIG. 11A shows an exemplary schematic of a cooling apparatus
1 having one heat sink module 100 mounted on a heat generating
surface 12. The heat-generating surface 12 can be any surface
having a temperature above ambient temperature that requires
cooling. For instance, the heat-generating surface 12 can be a
surface of a mechanical or electrical device, such as a surface of
a processor 415, such as a CPU or GPU. As identified by dashed
lines in FIG. 11B, the cooling apparatus 1 can include a primary
cooling loop 300 fluidly connecting a pump 20, at least one heat
sink module 100, a return line 230, and a reservoir 200. The pump
20 can be configured to draw single-phase liquid coolant from the
reservoir 200 and deliver a flow 51 of pressurized single-phase
liquid coolant 50 to an inlet port 105 of a heat sink module 100.
The heat sink module 100, being mounted on the heat-generating
surface 12, can be configured to direct a flow of pressurized
coolant 51 at the surface of the heat-generating surface 12 in the
form of a plurality of jet streams 16 of coolant impinging the
heat-generating surface 12, thereby facilitating heat transfer from
the heat-generating surface to the flow of coolant. The return line
230 can be configured to transport the flow of coolant 51, which
may include two-phase bubbly flow, from the outlet port 110 of the
heat sink module 100 back to the reservoir 200 where it can be
mixed with single-phase liquid coolant to promote condensation of
vapor bubbles within the two-phase bubbly flow, thereby resulting
in transition of the two-phase bubbly flow back to single-phase
liquid coolant that can once again be delivered to the pump 20
without risk of cavitation or vapor lock. FIG. 81 shows a preferred
variation of the schematic shown in FIG. 11A, where single-phase
and two-phase flow are visually represented in sections of tubing
fluidly connecting components of the system. Specifically,
two-phase bubbly flow is shown exiting an outlet port 110 of the
heat sink module 100. FIG. 81 also includes an external heat
rejection loop that is fluidly connected to an external dry cooler
40-2, which can be placed outside of the data center 425 or on a
roof of the data center, thereby allowing heat from the cooling
apparatus 1 to be rejected outside of the data center and avoiding
heating air within the data center.
[0294] As identified by dashed lines in FIG. 11C, the cooling
apparatus 1 can include a first bypass 305 including a valve 60 and
a heat exchanger 40. The purpose of the first bypass 305 can be to
divert a portion of the flow 51 away from the primary cooling loop
300 and through the heat exchanger 40 where the fluid can be
further subcooled and returned to the reservoir 200 to assist in
condensing vapor in the reservoir by further reducing the bulk
fluid temperature of the liquid coolant in the reservoir 200. As a
result, when the two-phase bubbly flow is delivered to the
reservoir via the return line 230, it immediately mixes in the
reservoir 200 with a large volume of coolant 50 that is well below
the saturation temperature of the liquid, thereby promoting
condensing of all vapor bubbles entering the reservoir via the
return line. The portion of flow 51 that is diverted through the
first bypass 305 can be controlled, at least in part, by adjusting
the valve 60 located in the first bypass 305. The preferred amount
of flow 51-1 that is diverted through the first bypass 305 may
depend on the reservoir temperature and/or the quality (x) of the
flow returning to the reservoir via the return line 230. For
example, if the temperature of the fluid in the reservoir 200
reaches a predetermined threshold value (e.g. if the temperature of
the coolant in the reservoir increases to about 10-15 degrees below
the saturation temperature of the coolant), or if the quality of
the flow in the return line 230 reaches a predetermined threshold
value (e.g. if the quality of the flow in the return line 230
reaches a value of about 0.25-0.35, 0.3-0.4, 0.35-0.5), it can be
desirable to increase the amount of flow through the first bypass
305 to reject heat from the coolant using the heat exchanger so
that cool liquid coolant can be circulated back to the reservoir
200 to ensure that vapor bubbles 275 entering via the return line
230 rapidly condense within the reservoir 200 and are not permitted
to reach the pump 20. Through this approach, a supply of
single-phase liquid coolant can be provided from the reservoir 200
to the pump to ensure stable pump operation.
[0295] In the schematic shown in FIG. 11A, the heat exchanger 40 is
positioned downstream of the valve 60, but this is not limiting. In
other examples, the valve 60 can be positioned downstream of the
heat exchanger 40, as shown in FIG. 12A, where the cooling
apparatus 1 has one heat sink module 100 mounted on a heat source
12 and a valve 60 located downstream of the heat exchanger 40 in
the first bypass 305.
[0296] As identified by dashed lines in FIG. 11D, the cooling
apparatus 1 can include a second bypass 310 including a valve 60.
The second bypass 310 can route a portion of the pressurized
single-phase liquid flow around the heat sink module 100 and can be
fluidly connect to the primary cooling loop 300 downstream of the
heat sink module 100. Depending on the surface temperature of the
heat-generating surface 12 and settings of the cooling apparatus
(e.g. pressure, flow rate, coolant type, bulk coolant temperature
at the module inlet 105, coolant saturation temperature, etc.), the
primary cooling loop 300 may be transporting two-phase bubbly flow
downstream of the outlet port 110 of the heat sink module 100. To
encourage condensing of bubbles 275 within the two-phase bubbly
flow before the coolant reaches the reservoir (and thereby reducing
the likelihood of vapor being introduced to the pump 20), the
second bypass 310 can route single-phase liquid coolant around the
heat sink module 100 and deliver the single-phase liquid coolant to
the primary cooling loop 300 that is carrying two-phase bubbly
flow, effectively mixing the two flows upstream of the reservoir
200. This mixing encourages condensing of all or a portion of the
bubbles in the two-phase bubbly flow before the flow is delivered
back to the reservoir 200 via the return line 230, thereby further
reducing the likelihood that any bubbles 275 will be drawn from the
reservoir 200 and fed to the pump, where they could cause unwanted
cavitation.
[0297] Because the bubbles 275 formed in the two-phase bubbly flow
are relatively small and are distributed (i.e. dispersed)
throughout the liquid coolant 50, the bubbles are carried through
the primary cooling loop 300 by the momentum of the liquid coolant
and do not travel vertically within the system due to gravitational
effects. Consequently, the cooling apparatus 1 does not require a
condenser mounted at a high point in the system to collect and
condense vapor bubbles back to liquid, as competing systems do.
Since no condenser is required, the cooling apparatus 1 can be much
smaller in size and less expensive than competing systems that
require a condenser. Also, the heat sink modules 100 and sections
of flexible tubing 225 described herein can be installed in any
orientation without concerns of vapor lock. To the contrary, in
competing systems, the orientation of system components can be
critical to ensure that all vapor is transported to a condenser
located at a high point in the system by way of gravity to ensure
that vapor does not make its way to the pump, where it could result
in vapor lock and/or pump cavitation and system failure.
[0298] As used herein, "fluid communication" between two or more
elements refers to a configuration in which fluid can be
communicated between or among the elements and does not preclude
the possibility of having a filter, flow meter, temperature or
pressure sensor, or other devices disposed between such elements.
The elements of the cooling apparatus 1 are preferably configured
in a closed fluidic system, as shown in FIG. 11A, thereby
permitting containment of the coolant 50 which could otherwise
evaporate into the environment.
Valve
[0299] The valve 60 can be any suitable type of valve that is
capable of maintaining suitable working pressure ranges and flow
rates within the cooling apparatus as described herein to ensure
smooth operation of the cooling apparatus 1. The valve 60 can
provide a differential pressure of about 1-100, 1-50, 5-25 psi, or
more preferably 1-5, 2-10, 5-12, 10-15, or 10-25 psi between an
inlet chamber 655 and an outlet chamber 665 of the manifold
assembly 680, as shown in FIGS. 103-105. In some examples, the
valve 60 can be a differential pressure bypass valve, as shown in
FIGS. 111 and 112. In other examples, the valve can be a ball
valve, gate valve, globe valve, needle valve, Tesla Valve,
diaphragm valve, or pressure regulator.
[0300] A differential pressure bypass valve 60 can include a valve
inlet 61 and a valve outlet 62, as shown in FIGS. 111 and 112. The
differential pressure bypass valve 60 can be configured to control
a flow of pressurized coolant through the bypass 310 of the cooling
apparatus 1 by establishing a pressure differential of about 1-5,
2-10, 5-12, 10-15, or 10-25 psi between the valve inlet 61 and the
valve outlet 62. The differential pressure bypass valve 60 can
include a bypass circuit 67 fluidly connecting the valve inlet 61
to the valve outlet 62 and a valve plug 64 disposed in the bypass
circuit, as shown in FIG. 112. The valve plug 64 can be configured
to restrict flow of pressurized coolant though the bypass circuit
67. The differential pressure bypass valve 60 can include a spring
68 disposed between the valve plug 64 and a control knob 63.
Tightening the control knob 63 can compress the spring 68 against
the valve plug 69 and increase a differential pressure setting of
the differential pressure bypass valve 60. The differential
pressure setting can be manually controlled or electronically
controlled and actuated by adjusting the control knob 63 with a
stepper motor or other suitable electromechanical device. In some
examples, the valve 60 can be a 519 Series differential pressure
bypass valve from Caleffi S.p.a of Italy.
[0301] In some examples, the differential pressure bypass valve 60
can be a two-way, self-contained proportional valve with an
integral differential pressure adjustment setting, as shown in
FIGS. 111 and 112. The valve 60 can have a valve inlet 61 and a
valve outlet 62. The valve 60 can be installed in the first bypass
305 and/or the second bypass 310, as shown, for example, in FIGS.
11D, 79, and 82. When installed in the second bypass 310, the valve
inlet 61 can be fluidly connected to the inlet chamber 655, and the
valve outlet 62 can be fluidly connected to the outlet chamber 665.
The differential pressure bypass valve 60 can prevent excessive
head pressure from occurring in the inlet chamber 655 by allowing a
flow of pressurized coolant to flow from the inlet chamber to the
outlet chamber 665 without passing through the flexible cooling
lines 300 and heat sink modules 100. The differential pressure
bypass valve 60 can open and begin bypassing flow when the
differential pressure reaches an adjustment setting, such as 1-100,
1-50, 5-25, or more preferably 1-5, 2-10, 5-12, 10-15, or 10-25
psi. In some examples, the second bypass 310 can be formed within
the manifold assembly 680, and the differential pressure bypass
valve 60 can be installed in the second bypass, as shown in FIG.
105, to provide an integrated valve manifold assembly. This
integrated valve manifold assembly 680 can reduce the number of
manifold assembly components and thereby reduce cost and assembly
time of the manifold assembly.
[0302] The size of the valve 60 can be selected based upon an
anticipated flow rate through the bypass (305, 310), which can
depend on, among other factors, the number of cooling lines 303
present in the cooling apparatus 1, the heat capacity of the
coolant 50 being used, and the heat load of the surfaces to be
cooled 12. In one example, the valve 60 can have a bypass circuit
67 with an inner diameter of about 0.75 inch and can flow up to 9
gpm. In another example, the valve 60 can have a bypass circuit 67
with an inner diameter of about 1 inch and can flow up to 40 gpm.
In yet another example, the bypass circuit 67 can have an inner
diameter of about 1.25 inches and can flow up to 45 gpm.
[0303] As shown in FIGS. 11A and 11D, the valve 60 can be located
in the second bypass 310 of the cooling apparatus 1 and can be used
to control the pressure differential between the inlet port 105 and
the outlet port 110 of the heat sink module (i.e. the pressure
differential between the high-pressure coolant 54 at the inlet port
105 and the low-pressure coolant 55 at the outlet port 110). By
doing so, the valve 60 can be used to adjust the flow rate through
the heat sink module 100. Where the cooling apparatus 1 has a
plurality of heat sink modules 100 fluidly connected in parallel to
the inlet manifold 210 and outlet manifold 215, as shown in FIG.
16, the valve 60 in the second bypass 310 can be used to control
the pressure differential between the inlet manifold 210 and the
outlet manifold 215, and thereby control flow through the heat sink
modules 100.
[0304] In the cooling apparatus 1 shown in FIG. 11A, by adjusting
the valve 60 located in the second bypass 310, the pressure
differential between the inlet port 105 and outlet port 110 can be
controlled. In the cooling apparatus 1 shown in FIG. 16, the valve
60 can be adjusted to provide a pressure differential between the
inlet manifold 210 and the outlet manifold 215. In one example, the
valve 60 can be adjusted to provide a pressure differential of
about 5-15 or 10-15 psi between the inlet manifold 210 and the
outlet manifold 215. For instance, if the high-pressure coolant 54
in the inlet manifold 210 is at a pressure of about 60 psi, the
valve 60 can be adjusted to maintain low-pressure coolant 55 in the
outlet manifold 215 at a pressure of about 45-55 or 45-50 psi. In
another example, if the high-pressure coolant 54 in the inlet
manifold 210 is at a pressure of about 30 psi, the valve 60 can be
adjusted to maintain low-pressure coolant 55 in the outlet manifold
215 at a pressure of about 15-25 or 15-20 psi. In yet another
example (where the contents of the cooling apparatus 1 are
evacuated using a vacuum pump prior to adding the coolant, such
that the resting pressure of the coolant is near or below
atmospheric pressure), if the high-pressure coolant 54 in the inlet
manifold 210 is at a pressure of about 15 psi, the valve 60 can be
adjusted to maintain low-pressure coolant 55 in the outlet manifold
215 at a pressure of about 0-10 or 0-5 psi.
[0305] The valve 60 located in the second bypass 310 of the cooling
apparatus 1, as shown in FIG. 16, can be adjusted to control the
coolant flow rate through the second bypass 310, and by doing so,
can simultaneously adjust the coolant flow rate through the heat
sink modules 100. For instance, as the pressure differential
between the inlet manifold 210 and the outlet manifold 215 shown in
FIG. 16 is decreased by adjusting the valve 60 located in the
second bypass 310, a higher percentage of coolant flow 51 will pass
through the valve 60, effectively bypassing the heat sink modules
100 and resulting in a reduced coolant flow rate through the heat
sink modules. Conversely, as the pressure differential between the
inlet manifold 210 and outlet manifold 215 is increased by
adjusting the valve 60 located in the second bypass 310, a lower
percentage of coolant flow 51 will pass through the valve 60,
resulting in an increased coolant flow rate through the heat sink
modules 100.
[0306] As shown in FIG. 16, the valve 60 can be arranged in
parallel with a plurality of cooling lines extending between the
inlet and outlet manifolds (210, 215). Coolant flow through the
valve 60 and the cooling lines can be similar to the way current
flows in a circuit with resistors arranged in parallel. Increasing
the flow resistance of the regulator 60 will decrease the flow
through the second bypass 310 and increase the flow rate through
the cooling lines. Conversely, decreasing the flow resistance of
the regulator 60 will increase the flow through the second bypass
310 and decrease the flow rate through the cooling lines.
Similarly, increasing the flow resistance of the regulator 60 in
the first bypass will decrease the flow rate through the heat
exchanger 40, and decreasing the flow resistance of the regulator
60 in the first bypass will increase the flow rate through the heat
exchanger 40.
[0307] In some examples, the valve 60 can be a relief valve, such
as a Series 69 relief valve manufactured by Aquatrol, Inc. of
Elburn, Ill. One suitable relief valve has an adjustment range of
about 0-15 psi and a maximum flow rate of about 6.9 gallons per
minute. The valve 60 can be suitable for a cooling apparatus 1
configured to cool multiple racks 410 of servers 400, as shown in
FIG. 3. For applications where a larger or smaller number of racks
of servers must be cooled, a valve with a larger or smaller maximum
flow rate can be selected, respectively.
Flow Control Based on Two-Phase Flow Sensor
[0308] In some examples, the quality (x) of the two-phase bubbly
flow exiting the heat sink module(s) 100 can be monitored with a
sensor 880, and an output signal from the sensor can be input to an
electronic control unit 850 capable of changing one or more
operating conditions of the cooling apparatus 1. For instance, when
the flow quality (x) exiting the heat sink module 100 reaches a
predetermined threshold value (e.g. about 0.25, 0.3, 0.35, or 0.4),
the flow resistance of the valve 60 in the second bypass 310 can be
increased to reduce the flow rate through the valve and increase
the flow rate through the heat sink module(s) 100, thereby reducing
the quality (x) of the flow exiting the heat sink module(s) to
ensure the bubbly-flow does not transition to slug flow or churn
flow (see FIG. 59B) within the flexible tubing 225, which could
result in flow instabilities.
[0309] In another example, when the flow quality (x) exiting the
heat sink module 100 reaches a predetermined threshold value, the
pump 20 speed can be increased to increase the mass flow rate of
coolant 50 (e.g. by increasing coolant pressure, velocity, or both)
through the cooling line(s) 303 and heat sink module(s) 100,
thereby reducing the quality (x) of the flow exiting the heat sink
module(s) to ensure the two-phase bubbly-flow does not transition
to slug flow or churn flow (see FIG. 59B) within the flexible
tubing 225, which could result in flow instabilities.
[0310] The flow sensor 880 can be any suitable sensor capable of
detecting flow quality, flow patterns, or void fraction
identification. The sensor can employ high-speed photography,
x-ray, or other suitable imaging techniques. In some examples, the
sensor 880 can employ ultrasonic sensing. The sensor 880 can
include one ultrasonic sensor or an array of ultrasonic sensors.
The sensor 880 can include integrated signal conditioning software.
The sensor 880 can be noninvasive to the cooling lines 303. The
output from the flow sensor 880 can be delivered as input to the
electronic control unit 850 wirelessly or through a wired
connection. In some examples, the electronic control unit 850 can
be connected to an intranet system, thereby allowing the output
from the flow sensor to be viewed on a remote terminal, such as a
computer in an adjacent office building. The output signal of the
flow sensor can be stored on a computer readable medium, and the
output versus time can be analyzed against CPU utilization to
identify unexpected variations in flow quality that may predict
when maintenance of the cooling apparatus, such as maintenance of
pump seals, is required.
Pump
[0311] The pump 20 can be any pump capable of generating a positive
coolant pressure that forces coolant 50 to circulate through the
cooling apparatus 1. In some examples, the pump 20 can generate a
positive coolant pressure that forces coolant through the primary
cooling loop 300, into an inlet port of a heat sink module 100, and
through a plurality of orifices 155 within the heat sink module,
thereby transforming the flow of coolant into a plurality of jet
streams 16 of coolant that impinge against the surface to be cooled
12, as shown in FIG. 26. In some examples, it can be desirable to
select a pump 20 that is capable of pumping single-phase liquid
coolant and increasing the pressure of the coolant to about 5-20,
15-30, 25-45, 30-50 40-65, 50-75, 60-85, 75-150, 5-200, 5-150, or
100-200 psi. Lower pressures can be desirable for reducing power
consumption by the pump and thereby increasing overall efficiency
of the cooling apparatus 1. A desired coolant pressure can depend
on the type of coolant selected, the boiling point of that coolant,
and the temperatures of the one or more surfaces to be cooled
12.
[0312] To allow the cooling apparatus 1 to operate at a relatively
low pump outlet pressure, and thereby consume minimal power and
allow for the use of lightweight, inexpensive, flexible tubing 225,
it can be desirable to select a coolant 50 that has a boiling point
that is a predetermined number of degrees below the temperature of
the surface to be cooled 12 at the system operating pressure. In
some examples, a coolant 50 with a boiling point about 10-20,
15-25, 20-30, 25-35, 30-45, 40-60, or 50-75 degrees C. below the
temperature of the surface to be cooled 12 can be selected, where
the boiling point of the coolant is determined at a pressure
coinciding with an inlet pressure at the heat sink module 100.
Experiments show that providing coolant to a first heat sink module
100 at about 10-20 degrees C. below the temperature of the surface
to be cooled 12 provides effective cooling and formation of bubbly
flow in subsequent series-connected heat sink modules 100.
[0313] When adapting the cooling apparatus 1 to cool
microprocessors 415 that operate with junction temperatures of
about 50-90 degrees C., it can be desirable to select a dielectric
coolant such as HFE-7000 that has a boiling point of about 34
degrees C. at 1 atm. In this arrangement, the pump outlet pressure
can be set to about 5-35 or 15-25 psia to achieve suitable
operation, and the valve 60 in the first bypass 305 can be adjusted
to divert about 30-60% of the flow 51 from the pump outlet 22
through the first bypass 305 and through the heat exchanger 40 to
ensure a volume of adequately subcooled coolant in the reservoir
200. In FIG. 75, this first bypass flow is identified as 51-1. When
adapting the cooling apparatus 1 to cool power electronic devices
that operate at temperatures of about 90-120 degrees C., it can be
desirable to select a dielectric coolant with a higher boiling
point, such as HFE-7100 that has boiling point of about 61 degrees
C. at 1 atm. When adapting the cooling apparatus 1 to cool an
electrical device having a temperature of about 45-100 degrees C.,
it can be desirable to select a dielectric coolant such as HFE-7000
that has a boiling point of about 34 degrees C. at 1 atm or R-245fa
that has a boiling point of about 15 degrees C. at 1 atm.
[0314] The pump outlet pressure and valves 60 can be adjusted to
provide a suitable flow of coolant though the heat sink module 100
whereby a portion of the liquid coolant changes to vapor and a
portion of the coolant remains liquid to produce a two-phase bubbly
flow having a quality below a predetermined threshold to ensure
stable flow within the cooling apparatus 1.
[0315] In some examples, the contents of the cooling apparatus 1
can be evacuated using a vacuum pump prior to adding the coolant
50, thereby resulting in a sub-atmospheric pressure within the
cooling apparatus 1. The coolant can then be added to the system
from a container that has been degassed and is also at a
sub-atmospheric pressure. Once inside the system, the coolant will
remain at a sub-atmospheric pressure. When the pump 20 is
activated, it pumps single-phase liquid coolant and increases the
pressure of the coolant to about 5-20, 10-25, or 15-30 psi at the
pump outlet 22. In this example, the coolant 50 can be HFE-7000,
and the pump pressure can be set at a suitable value to provide a
flow rate of about 0.25-1.75, 0.7-1.3, 0.8-1.2, or 0.9-1.1 liters
per minute or about 1.0 liter per minute through each heat sink
module 100 in the cooling apparatus 1.
[0316] In other examples, the coolant can be HFE-7000, HFE-7100,
R-245fa, or a mixture thereof. In some examples, the coolant can be
100% HFE-7000, 100% HFE-7100, or about 60-95, 70-95, or 85-95%
HFE-7000 by volume and the remainder can include R-245fa. In any of
these examples, the pump pressure can be set at a suitable value to
provide a flow rate of about 0.25-1.75, 0.7-1.3, 0.8-1.2, or
0.9-1.1 liters per minute through each heat sink module 100 in the
cooling apparatus 1. Where multiple (i.e. two or more) heat sink
modules 100 are connected in series along a cooling line 303, the
pump pressure can be set a suitable value to provide a flow rate of
about 0.25-1.75, 0.7-1.3, 0.8-1.2, or 0.9-1.1 liters per minute
through the cooling line 303 in the cooling apparatus 1.
[0317] In one example, the pump 20 can be a variable speed positive
displacement pump, such as a MICROPUMP gear pump by Cole-Parmer of
Vernon Hills, Ill. In another example, where the cooling apparatus
1 is configured to cool several racks 410 of servers 400, as shown
in FIGS. 1-3, the pump 20 can be a 1.5 HP vertical, multistage,
in-line, centrifugal pump, such as Model No. A96084444P115030745
from Grundfos headquartered in Denmark. In a redundant
configuration, as shown in FIGS. 9 and 10, the redundant cooling
apparatus 2 can have two Grundfos pumps 20 operating simultaneously
or with one pump operating and an automatic failover circuit that
activates the second pump if the first pump fails. FIG. 96 shows an
exploded view of a horizontal, in-line, centrifugal pump 20 with a
first shut-off valve 250 located near a pump inlet 21 and a second
shut-off valve 250 located near a pump outlet 22.
[0318] In one configuration shown in FIGS. 92-95, the cooling
apparatus 1 can have two parallel redundant pumps (20-1, 20-2) that
supply pressurized coolant to a common cooling apparatus 1. In this
configuration, each pump 20 can be sized to independently provide
an adequate flow 51 of pressurized coolant 50 to the cooling
apparatus 1, thereby requiring operation of only one pump at a
time, while the other pump remains on standby. The cooling
apparatus 1 can include a failover circuit that, in case of failure
of a first pump 20-1, automatically detects the failure and
activates a second pump 20-2 to provide a nearly uninterrupted flow
51 of pressurized coolant 50 through the system 1. In one example,
pump failure can be detected by monitoring a signal from a pressure
sensor 880 mounted at a sensor mounting location 875 near a pump
outlet 22 and identifying a failure when the signal decreases below
a predetermined lower threshold value. For instance, if the
pressure decreases more than 20 percent below a target value, the
microcontroller 850 may identify a pump failure, deactivate the
first pump 20-1, and activate the second pump 20-2. Deactivating
the first pump 20-1 can include commanding shut-off valves 250 at
in inlet and an outlet of the first pump to close, and activating
the second pump 20-2 can include commanding shut-off valves 250 at
an inlet and an outlet of the second pump to open. Closing shut-off
valves 250 associated with the first pump 20-1 can minimize flow
restrictions in the primary cooling loop 300 and thereby reduce
pumping losses and improve system efficiency.
[0319] Although a constant speed pump 20 can be used for
simplicity, a variable speed pump (e.g. a pump 20 having a variable
speed drive 80) can provide greater flexibility for cooling dynamic
heat loads, such as microprocessors 415 with varying utilization
rates and temperatures, since the variable speed pump can enable
the flow 51 of coolant 50 to be adjusted to meet a flow rate
required to cool the estimated (e.g. theoretical) or actual (e.g.
measured) heat load at the one or more surfaces to be cooled 12,
and then adjusted in real-time if the heat load is greater or less
than the estimated heat load. More specifically, increasing the
flow rate of coolant 50 may be required where the heat load is
greater than the estimated heat load to avoid reaching critical
heat flux at the surface to be cooled 12. Alternately, decreasing
the flow rate of coolant 50 may be required where the heat load is
less than the estimated heat load to reduce unnecessary power
consumption by the pump 20. The variable speed drive 80 can be
controlled by an electronic control unit 850 of the cooling
apparatus 1.
[0320] A variable speed pump 20 can also be used to automatically
adjust pump speed to compensate for changes in the number of
servers 400 connected to the cooling apparatus 1. For instance,
where quick-connect fittings are provided on the inlet and outlet
manifolds, a service technician may need to connect or disconnect
several servers 400 (or an entire rack 410 of servers) from the
cooling apparatus 1 without the facility experiencing downtime. In
these instances, the servers 400 can be added or removed without
requiring the service technician to make any adjustments to the
pump pressure. In many data center facilities, a clear division
exists between information technology (IT) departments and
facilities departments. Servers are maintained by the IT
department, and mechanical systems, such as pumps 20, are
maintained by the facilities department. Allowing the IT department
to add and remove servers without requiring assistance from the
facilities department is desirable and saves both departments time.
Therefore, having a variable speed drive on the pump 20 is
desirable, since it allows the cooling apparatus 1 to automatically
adjust the pump outlet pressure to accommodate a change to the
number of servers. This allows an IT professional to change the
number of servers without requiring a facilities professional to
adjust the pump or regulator settings immediately thereafter.
[0321] In some examples, a pressurizer can be used in place of or
in addition to the pump 20. The pressurizer can be pressurized by
any suitable method or device, such as a pneumatic or hydraulic
device that coverts mechanical motion to fluid pressure to provide
a volume of pressurized coolant within the pressurizer that is then
used to circulate coolant 50 through the cooling apparatus 1.
Reservoir
[0322] In the cooling system 1, the pump 20 can be in fluid
communication with a coolant reservoir 200. In some examples, the
reservoir 200 can be a metal tank, such as a steel or aluminum tank
(see, e.g. FIG. 3), or a plastic tank with a suitable pressure
rating and made of a polymer that is compatible with the coolant
50. In other examples, the reservoir 200 can be any suitable vessel
that is capable of receiving a volume of coolant and safely housing
the volume of coolant in compliance with governing regulations. For
instance, as shown in FIGS. 92-95, the reservoir 200 can be a
section of pipe having a suitable interior volume to hold an
adequate supply of coolant, where the interior volume of the pipe
is defined by a length and inner diameter of the pipe. The
reservoir 200 shown in FIGS. 92-95 can have an inner diameter of
about 1.5-3.0 inches and a length of about 4-6 feet. In some
examples, it can be desirable for the reservoir 200 to have an
interior volume capable of holding at least 15, 20, or 25 percent
of the total volume of coolant in the cooling apparatus 1. The
reservoir 200 can supply subcooled liquid coolant to the pump 20
for stable pump operation. The reservoir 200 can be located above
the pump 20, as shown in FIGS. 92-95, to provide adequate head
pressure to ensure a continuous supply of coolant 50 from the
reservoir 200 to the pump inlet 21.
[0323] As described herein, with respect to certain embodiments of
the cooling apparatus 1, such as embodiments shown in FIGS. 11A-D,
the reservoir 200 can be configured to receive a variety of fluid
flows, including two-phase bubbly flow via a primary cooling loop
300 and single-phase liquid flow via a first bypass loop 305.
However, despite receiving two-phase bubbly flow via the return
line 230 of the primary cooling loop 300, the cooling apparatus 1
can be configured to provide exclusively single-phase liquid
coolant from a reservoir outlet to an inlet 21 of the pump 20. As
vapor bubbles 275 are introduced to the reservoir by bubbly flow
from the return line 230, the bubbles 275 tend to migrate to the
top of the reservoir 200, and single-phase liquid tends to settle
in the lower portion of the reservoir due to gravitational effects.
A section of tubing 220, such as rigid or flexible section of
tubing, can connect the reservoir 200 to the inlet 21 of the pump
20. In some examples, the section of tubing 220 can connect to a
reservoir outlet located along a lower portion of the reservoir
200, and preferably at or near a bottom portion of the reservoir,
to ensure that only single-phase liquid coolant, and not two-phase
coolant, is drawn from the reservoir and provided to the inlet 21
of the pump 22. Providing only single-phase liquid coolant to the
pump 20 can ensure that cavitation within the pump is avoided.
Cavitation can occur if two-phase flow is provided to the pump, and
is undesirable, since it can damage pump components, resulting in
diminished pump capacity or pump failure.
[0324] To ensure that only single-phase liquid coolant is provided
to the pump 20, and thereby avoiding pump cavitation, the volume of
coolant in the reservoir 200 can be selected to be a certain volume
ratio of the total volume of coolant in the cooling apparatus 1.
Increasing the volume ratio can increase the likelihood that any
vapor bubbles 275 within the two-phase bubbly flow being delivered
to the reservoir 200 from the one or more heat sink modules 100
will have an opportunity to condense back to liquid before that
quantity of coolant is drawn from the reservoir 200 and delivered
back to the pump inlet 21 for recirculation through the cooling
apparatus 1. The preferred volume ratio can depend on a variety of
factors, including, for example, the heat load associated with the
surface being cooled 12, the properties of the coolant 50 being
used, the flow rate of coolant in the system, the flow quality (x)
of coolant being returned to the reservoir 200, the percentage of
coolant flow 51 being diverted through the first and second
bypasses (305, 310), the operating pressure of the coolant, and the
performance of the heat exchanger 40. In some examples, the volume
ratio can be about 0.2-0.5, 0.4-1.0, 0.6-1.5, 1.0-2.0, or greater
than 2.0. It can be desirable to encourage condensing of any
bubbles that may be delivered to the reservoir 200 as two-phase
bubbly flow from the one or more heat sink modules 100. Experiments
have shown that maintaining the reservoir 200 at a fill level of
about 30-90%, 40-80%, or 50-70%, (where fill level is defined as
the percent volume of the reservoir 200 occupied by liquid coolant
50) results in effective condensing of bubbles 275 that are
delivered to the reservoir by the return line 230. A liquid-vapor
interface is established at the fill level of the reservoir 200,
and this liquid-vapor interface may encourage condensation of the
bubbles 275 due to hydrodynamic effects acting on the two-phase
bubbly flow as it is delivered to (e.g. poured or sprayed into) the
reservoir 200 and passes through the liquid-vapor interface within
the reservoir and mixes with the sub-cooled single-phase liquid
coolant residing in the reservoir. As shown in FIG. 3, the return
line 230 carrying the two-phase bubbly flow can deliver the
two-phase bubbly flow near an upper portion of the reservoir 200.
In some examples, the delivery point of two-phase bubbly flow to
the reservoir 200 can be located above the fill level of the
reservoir to ensure the two-phase bubbly flow is delivered into the
head space (i.e. vapor region) of the reservoir, such that gravity
draws the two-phase bubbly flow downward through the liquid-vapor
interface.
[0325] In some examples, the reservoir 200 can include a baffle 204
positioned in the head space of the reservoir; partially in the
head space filled with coolant vapor 203 and partially below the
fill level (i.e. passing through the liquid-vapor interface 202),
as shown in FIGS. 82 and 115; or beneath the liquid-vapor interface
202, as shown in FIG. 83. The baffle 204 can promote condensing of
vapor bubbles 275 in two-phase bubbly flow entering the reservoir
200. The baffle 204 can span all or a portion of the reservoir 200
and can be positioned horizontally, vertically, or obliquely within
the reservoir. The baffle can ensure that no direct (i.e. linear)
flow pathway exists in the reservoir 200 between a flow inlet and a
flow outlet, thereby establishing only non-linear flow pathways
that provide longer average residence times for coolant returning
to the reservoir, which increases the likelihood that all vapor
bubbles 275 in the coolant will condense (through interactions with
subcooled liquid coolant in the reservoir) prior to exiting the
reservoir through the flow outlet and reaching the pump inlet
21.
[0326] The baffle 204 can be made of a thermally conductive
material, such as steel, aluminum, or copper. When two-phase bubbly
flow 51 is delivered to the reservoir 200, the flow can pass
through openings (e.g. a plurality of slots or holes) in the
baffle, and heat can transfer from the two-phase bubbly flow to the
baffle and, in some cases, to the walls of the reservoir 200 to
which the baffle is mounted or in contact with. As heat is
transferred away from the two-phase bubbly flow, bubbles 275 within
the coolant 50 can condense, either due to decreases in the bulk
fluid temperature in the reservoir or due to local decreases in
fluid temperature proximate the condensing bubbles. The openings in
the baffle can have any suitable shape. Non-limiting examples of
baffle opening shapes include triangular, round, oval, rectangular,
or hexagonal, or polygonal.
Manifold Assembly
[0327] The cooling apparatus 1 can include a manifold assembly 680
for conveying and distributing coolant within the cooling
apparatus. The manifold assembly 680 can deliver coolant to the
cooling lines 300 connected to the heat sink modules 100 and
receive coolant from the cooling lines 300. The manifold assembly
680 can include a separate inlet manifold 210 and a separate outlet
manifold 215, as shown in FIGS. 4, 82, and 104, where the inlet
manifold 210 includes an inlet chamber 655 and the outlet manifold
215 includes an outlet chamber 665. Alternately, the manifold
assembly 680 can be a single manifold body 681, as shown in FIGS.
101-103, 105, and 106, with an inlet chamber 655, an outlet chamber
665, and a bypass 310, formed within the manifold body 680.
[0328] As shown in FIG. 12T, an inlet manifold 210 can receive
coolant 50 and can deliver the coolant to one or more flexible
tubes 225 that deliver the coolant to one or more heat sink modules
100 fluidly connected between the inlet manifold 210 and an outlet
manifold 215. The inlet manifold 210 can have an inlet chamber 655
with an inner volume that serves as an in-line reservoir for the
coolant and effectively dampens pressure pulsations in the flow 51
of coolant that may be transmitted from the pump 20. In some
examples, the proper size of the inner volume of the inlet manifold
210 can be determined by the flow rate of coolant 50 through the
inlet manifold. For instance, the inner volume of the inlet
manifold 210 can be configured to hold a volume of coolant that is
greater than or equal to a volume equivalent to at least 5 seconds
of coolant flow through the manifold. So for a coolant flow rate of
about 1 liter/minute, the inlet manifold 210 can have an inner
volume of about 0.083 liters. For smoother operation, and greater
damping of pressure pulsations, the inlet manifold 210 can have an
inner volume capable of storing at least 10, 15, 20, 60 or more
seconds of coolant flow 51. The outlet manifold 215 can be
configured to have an outlet chamber 665 with a similar internal
volume as the inlet manifold 210 to provide similar damping of
pressure pulsations between the heat sink modules 100 and the
return line 230.
[0329] The manifold assembly 680 shown in FIGS. 100-102 and 128 can
support up to 30 cooling lines 303. The inlet chamber 655 and
outlet chamber 665 of the manifold assembly 680 shown in FIGS.
100-102 and 128 can each have an inner diameter of about 0.5-1.5,
0.75-1.25, or preferably about 0.9 in. The inlet and outlet chamber
(655, 665) of the manifold assembly 680 can each have a length of
about 45-80, 50-70, or preferably about 60 inches. The inlet and
outlet chamber (655, 665) of the manifold assembly 680 can each
have an inner volume of about 20-60 or 30-50 in.sup.3 or preferably
about 38 in.sup.3 and can each hold about 0.08-0.25, 0.12-0.21, or
preferably about 0.17 gallons of coolant 50.
[0330] The manifold assembly 680 shown in FIG. 106 can support up
to 7 cooling lines 303. The inlet chamber 655 and outlet chamber
665 of the manifold assembly 680 shown in FIG. 106 can each have an
inner diameter of about 0.5-1.5, 0.75-1.25, or preferably about 0.9
in. The inlet and outlet chamber (655, 665) of the manifold
assembly 680 can each have a length of about 10-20, 12-16, or
preferably about 13.8 inches. The inlet and outlet chamber (655,
665) of the manifold assembly 680 can each have an inner volume of
about 4-14 or 7-12 in.sup.3 or preferably about 9 in.sup.3 and can
each hold about 0.02-0.06, 0.03-0.05, or preferably about 0.04
gallons of coolant 50.
[0331] FIG. 12T shows a schematic of a cooling apparatus 1
configured to cool two racks 410 of servers 400. The cooling
apparatus 1 in FIG. 12T has a similar configuration as the cooling
apparatus 1 shown in FIGS. 1-3, but the cooling apparatus 1 in FIG.
12T only shows two server racks 410, whereas the cooling apparatus
in FIGS. 1-3 shows eight server racks 410. Also, the cooling
apparatus 1 in FIG. 12T shows fewer parallel cooling lines
extending between each inlet and outlet manifold (210, 215).
Nevertheless, the concept is similar. The cooling apparatus 1 in
FIG. 12T includes a dedicated inlet manifold 210 and outlet
manifold 215 for each server rack 410. This configuration provides
a modular cooling system 1 that can be increased in size to
accommodate additional server racks 410, for example, as a data
center 425 increases its server count. Therefore, the configuration
in FIG. 12T can easily be modified to resemble the configuration
shown in FIGS. 1-3 by adding six additional server racks 410 and by
increasing the number of cooling lines extending between each inlet
and outlet manifold (210, 215).
[0332] FIG. 4 shows a rear side view of a server rack 410 with an
inlet manifold 210 and outlet manifold 215 mounted vertically to
the server rack 410. The inlet manifold 210 and the outlet manifold
215 can be fitted with a plurality of fittings 235, such as
quick-connect fittings, that permit individual cooling loops 300 to
be hot swapped without interrupting coolant flow through other
cooling loops 300 of the apparatus 1. As shown in FIG. 4, the inlet
and outlet manifolds (210, 215) can each include a plurality of
fittings to permit a plurality of cooling lines 300 to be connected
to each manifold. In some examples, the inlet and outlet manifolds
(210, 215) can include extra, unutilized fittings 235, as shown in
FIG. 4, to permit future expansion of the number of servers 400
cooled by the cooling apparatus 1.
[0333] Although the inlet and outlet manifolds (210, 215) are shown
in a vertical orientation in FIG. 4, this is not limiting. As
discussed herein, because the vapor bubbles 275 within the
two-phase bubbly flow are effectively dispersed and suspended in
the coolant flow and do not seek a high point in the cooling
apparatus 1 in response to gravitational effects, the system
components (such as the outlet manifold 215) do not need to be
vertically oriented to ensure collection of vapor, as competing
systems do. Consequently, the outlet manifold 215 can be oriented
horizontally or at any other suitable orientation that is
preferable for a particular installation in view of space
constraints and manifold size and shape.
[0334] FIG. 100 shows a front perspective view of a manifold
assembly 680 for use with a cooling apparatus 1. The manifold
assembling 1 includes an inlet chamber 655, an outlet chamber 665,
thirty quick-connect fittings 235 fluidly connected to the inlet
chamber, thirty quick-connect fittings 235 fluidly connected to the
outlet chamber, a bypass 310 fluidly connecting the inlet chamber
to the outlet chamber, and a valve 60 disposed in the bypass. FIG.
101 shows a left side view of the manifold assembly 680 of FIG.
100. FIG. 102 shows the manifold assembly 680 of FIG. 100 mounted
to a server rack 410.
[0335] FIG. 103 shows a rear view of a manifold assembly 680 with a
valve 60. Fluid passageways through the manifold assembly 680 are
depicted with dashed lines. FIG. 104 shows a rear view of a
manifold assembly 680 having a valve 60 and separate inlet and
outlet manifolds (210, 215). Fluid passageways through the manifold
assembly 680 are depicted with dashed lines. FIG. 105 shows a rear
view of a manifold assembly 680 including an integrated valve 60.
Fluid passageways through the manifold body 681 are depicted with
dashed lines.
[0336] FIG. 106 shows a front perspective view of a manifold
assembly 680 for use with a cooling apparatus 1. The manifold
assembling includes an inlet chamber 655, an outlet chamber 665,
seven quick-connect fittings 235 fluidly connected to the inlet
chamber, seven quick-connect fittings 235 fluidly connected to the
outlet chamber, a bypass 310 fluidly connecting the inlet chamber
to the outlet chamber, and a valve 60, such as a differential
pressure bypass valve, disposed in the bypass.
[0337] A manifold assembly 680 for a two-phase cooling system 1 can
include an inlet chamber 655, as shown in FIGS. 103-105. The inlet
chamber 655 can include a first inlet chamber end 605, a second
inlet chamber end 610 opposite the first inlet chamber end, a first
flow inlet 615 proximate the first inlet chamber end, and a first
flow outlet 620 proximate the second inlet chamber end. A first
plurality of quick-connect fittings 235 can be installed in a first
plurality of openings 661. The first plurality of openings 661 are
shown in FIGS. 103-105. The first plurality of openings 661 can
pass through a bounding surface, such as a wall, of the inlet
chamber 655. Quick connect fittings 235 are shown installed in the
first plurality of openings 661 in the manifold body 681 in FIGS.
100-102 and 106. The manifold assembly 680 can include an outlet
chamber 665 having a first outlet chamber end 625, a second outlet
chamber end 630 opposite the first outlet chamber end, a second
flow inlet 635 proximate the first outlet chamber end, and a second
flow outlet 640 proximate the second outlet chamber end. A second
plurality of quick-connect fittings 235 can be installed in a
second plurality of openings 676 that extend through a bounding
surface, such as a wall, of the outlet chamber 665. The manifold
assembly 680 can include a bypass 310 fluidly connecting the first
flow outlet 620 of the inlet chamber 655 to the second flow inlet
635 of the outlet chamber. A differential pressure bypass valve 60
can be positioned in the bypass 310 and configured to control a
flow of pressurized coolant from the inlet chamber 655 to the
outlet chamber 665 through the bypass to maintain a pressure
differential between the inlet chamber and the outlet chamber.
[0338] The differential pressure bypass valve 60 can include a
valve inlet 61 and a valve outlet 62, as shown in FIGS. 111 and
112. The differential pressure bypass valve 60 can be configured to
control a flow of pressurized coolant through the bypass 310 of the
cooling apparatus 1 by establishing a pressure differential of
about 1-5, 2-10, 5-12, 10-15, or 10-25 psi between the valve inlet
61 and the valve outlet 62. The differential pressure bypass valve
60 can include a bypass circuit 67 fluidly connecting the valve
inlet 61 to the valve outlet 62 and a valve plug 64 disposed in the
bypass circuit, as shown in FIG. 112. The valve plug 64 can be
configured to restrict flow of pressurized coolant though the
bypass circuit 67. The differential pressure bypass valve 60 can
include a spring 68 disposed between the valve plug 64 and a
control knob 63. Tightening the control knob 63 can compress the
spring 68 against the valve plug 69 and increase a differential
pressure setting of the differential pressure bypass valve 60. The
differential pressure setting can be manually controlled or
electronically controlled and actuated by adjusting the control
knob 63 with a stepper motor or other suitable electromechanical
device.
[0339] The first plurality of quick-connect fittings 235, as shown
in FIGS. 107-110, can each include an internal non-spill shut-off
valve 723. The non-spill shut-off valve 723 can be formed within a
body of the quick-connect fitting. The non-spill shut-off valve 723
can prevent coolant from spilling on a facility floor when servers
are being hot swapped and a coupler insert 725 is engaged with or
disengaged from a coupler body 720. When the cooling line assembly
303 is detached from the manifold assembly 680 during hot-swapping,
the non-spill shut-off valves 723 in the quick-connect fittings 235
can allow the cooling line assembly to retain pressurized coolant
50 within its inner volume, thereby preventing the cooling line
assembly from ingesting air and avoiding introducing air into the
cooling system when the cooling line assembly is reconnected to the
manifold assembly.
[0340] To ensure compatibility with a hydrofluoroether coolant,
each non-spill shut-off valve 723 can be lubricated with
silicone-based grease to prevent the non-spill valve from sticking.
The quick-connect fittings 235 can each include a butyl rubber
sealing member 741, as shown in FIGS. 108 and 110, that is
compatible with hydrofluoroether coolant.
[0341] FIGS. 107-110 show a variety of quick-connect fittings with
non-spill shut off valves 723 that can be used in the manifold
assembly 680 and the cooling line assembly 303. FIG. 107 shows a
quick connect fitting 235 having a connection feature (e.g. a
barbed end 735) and a coupler body 721 configured to receive a
coupler insert 725. The quick-connect fitting 235 in FIG. 107
includes a non-spill shut-off valve recessed within a body of the
fitting. The barbed end 735 can be configured to insert within in
an inner diameter of flexible tubing 225 of a cooling line 303. The
fitting 235 shown in FIG. 107 also includes a release button 721
that disengages the coupler body 720 from the coupler insert 725.
FIG. 108 shows a quick connect fitting 235 with a threaded end 730
and a coupler insert 725 configured to mate with the coupler body
720 shown in FIG. 107. The threaded end 730 can be suitable for
threading into an opening (661, 676) in the manifold assembly 680
(see, e.g., FIG. 106). FIG. 109 shows a quick connect fitting 235
having a threaded end 730 and a coupler body 720 configured to
receive a coupler insert 725, as shown in FIG. 110. FIG. 110 shows
a quick connect fitting 235 with a connection feature (e.g. a
barbed end 735) and a coupler insert 725 configured to mate with
the coupler body 720 shown in FIG. 109. The coupler insert 725 of
FIG. 110 has a sealing member 741, such as a butyl rubber O-ring,
to provide a fluid-tight seal against an inner surface of the
coupler body 720 of FIG. 109.
[0342] A manifold assembly 680 for a cooling system 1 can include
an inlet chamber 655 having a first inlet chamber end 605, a second
inlet chamber end 610 opposite the first inlet chamber end, a first
flow inlet 615 proximate the first inlet chamber end, and a first
flow outlet 620 proximate the second inlet chamber end, as shown in
FIGS. 103-105. The manifold assembly 680 can include a first
plurality of openings 661 extending through a bounding wall of the
inlet chamber 655. The first plurality of openings 661 can include
two or more openings each configured to receive a quick-connect
fitting 235, such as a threaded fitting shown in FIG. 108 or FIG.
109. The manifold assembly 680 can include an outlet chamber 665
including a first outlet chamber end 625, a second outlet chamber
end 630 opposite the first outlet chamber end, a second flow inlet
635 proximate the first outlet chamber end, and a second flow
outlet 640 proximate the second outlet chamber end. A second
plurality of openings 661 can extend through a bounding wall of the
outlet chamber 655. The second plurality of openings 676 can
include two or more openings each configured to receive a
quick-connect fitting 235, such as a threaded fitting shown in FIG.
108 or FIG. 109. The manifold assembly 680 can include a bypass 310
fluidly connecting the first flow outlet 620 of the inlet chamber
655 to the second flow inlet 635 of the outlet chamber 665. A
differential pressure bypass valve 60 can be positioned in the
bypass 310 and configured to regulate a flow of pressurized coolant
from the inlet chamber 655 to the outlet chamber 665 through the
bypass 310.
[0343] As shown in FIG. 105, a manifold 681 for a cooling system
can include an inlet chamber 655 and an outlet chamber 665. The
inlet chamber 655 can have a first flow inlet 615 and a first flow
outlet 620. A first plurality of openings 661 can extend through a
wall of the inlet chamber. The first plurality of openings 661 can
include two or more openings each configured to receive a
quick-connect fitting 235. The outlet chamber 665 can include a
second flow inlet 635 and a second flow outlet 640. A second
plurality of openings 676 can extend through a wall of the outlet
chamber. The second plurality of openings 676 can include two or
more openings each configured to receive a quick-connect fitting
235. The manifold 681 can include a bypass 310 fluidly connecting
the first outlet 620 of the inlet chamber 655 to the second inlet
635 of the outlet chamber 665. A valve 60 can be integrated into
the bypass 310 and configured to control a flow of pressurized
coolant from the inlet chamber 655 to the outlet chamber 665
through the bypass 310. By doing so, the valve 60 can maintain a
pressure differential between the inlet chamber 655 and the outlet
chamber 665 of the manifold assembly 680. The valve 60 can be a
differential pressure bypass valve. The differential pressure
bypass valve may not include a valve body 69 like the one shown in
FIGS. 112 and 113. Instead, the inner components of the valve 60
can be installed directly in the bypass, and the inner walls of the
bypass can have dimensions that replicate the inner surfaces of the
valve body 69. For instance, the bypass 310 can include a bore 682
configured to receive the valve plug 64 and spring 68 of the valve
60, as shown in FIG. 105.
[0344] The manifold body 681 shown in FIGS. 100 and 106 can be an
extruded member, such as an extruded aluminum member. The openings
(661, 676) for the quick-connect fittings 235 can be machined into
the manifold body and subsequently threaded to allow threaded ends
730 of the quick-connect fittings 235, such as those shown in FIGS.
108 and 109, to be threaded into the openings. The bore 682 shown
in FIG. 105 can be machined into the manifold body 681 to provide a
bore with a smooth surface finish that can be easily sealed with a
sealing member associated with the valve 60. In some examples, the
manifold body 681 can be formed from one or more injection molded
plastic members where internal fluid passages, bores, and threads
are formed in the plastic members during the injection molding
process to eliminate the need for post-processing, thereby reducing
manufacturing time and expense.
[0345] The differential pressure bypass valve 60 can include an
integral differential pressure adjustment setting. The differential
pressure bypass valve 60 can be configured to control, regulate, or
otherwise restrict a flow of pressurized coolant through the bypass
to establish and maintain a pressure differential of about 1-5,
2-10, 5-12, 10-15, or 10-25 psi between a valve inlet 61 and a
valve outlet 62.
[0346] As shown in FIG. 105, the inlet chamber 655, the outlet
chamber 665, the first plurality of openings 661, the second
plurality of openings 676, and the bypass 310 can be fluid
passageways formed in the manifold body 681. In this example, the
internal components of the valve can be removed from the valve body
and installed directly in the bypass 310. For instance, a valve
plug 64 and a spring 68 can be installed in a bore 682 of the
bypass 310 to effectively integrate the functionality of the valve
60 into the manifold body 681 without need for external components,
such as external bypass piping shown in FIG. 106.
[0347] The differential pressure setting of the valve 60 can be
manually controlled or electronically controlled. If electronically
controlled, the differential pressure setting can be actuated by
adjusting the control knob 63, or related mechanical adjustment
feature, with a stepper motor or other suitable electromechanical
device. In this example, the microcontroller 850 can be
electrically connected to the stepper motor and can dynamically
adjust the differential pressure setting of the valve 60 during
operation of the cooling apparatus 1 to enhance heat removal
capacity and/or reduce overall power consumption. The
microcontroller 850 can adjust the differential pressure setting
based on feedback from one or more sensors of the cooling apparatus
1, such as a pressure sensor, flow rate sensor, temperature sensor,
fluid level sensor, and/or vapor quality sensor.
[0348] The manifold 681 can include a first quick-connect fitting
662 proximate the first flow inlet 615 of the inlet chamber 665, as
shown in FIG. 106. The first quick connect fitting 662 can permit
the manifold 681 to be fluidly connected to a fluid supply line 231
of the cooling system 1. The manifold can include a second
quick-connect fitting 677 proximate the second flow outlet 640 of
the outlet chamber 665. The second quick connect fitting 677 can be
configured to allow the manifold 681 to be fluidly connected to a
return line 230 of the cooling system 1.
Fluid Distribution Unit
[0349] The cooling apparatus 1 can include a fluid distribution
unit 10. The fluid distribution unit 10 can deliver fluid to one or
more heat sink modules 100 fluidly connected to the fluid
distribution unit. A variety of configurations of fluid
distribution units 10 are presenting herein, ranging from small
fluid distribution units 10 suitable for cooling CPUs, GPUs, and
memory modules in personal computers (see, e.g., FIGS. 130, 131,
and 134-138), gaming consoles, LED arrays, and mobile electronic
devices; mid-sized fluid distribution units 10 (see, e.g., FIGS.
118-128) suitable for cooling CPUs, GPUs, and memory modules in
multiple servers in computer rooms and small data centers or
batteries and power electronics in electric or hybrid vehicles; and
large fluid distribution units 10 (see, e.g., FIGS. 1-3, 9, and 10)
suitable for cooling CPUs, GPUs, and memory modules in hundreds or
even thousands of servers in mid-size, large, and mega-scale
datacenters.
[0350] FIG. 128 shows a rack-mountable fluid distribution unit 10.
The fluid distribution unit 10 can install in a standard server
rack 410 and can be secured to the rack with suitable fasteners.
The fluid distribution unit 10 can have quick connect fluid
couplers that allow the unit to be rapidly uninstalled and removed
from the server rack 410 without tools, thereby allowing an IT
professional to remove the fluid distribution unit in the event of
a component failure and install a functioning fluid distribution
unit rapidly to minimize server downtime.
[0351] FIGS. 118-125 show a fluid distribution unit 10 for a
cooling apparatus 1. The fluid distribution can include a reservoir
200. The reservoir 200 shown in FIGS. 118-125 is a cylindrical
reservoir oriented on its side to reduce the height of the cooling
apparatus. Where the height of the unit 10 is not a concern, the
reservoir can be oriented upright as shown in FIG. 3. A first pump
20-1 can be fluidly connected to the reservoir 200 along a lower
portion of the reservoir (i.e. below a centerline of the reservoir)
to ensure the first pump will only draw single-phase liquid coolant
from the reservoir. A supply tube 230-0 can extend from an outlet
of the first pump 20-1 and can include a first quick-connect
coupler 235-1 that allows the fluid distribution unit 100 to
fluidly connect to a supply line 230 of a cooling apparatus, as
shown in FIG. 117. The fluid distribution can include a return tube
231-0 with a second quick connect coupler 235-2 that allows the
fluid distribution unit 10 to fluidly connect to a return line
231-0 of the cooling apparatus, as shown in FIG. 117. The return
tube 231-0 can be fluidly connected to an upper portion of the
reservoir above a liquid-gas interface within the reservoir.
Returning two-phase bubbly flow to a location in the reservoir 200
above the liquid-vapor interface can promote condensing of vapor
bubbles 275 dispersed in the saturated liquid coolant, which is
desirable. The direction of coolant flow 51 to and from the
reservoir 200 is shown with arrows in FIGS. 118 and 120.
[0352] The fluid distribution unit 10 can include a heat rejection
loop 43 that draws fluid from the reservoir, passes the fluid
through a heat exchanger to subcool the fluid, and returns the
fluid to the reservoir at a lower temperature, thereby promoting
condensing of vapor bubbles in two-phase flow that is returning to
the reservoir from the primary cooling loop 300. As shown in FIGS.
118-125, the heat rejection loop 43 can include a second pump 20-2
fluidly connected to a lower portion of the reservoir 200 (i.e.
below a centerline of the reservoir). The second pump 20-2 can draw
coolant from the reservoir and force the coolant through a section
of tubing 220 to the heat exchanger 40 and back to the reservoir
200. The subcooled fluid can be returned to an upper portion of the
reservoir 200 located above a liquid-gas interface. The heat
exchanger can be any suitable heat exchanger, such as a
liquid-to-liquid heat exchanger or a liquid-to-gas heat exchanger.
If a liquid-to-liquid heat exchanger is used, the heat exchanger
can be connected to chilled water supply from the facility where
the unit 10 is installed. Heat from the coolant circulating through
the heat exchanger can be rejected to the chilled water. The
direction of chilled water flow 46 to and from the heat exchanger
40 is shown with arrows in FIG. 118. The heat exchanger 40 can be
configured to prevent mixing of the flows of coolant and chilled
water. The fluid distribution unit 10 can include a blow-off valve
13 extending from the reservoir 200, as shown in FIG. 121, for
safety purposes.
[0353] The rack-mountable fluid distribution unit 10 shown in FIG.
128 is suitable for a cooling apparatus 1 configured to cool up to
35 POWEREDGE servers from Dell Inc. of Round Rock, Tex. with dual
2.4 GHz Intel XEON processors ("standard servers"). For this
application, the reservoir 200 can have a volume of about 1.0-4.0,
1.5-2.5, or preferably about 2.0 gallons, where a gallon is defined
as 231 cubic inches. Although a larger volume reservoir can be
used, it is desirable to use the smallest suitable reservoir to
reduce the amount of dielectric coolant needed. When cooling
high-performance servers with processors that generate higher heat
fluxes than standard servers, the number of servers the cooling
system can effectively cool will decrease accordingly.
[0354] As shown in FIGS. 115 and 117, a fluid distribution unit 10
for a two-phase cooling system 1 can include a reservoir 200
configured to receive a two-phase flow 51 of dielectric coolant
including liquid coolant 50 and vapor coolant 203. The fluid
distribution unit 10 can include a supply line 231-0 having a first
end and a second end. The first end of the supply line 231-0 can be
fluidly connected to the reservoir 200, and the second end of the
supply line can include a first fitting 235-1. The fluid
distribution unit 10 can include a first pump 20-1 fluidly
connected between the first end of the supply line and the second
end of the supply line. The fluid distribution unit 10 can include
a return line 230-0 having a first end and a second end. The first
end of the return line can include a second fitting 235-2, and the
second end of the return line can be fluidly connected to the
reservoir 200. The fluid distribution unit 10 can include a heat
rejection loop 43 having a first end and a second end. The first
end of the heat rejection loop can be fluidly connected to the
reservoir 200, and the second end of the heat rejection loop can be
fluidly connected to the reservoir 200. A heat exchanger 40 can be
fluidly connected to the heat rejection loop 43 between the first
end of the heat rejection loop and the second end of the heat
rejection loop. A second pump 20-2 can be fluidly connected to the
heat rejection loop between the first end of the heat rejection
loop and the second end of the heat rejection loop. The second pump
20-2 can be located upstream of the heat exchanger 40 and can be
configured to circulate a flow 51-3 of coolant 50 from the
reservoir 200, through the heat exchanger 40, and back to the
reservoir 200.
[0355] As shown in FIG. 120, the first end of the supply line 231-0
can be fluidly connected to the reservoir 200 at a first location
234-1, and the second end of the return line 230-0 can be fluidly
connected to the reservoir 200 at a second location 234-2. The
first location 234-1 can be at least one inch lower on the
reservoir 200 than the second location 234-2, where the distance
(d1) is measured vertically between midpoints of the first location
234-1 and the second location 234-1. In the example shown in FIG.
120, the centerline of the return line 230-0 is aligned with a
centerline of the reservoir 200.
[0356] As shown in FIG. 121, the first end of the heat rejection
loop 43 can be fluidly connected to the reservoir 200 at a third
location 234-3, and the second end of the heat rejection loop can
be fluidly connected to the reservoir at a fourth location 234-4.
The third location 234-3 can be at least one inch lower on the
reservoir 200 than the fourth location, where the distance (d2) is
measured vertically between midpoints of the third location 234-3
and the fourth location 234-4.
[0357] As shown in FIG. 97, the heat exchanger 40 can be a
liquid-to-liquid heat exchanger having a first isolated fluid
pathway configured to transport a first flow (51-3 in FIG. 115) of
dielectric coolant 50 received from the heat rejection loop 43 and
a second isolated fluid pathway configured to transport a second
flow 42 chilled water or a water-glycol mixture. An inner volume of
the first isolated fluid pathway can be about 0.25-1.5, 1.0-3.5,
2.0-4.5, 4.0-8.0, 6.0-12, or 10-15 gallons.
[0358] The reservoir 200 can have an inner volume of about
0.25-1.5, 1.0-3.5, 2.0-4.5, 4.0-8.0, 6.0-12, or 10-15 gallons. The
reservoir 200 can include a baffle 204 in its inner volume, as
shown in FIG. 115. The baffle 204 can establish only non-linear
flow pathways between reservoir flow inlets and reservoir flow
outlets. Reservoir flow inlets include the second end of the return
line 230-0 and the first end of the heat rejection loop 43, and
reservoir flow outlets include the first end of the supply line
231-0 and the second end of the heat rejection loop 43, as shown in
FIG. 117.
[0359] In another example, a rack-mountable fluid distribution unit
10 for a two-phase cooling system for cooling servers can include a
reservoir 200, as shown in FIGS. 118-125 and 128. The reservoir 200
can have an inner volume configured to receive a flow of two-phase
dielectric coolant including liquid coolant 50 and vapor coolant
203. The fluid distribution unit 10 can include a supply line 231-0
having a first end and a second end. The first end of the supply
line can be fluidly connected to the reservoir 200, and the second
end of the supply line can include a first quick-connect fitting
235-1. A first pump 20-1 can be fluidly connected between the first
end of the supply line and the second end of the supply line. A
return line 230-0 can include a first end and a second end. The
first end of the return line can include a second quick-connect
fitting 235-2, and the second end of the return line can be fluidly
connected to the reservoir 200. The fluid distribution unit 10 can
include a heat rejection loop 43 having a first end and a second
end. The first end of the heat rejection loop can be fluidly
connected to the reservoir 200, and the second end of the heat
rejection loop can be fluidly connected to the reservoir. A heat
exchanger 40 can be fluidly connected to the heat rejection loop 43
between the first end of the heat exchanger loop and the second end
of the heat rejection loop. A second pump 20-2 can be fluidly
connected to the heat rejection loop 43 between the first end of
the heat exchanger loop and the second end of the heat rejection
loop and configured to circulate a flow 51-3 of single-phase liquid
coolant 50 from the reservoir, through the heat exchanger 40, and
back to the reservoir 200.
[0360] The fluid distribution unit 10 can include a support
structure 11 configured to mount within a server rack 410, as shown
in FIG. 128. The reservoir 200, the first pump 20-1, and the second
pump 20-2 can be mounted to the support structure 11. The support
structure 11 can be configured to slidably engage with a server
rack 410 to permit rapid installation of the fluid distribution
unit 10 during service or maintenance of the unit. The first
quick-connect fitting 235-1 can be a blind-mate coupler having a
first non-spill valve, and the second quick-connect fitting 235 can
be a blind-mate quick-connect coupler having a second non-spill
valve.
[0361] As shown in FIG. 115, the fluid distribution unit 10 can
include a flow quality (x) sensor 880 attached (externally or
internally) to the return line 230-0. The flow quality sensor 880
can be configured to provide an output signal based on a flow
quality (x) of two-phase flow passing through the return line to
the reservoir 200. The fluid distribution unit 10 can include an
electronic control unit 850 mounted to the support structure 11.
The flow quality sensor 880 can be electrically connected to the
electronic control unit 850 to permit the output signal from the
flow quality sensor to be received by the electronic control
unit.
[0362] The first pump 20-1 can include a first variable speed drive
80-1 electrically connected to the electronic control unit, as
shown in FIG. 115. The electronic control unit 850 can be
configured to increase a speed of the first variable speed drive
80-1 when the output signal from the flow quality sensor 880
indicates a flow quality (x) greater than about 0.3, 0.4, or 0.5.
The electronic control unit 850 can be configured to decrease a
speed of the first variable speed drive 80-1 when the output signal
from the flow quality sensor 880 indicates a flow quality (x) less
than 0.1, 0.2, or 0.3.
[0363] The second pump 20-2 can include a second variable speed
drive 80-2 electrically connected to the electronic control unit,
as shown in FIG. 115. The electronic control unit 850 can be
configured to increase a speed of the second variable speed drive
80-2 when the output signal from the flow quality sensor 880
indicates a flow quality (x) greater than 0.3, 0.4, or 0.5. The
electronic control unit 850 can be configured to decrease a speed
of the second variable speed drive 80-2 when the output signal from
the flow quality sensor 880 indicates a flow quality (x) less than
0.1, 0.2, or 0.3.
[0364] In yet another example, a fluid distribution unit 10 for a
two-phase cooling apparatus can include a reservoir 200 having an
inner volume configured to receive an amount of two-phase
dielectric coolant, as shown in FIGS. 126, 127, and 139. The fluid
distribution unit 10 can include a supply line 230-0 having a first
end and a second end. A first pump 20-1 can be fluidly connected
between the first end of the supply line and the second end of the
supply line. The first end of the supply line can be fluidly
connected to the reservoir 200, and the second end of the supply
line can be fluidly connected to an inlet chamber 655 of a manifold
assembly 680. The fluid distribution unit 10 can include a return
line 230-0 having a first end and a second end. The first end of
the return line can be fluidly connected to an outlet chamber 665
of the manifold assembly 680, and the second end of the return line
can be fluidly connected to the reservoir 200. The fluid
distribution unit can include a heat rejection loop 43 having a
first end and a second end. The first end of the heat rejection
loop can be fluidly connected to the reservoir 200, and the second
end of the heat rejection loop can be fluidly connected to the
reservoir 200. A heat exchanger 40 can be fluidly connected to the
heat rejection loop between the first end of the heat rejection
loop and the second end of the heat rejection loop. A second pump
20-2 can be fluidly connected to the heat rejection loop 43 between
the first end of the heat rejection loop and the second end of the
heat rejection loop and configured to circulate a flow 51-3 of
single-phase dielectric coolant 50 from the reservoir 200, through
the heat exchanger 40, and back to the reservoir.
[0365] A detailed example of the manifold assembly 680 is presented
in FIG. 105. The inlet chamber 655 of the manifold assembly 680 can
include a first inlet chamber end 605, a second inlet chamber end
610 opposite the first inlet chamber end, a first flow inlet 615
proximate the first inlet chamber end, and a first flow outlet 620
proximate the second inlet chamber end. The manifold assembly 680
can include a first plurality of quick-connect fittings 235-1 (see,
e.g., FIG. 106) installed in a first plurality of openings 661
passing through a bounding surface of the inlet chamber 655. As
shown in FIG. 105, the outlet chamber 665 of the manifold assembly
680 can include a first outlet chamber end 625, a second outlet
chamber end 630 opposite the first outlet chamber end, a second
flow inlet 635 proximate the first outlet chamber end, and a second
flow outlet 640 proximate the second outlet chamber end. The
manifold assembly 680 can include a second plurality of
quick-connect fittings 235-2 (see, e.g., FIG. 106) installed in a
second plurality of openings extending through a bounding surface
of the outlet chamber 665. The first and second pluralities of
quick-connect fittings (235-1, 235-2) can be non-spill shut-off
valves 723 including a silicone-based grease and a butyl rubber
sealing member to ensure compatibility with the dielectric coolant
50.
[0366] The manifold assembly 680 can include a bypass 310 fluidly
connecting the first flow outlet 620 of the inlet chamber 655 to
the second flow inlet 635 of the outlet chamber 665, as shown in
FIG. 105. The manifold assembly 680 can include a differential
pressure bypass valve 60 positioned in the bypass 310 and
configured to control a flow 51-3 of pressurized coolant from the
inlet chamber 655 to the outlet chamber 665 through the bypass 310
to maintain a pressure differential between the inlet chamber and
the outlet chamber, as shown in FIG. 126. As shown in FIG. 112, the
differential pressure bypass valve 60 can include a valve inlet 61
and a valve outlet 62 and can be configured to control a flow (see,
e.g., 51-3 of FIG. 126) of pressurized coolant through the bypass
310 of the manifold assembly 680 by establishing the pressure
differential of about 1-5, 2-10, 5-12, 10-15, or 10-25 psi between
the valve inlet 61 and the valve outlet 62. The differential
pressure bypass valve 60 can include a bypass circuit 67 fluidly
connecting the valve inlet 61 to the valve outlet 62, a valve plug
64 disposed in the bypass circuit 67, and a spring 68, as shown in
FIG. 112. The valve plug 64 can be configured to restrict flow 51-3
of pressurized coolant though the bypass circuit 67. The spring 68
can be disposed between the valve plug 64 and a control knob 63.
Tightening the control knob 63 can compress the spring 68 against
the valve plug 64 and increase a differential pressure setting of
the differential pressure bypass valve 60.
[0367] The manifold assembly 680 can include a manifold body 681,
as shown in FIG. 105. The inlet chamber 655, the outlet chamber
665, the first plurality of openings 661, the second plurality of
openings 676, and the bypass 310 can be fluid passageways formed in
a manifold body. The valve plug 64 and the spring 68 of the
differential pressure bypass valve can be installed within a bore
682 of the bypass 310 formed in the manifold body 681.
Server Rack with Fluid Distribution Unit
[0368] A fluid distribution unit can be integrated into a server
rack to provide a compact solution for cooling servers. FIGS.
118-125 show a server rack-mountable fluid distribution unit 10
that is suitable for inclusion in the cooling apparatus of FIG.
117. The fluid distribution unit 10 can have a primary cooling loop
and a heat rejection loop. The primary cooling loop can include a
first pump fluidly connected to a reservoir 200. The heat rejection
loop can include a second pump and a heat exchanger fluidly
connected to the reservoir 200. Components of the fluid
distribution unit 10, such as the pumps (20-1, 20-2) and reservoir
200, can be mounted to a support structure 11. The support
structure 11 can allow the fluid distribution unit 10 to be easily
transported to and installed in a server rack 410, as shown in FIG.
128. Likewise, the support structure 11 can allow the fluid
distribution unit 10 to be easily uninstalled from the server rack
410 for maintenance or repair. In some examples, the support
structure 11 can include a handle for carrying the fluid
distribution unit or a handle for aiding in removing the fluid
distribution unit from the server rack.
[0369] In some examples, the fluid distribution unit can include
blind fluid connections that automatically connect the fluid
distribution unit to the cooling apparatus when the fluid
distribution unit 10 is inserted into the server rack. For
instance, upon fully inserting the fluid distribution unit 10 into
the server rack 410, the supply pipe 231-0 of the fluid
distribution unit can blindly connect to a supply line 231 of the
cooling apparatus, and the return pipe 230-0 of the fluid
distribution unit can blindly connect to a return line of the
cooling apparatus. This approach allows the fluid distribution unit
to be fluidly connected to the cooling apparatus by hand (with no
tools) and eliminates the need for a service person to access more
than one side of the server rack 410 during installation and
removal of the fluid distribution. This is desirable since more
than one side of the server racks may not be accessible when racks
are arranged in close proximity to each other in rows within a data
center or computer room 425, as shown in FIGS. 19 and 20. In
addition to blind fluid connections, the fluid distribution unit
can also include blind connections for power, network
communications (e.g. Ethernet), and a control system wiring
harness. The control system wiring harness can allow the
microcontroller to receive information from various system sensors
as described herein. The network connection can allow an electronic
control unit 850 installed in the fluid distribution unit 10 to
report cooling system parameters and metrics (e.g. temperatures,
pressures, flow rates, total heat removed) and system faults (e.g.
low coolant level, low pressure, high temperature, low flow rates)
to a facility monitoring computer network. Cooling system 1
performance can be monitored remotely, and if a fault occurs, a
service professional can be dispatched to address the issue.
[0370] FIG. 117 shows a schematic of a preferred cooling apparatus
1 for a server rack 410 with a rack-mounted fluid distribution unit
10, as shown in FIGS. 118-125. The cooling apparatus 1 can have a
primary cooling loop 300 and a heat rejection loop 43. The primary
cooling loop 300 can include a first pump 20-1, a manifold assembly
680, a bypass 310, and a plurality of cooling line assemblies 303
each routed through one server 400 having one or more surfaces to
be cooled 12 (e.g. CPUs, GPUs, motherboard chipset, drives, power
supplies, and memory modules). The heat rejection loop 43 can
include a second pump 20-2 and a heat exchanger 40. The primary
cooling loop 300 and the heat rejection loop 43 are both fluidly
connected to a common reservoir 200 that resides in a fluid
distribution unit 10 housed within a server rack 410. The fluid
distribution unit includes inlet and outlet fittings 235 that can
be standard fittings or quick-connect fittings. The quick-connect
fitting can be blind-mate fittings to allow the fluid distribution
unit 10 to be fluidly connected to the cooling apparatus 1 blindly
by simply inserting the fluid distribution unit into the server
rack. Examples of quick-connect blind-mate fittings are AEROQUIP
brand fittings from Eaton Corporation of Cleveland, Ohio. The
fittings 235 can include non-spill shut-off valves 723 to prevent
spillage of dielectric coolant when installing or removing the
fluid distribution unit 10.
[0371] To allow more servers 400 to be connected to a manifold
assembly 680, one or more cooling line assemblies 303 can be routed
through more than one server 400. FIG. 129 shows a schematic of a
cooling apparatus 1 having a primary cooling loop 300 and a heat
rejection loop 43. The primary cooling loop 300 includes a first
pump 20-1, a manifold assembly 680, a bypass 310, and a plurality
of cooling line assemblies 303 each routed through one or more
servers 400. The heat rejection loop 43 includes a second pump 20-2
and a heat exchanger 40. The primary cooling loop 300 and the heat
rejection loop 43 are both fluidly connected to a common reservoir
200 that resides in a fluid distribution unit 10 housed within a
server rack 410. In this example, each cooling line assembly 303
can include up to eight series-connected heat sink modules 100
mounted on heat-generating components (e.g. CPUs, GPUs, memory
modules) within two or more servers 400.
[0372] In some examples, the fluid distribution unit 10 can include
a manifold assembly 680, as shown in FIGS. 126 and 127. This
arrangement can eliminate the need for an externally mounted
manifold, which can be preferable in some applications. For
instance, if there is insufficient space on a front or rear side of
a server rack 410 to mount a manifold assembly 680, it can be
desirable to mount the manifold assembly 680 within the fluid
distribution unit, which can be mounted within the server rack. In
one example, the fluid distribution unit 10 can be centrally
mounted in a server rack to minimize the length of the cooling line
assemblies 303 needed to reach from an inlet manifold, to the
servers, and back to an outlet manifold 215.
[0373] As shown in FIG. 139, the manifold assembly 680 can be
packaged as part of the fluid distribution 10 to provide for a more
compact cooling apparatus 1 for space-constrained applications. For
instance, in vehicle 950 applications, space may be limited and a
configuration as shown in FIG. 139 may be useful to minimize the
size of the cooling system 1 to allow the system to fit within
packaging constraints dictated by a vehicle manufacturer. In this
example, the fluid distribution unit 10 can be installed in the
vehicle 950 (e.g. under a seat, in a trunk, within a body
structure, or in an engine bay) and flexible cooling line
assemblies 303 can be routed from the fluid distribution unit to
various surfaces to be cooled 12 throughout the vehicle, such as
power electronics, battery packs, battery terminals, infotainment
displays, inverters, and engine control unit (ECU). In this
example, the flexible cooling line assemblies 303 can attach to the
manifold via quick-connect fittings or standard fittings. In
addition to automotive applications, the configuration shown in
FIG. 139 is well suited to many non-automotive applications,
including any of the wide-ranging applications mentioned throughout
this disclosure.
Two-Phase Cooling Apparatus for a Personal Computer
[0374] The two-phase cooling apparatuses 1 described herein can be
used to safely cool any type of computer, including personal
computers (PCs) (e.g. desktop computers, office workstations, and
PC gaming systems), gaming consoles, video gambling machines, and
servers, to name a few. In some examples, it can be desirable to
provide a two-phase cooling apparatus 1 that is capable of
installing within a computer housing, thereby allowing the computer
to maintain its original level of mobility.
[0375] An example of a gaming console is an XBOX ONE from Microsoft
Corporation of Redmond, Wash. An example of a PC gaming system is a
HAILSTORM II 37047 from Digital Storm Online, Inc. of Fremont,
Calif., which includes an INTEL CORE i7 Extreme Edition 4960X 3.6
GHz (six-core) processor, two NVIDIA GeForce GTX TITAN Z 12 GB
graphics cards, ASUS Rampage IV Black Edition X79 (Intel X79
chipset) motherboard, and 64 GB DDR3 1866 MHz Corsair Dominator
Platinum DHX memory.
[0376] Examples of two-phase cooling systems suitable for computers
400, including PC gaming systems and gaming consoles, are shown in
FIGS. 130, 131, and 134-138. FIG. 130 shows a schematic of a
two-phase cooling apparatus 1 having a primary cooling loop 300 and
a heat rejection loop 43. The primary cooling loop 300 can include
a first pump 20-1 fluidly connected to a reservoir 200 and fluidly
connected to one or more heat sink modules 100 that can be fitted
on components of the computer that require cooling, such as CPUs,
GPUs, chipsets, memory modules, and power supplies. The heat
rejection loop 43 can include a second pump 20-2 fluidly connected
to a heat exchanger 40 and the reservoir 200. A suitable pump for
the cooling apparatuses shown in FIGS. 130, 131, and 134-138 is a
DDC Series pump from Laing Thermotech, a subsidiary of Xylem, Inc.
of White Plains, N.Y. The DDC Series pump has an electronically
commutated spherical motor, a maximum pressure of 21.75 psi, a
rated voltage of 12 Volts DC, and a maximum operating temperature
of 140 degrees F. The DDC-3.15 pump can deliver a flow rate of
about 1.5 gallons per minute at a power consumption of about 11
Watts.
[0377] In many instances, owners of PC gaming systems 400 enjoy
adding additional high-performance components, such as additional
GPUs and memory modules, to their computers. To improve computer
performance, it is desirable to provide two-phase cooling of these
additional components. It is therefore desirable to provide a
two-phase cooling apparatus that is modular and that can grow in
size to accommodate an owner's upgrades to their gaming system.
FIG. 131 shows a schematic of a modular cooling apparatus 1 having
a primary cooling loop 300 and a heat rejection loop 43. The
primary cooling loop 300 can include a first pump 20-1 fluidly
connected to a reservoir 200 and fluidly connected to three
series-connected modular cooling line assemblies 303 similar to the
one shown in FIG. 132. The heat rejection loop 43 can include a
second pump 20-2 and a heat exchanger 40 fluidly connected to the
reservoir 200.
[0378] Modular cooling line assemblies 303 can be provided with any
suitable number of heat sink modules 100 to accommodate a
particular application with heat removal requirements. Common
examples of modular cooling line assemblies 303 range from one heat
sink module 100 up to eight series-connected modules. Other
examples of modular cooling line assemblies 303 can include
parallel configurations of heat sink modules 100 or combinations of
parallel and series-connected modules.
[0379] FIG. 132 shows a flexible cooling line assembly 303 with one
heat sink module 100. More specifically, the cooling line assembly
303 includes one heat sink module 100 with an inlet port 105 and an
outlet port 110, a first section of flexible tubing 225-1 having a
first end connected to an inlet fitting 235-1 and a second end
connected to the inlet port 105, and a second section of flexible
tubing 225-2 having a first end connected to the outlet port 110
and a second end connected to an outlet fitting 235-1.
[0380] FIG. 133 shows a modular cooling line assembly 133 with two
heat sink modules 100. More specifically, the cooling line assembly
303 includes a first heat sink module 100-1 with an inlet port 105
and an outlet port 110, a first section of flexible tubing 225-1
having a first end connected to an inlet fitting 235-1 and a second
end connected to the inlet port 110 of the first heat sink module,
a second heat sink module 100-2 with an inlet port 105 and an
outlet port 110, a second section of flexible tubing 225-2
connecting the outlet port 110 of the first heat sink module 100-1
to the inlet port 105 of the second heat sink module 100-2, and a
third section of flexible tubing 225-3 having a first end connected
to the outlet port 110 of the second heat sink module and a second
end connected to an outlet fitting 235-2.
[0381] The modular cooling line assemblies 303 can include standard
fittings or quick-connect fittings 235, as shown in FIGS. 107-110,
132, and 133, and to facilitate rapid expansion of the cooling
system 1 to provide cooling of newly added computer components. To
avoid spilling dielectric coolant when an additional cooling line
assembly 303 is added to the cooling apparatus 1, the fittings can
include internal non-spill shut-off valves 723.
[0382] FIG. 134 shows a schematic of a modular cooling apparatus
100 having a primary cooling loop 300 and a heat rejection loop 43.
The primary cooling loop 300 includes a first pump 20-1 fluidly
connected to a reservoir 200 and fluidly connected to three
series-connected modular cooling line assemblies 303. The first
modular cooling line assembly 303-1 includes two series-connected
heat sink modules 100, the second modular cooling line assembly
303-2 includes two series-connected heat sink modules 100, and the
third modular cooling line assembly 303-3 includes four
series-connected heat sink modules 100. The heat rejection loop 43
includes a second pump 20-2 and a heat exchanger 40 fluidly
connected to the reservoir 200.
[0383] FIG. 135 shows a schematic of a modular cooling apparatus
100 having a primary cooling loop 300 and a heat rejection loop 43.
The primary cooling loop 300 includes a first pair of redundant
pumps (20-1, 20-2) fluidly connected to a reservoir and fluidly
connected to three series-connected modular cooling line
assemblies. The first modular cooling line assembly 303-1 has two
series-connected heat sink modules 100, the second modular cooling
line assembly 303-2 has two series-connected heat sink modules 100,
and the third modular cooling line assembly 303-3 has four
series-connected heat sink modules 100. The heat rejection loop 43
includes a second pair of redundant pumps (20-3, 20-4) and a heat
exchanger 40 fluidly connected to the reservoir 200.
[0384] FIG. 136 shows a schematic of a redundant cooling apparatus
2 having a first cooling apparatus 1 and a second cooling apparatus
1. The first cooling apparatus 1 includes a first primary cooling
loop 300-1 and a first heat rejection loop 43-1. The first primary
cooling loop 300-1 includes a first pump 20-1 fluidly connected to
a first reservoir 200-1 and two series-connected redundant heat
sink modules 200. The first heat rejection loop 43-1 includes a
second pump 20-2 fluidly connected to a first heat exchanger 40-1
and the first reservoir 200-1. The second cooling apparatus 1
includes a second primary cooling loop 300-2 and a second heat
rejection loop 43-2. The second primary cooling loop 300-2 includes
a third pump 20-3 fluidly connected to a second reservoir 200-2 and
the two redundant series-connected heat sink modules 200. The
second heat rejection loop 43-2 includes a fourth pump 20-4 fluidly
connected to a second heat exchanger 40-2 and the second reservoir
200-2.
[0385] FIG. 137 shows a schematic of a cooling apparatus 1 having a
primary cooling loop 300 and a heat rejection loop 43. The primary
cooling loop 300 can include a first pump 20-1 fluidly connected to
a reservoir 200 and fluidly connected to three series-connected
heat sink modules 100 and a series-connected memory cooler 421. The
series-connected memory cooler 421 can include cooling members that
extend downward into channels located between adjacent
vertically-arranged memory modules 420, thereby providing cooling
of both sides of each memory module. The heat rejection loop 43 can
include a second pump 20-2 fluidly connected to a heat exchanger 40
and the reservoir 200.
[0386] FIG. 138 shows a schematic of a cooling apparatus 1 having a
primary cooling loop 300 and a heat rejection loop 43. The primary
cooling loop 300 can include a first pump 20-1 fluidly connected to
a reservoir 200 and fluidly connected to three series-connected
heat sink modules 100 and a series-connected memory cooler 421. The
series-connected memory cooler 421 can include cooling members that
extend downward into channels located between adjacent
vertically-arranged memory modules 420, thereby providing cooling
of both sides of each memory module. The heat rejection loop 43 can
include a second pump 20-2 fluidly connected to a heat exchanger 40
and the reservoir 200. The heat exchanger 40 can be a heat
exchanger disclosed in U.S. patent application Ser. Nos. 14/833,087
and 14/833,092.
Internal Volumes of Cooling System
[0387] The total inner volume in the cooling apparatus 1 is the sum
of inner volumes of all system components, including the cooling
line assemblies 303 (module loops), manifold assemblies 680,
distribution tubing, and fluid distribution unit 10, which includes
the reservoir 200 and heat exchanger 40.
[0388] The reservoir 200 volume can be sized based on the number of
servers 400 the system 1 will cool. As the dielectric coolant is
heated from room temperature to its saturation temperature, the
coolant volume will expand. This expansion can be calculated based
on the fluid's thermal expansion coefficient, while accounting for
changes in coolant temperature and pressure. The reservoir 200 can
be sized to accommodate the expansion of coolant while maintaining
headroom above the liquid level to ensure a liquid-vapor interface
is preserved in the reservoir to aid in condensing vapor bubbles in
the return flow of two phase bubbly flow via the return line
230.
[0389] In a cooling apparatus 1 designed to cool 60 standard
servers arranged in six server racks 410, the cooling apparatus can
include 60 cooling line assemblies 303 each made of three sections
of 1/4 in. flexible tubing 225 with an inner diameter of 0.18 in.
The sections of flexible tubing 225 can be connected to two heat
sink modules 100, similar to the cooling line assemblies 303 shown
in FIGS. 113 and 114, which have three modules 100. Using
rack-mounted manifold assemblies 680, the average length of each
cooling line assembly 303 (extending from the inlet manifold 210
into the server 400 and back to the outlet manifold 215) can be
about 70-110, 80-100, or preferably about 90 inches. Preferably,
each cooling line assembly 303 is connected to a pair of inlet and
outlet quick-connect fittings 235 nearest to the server 400 to be
cooled, which decreases the amount of flexible tubing 225 needed as
well as coolant volume. On average, each cooling line assembly 303
can have an inner volume of about 2.0-3.0, 2.2-2.6, or preferably
about 2.4 in.sup.3. Collectively, the 60 cooling line assemblies
303 can have an inner volume of about 0.3-0.9, 0.4-0.8, or
preferably about 0.6 gallons. The reservoir 200 can have an inner
volume of about 2-6, 3-4, or preferably about 3.5 gallons. The heat
exchanger volume can be 0.8-1.5, 1.0-1.4, or preferably about 1.2.
Sections of tubing that connect components in the fluid
distribution unit 10 can have inner diameters of about 1.0 inches
or 1.5 inches and, collectively, can have an inner volume of about
1.0-2.0, 1.2-1.8, or preferably about 1.5 gallons. The distribution
tubing, including the supply line 230 and the return line that
deliver coolant to the manifolds, can average about 1000-1400,
1100-1300, or preferably about 1200 inches and can have an inner
volume of about 3-6, 4-5, or preferably about 4.5 gallons. The
cooling apparatus can include a manifold assembly 680 on each of
the six server racks 410. The inlet chamber 655 and outlet chamber
665 of the manifold assembly 680 can each have an inner diameter of
about 0.5-1.5, 0.75-1.25, or preferably about 0.9 in. The inlet and
outlet chamber (655, 665) of the manifold assembly 680 can each
have a length of about 45-80, 50-70, or preferably about 60 inches.
The inlet and outlet chamber (655, 665) of the manifold assembly
680 can each have an inner volume of about 20-60 or 30-50 in.sup.3
or preferably about 38 in.sup.3 and can each have an inner volume
of about 0.08-0.25, 0.12-0.21, or preferably about 0.17 gallons.
Together, the six manifold assemblies can have a total inner volume
of about 1.75-2.75, 2.0-2.5, or preferably about 2.35 gallons. The
total inner volume of the cooling apparatus can be about 8-18,
11-16, or preferably about 13.5 gallons. In this example where the
cooling apparatus is configured to cool 60 standard servers, the
inner volume of the reservoir 200 can be equal to about 15-25,
20-35, or 30-40% of the total inner volume of the cooling apparatus
1.
[0390] In a cooling apparatus 1 designed to cool 120 standard
servers arranged in twelve server racks 410, the cooling apparatus
can include 120 cooling line assemblies 303 each made of three
sections of 1/4 in. flexible tubing 225 with an inner diameter of
0.18 in. The sections of flexible tubing 225 can be connected to
two heat sink modules 100, similar to the cooling line assemblies
303 shown in FIGS. 113 and 114, which have three modules 100. Using
rack-mounted manifold assemblies 680, the average length of each
cooling line assembly 303 (extending from the inlet manifold 210
into the server 400 and back to the outlet manifold 215) can be
about 70-110, 80-100, or preferably about 90 inches. Preferably,
each cooling line assembly 303 is connected to a pair of inlet and
outlet quick-connect fittings 235 nearest to the server 400 to be
cooled, which decreases the amount of flexible tubing 225 needed as
well as coolant volume. On average, each cooling line assembly 303
can have an inner volume of about 2.0-3.0, 2.2-2.6, or preferably
about 2.4 in.sup.3. Collectively, the 120 cooling line assemblies
303 can have an inner volume of about 0.75-1.75, 1.0-1.5, or
preferably about 1.25 gallons. The reservoir 200 can have an inner
volume of about 2-6, 3-4, or preferably about 3.5 gallons. The heat
exchanger volume can be 1.6-3.0, 2.0-2.8, or preferably about 2.2
gallons. Sections of tubing that connect components in the fluid
distribution unit 10 can have inner diameters of about 1.5 inches
or 2.0 inches and, collectively, can have an inner volume of about
1.8-3.0, 2.0-2.8, or preferably about 2.4 gallons. The distribution
tubing, including the supply line 230 and the return line that
deliver coolant to the manifolds, can average about 1200-2000,
1400-1800, or 1680 inches and can have an inner volume of about
10-20, 12-18, or preferably about 14.8 gallons. The cooling
apparatus 1 can include a manifold assembly 680 on each of the
twelve server racks 410. The inlet chamber 655 and outlet chamber
665 of the manifold assembly 680 can each have an inner diameter of
about 0.5-1.5, 0.75-1.25, or preferably about 0.9 in. The inlet and
outlet chamber (655, 665) of the manifold assembly 680 can each
have a length of about 45-80, 50-70, or preferably about 60 inches.
The inlet and outlet chamber (655, 665) of the manifold assembly
680 can each have an inner volume of about 20-60 or 30-50 in.sup.3
or preferably about 38 in.sup.3 and can each have an inner volume
of about 0.08-0.25, 0.12-0.21, or preferably about 0.17 gallons.
Together, the twelve manifold assemblies can have a total inner
volume of about 3.7-5.7, 4.2-5.2, or preferably about 4.7 gallons.
The total inner volume of the cooling apparatus can be about 25-35,
26-32, or preferably about 29 gallons. In this example where the
cooling apparatus is configured to cool 120 standard servers, the
inner volume of the reservoir 200 can be equal to about 7-15,
12-20, or 15-30% of the total inner volume of the cooling
apparatus. This percentage can be lower than the percentage for the
60-server cooling system described above.
[0391] In a cooling apparatus 1 designed to cool 240 standard
servers arranged in twelve server racks 410, the cooling apparatus
can include 240 cooling line assemblies 303 each made of three
sections of 1/4 in. flexible tubing 225 with an inner diameter of
0.18 in. The sections of flexible tubing 225 can be connected to
two heat sink modules 100, similar to the cooling line assemblies
303 shown in FIGS. 113 and 114, which have three modules 100. Using
rack-mounted manifold assemblies 680, the average length of each
cooling line assembly 303 (extending from the inlet manifold 210
into the server 400 and back to the outlet manifold 215) can be
about 70-110, 80-100, or preferably about 90 inches. Preferably,
each cooling line assembly 303 is connected to a pair of inlet and
outlet quick-connect fittings 235 nearest to the server 400 to be
cooled, which decreases the amount of flexible tubing 225 needed as
well as coolant volume. On average, each cooling line assembly 303
can have an inner volume of about 2.0-3.0, 2.2-2.6, or preferably
about 2.4 in.sup.3. Collectively, the 240 cooling line assemblies
303 can have an inner volume of about 2.0-3.0, 2.2-2.8, or
preferably about 2.5 gallons. The reservoir 200 can have an inner
volume of about 2-6, 3-4, or preferably about 3.5 gallons. The heat
exchanger volume can be 3.8-5.8, 4.2-5.4, or preferably about 4.8
gallons. Sections of tubing that connect components in the fluid
distribution unit 10 can have inner diameters of about 2.0 inches
or 2.5 inches and, collectively, can have an inner volume of about
3.0-4.4, 3.2-4.2, or preferably about 3.7 gallons. The distribution
tubing, including the supply line 230 and the return line that
deliver coolant to the manifolds 680, can average about 1700-2500,
1900-2300, or 2150 inches and can have an inner volume of about
25-37, 27-35, or preferably about 31 gallons. The cooling apparatus
1 can include a manifold assembly 680 on each of the twenty-four
server racks 410. The inlet chamber 655 and outlet chamber 665 of
the manifold assembly 680 can each have an inner diameter of about
0.5-1.5, 0.75-1.25, or preferably about 0.9 in. The inlet and
outlet chamber (655, 665) of the manifold assembly 680 can each
have a length of about 45-80, 50-70, or preferably about 60 inches.
The inlet and outlet chamber (655, 665) of the manifold assembly
680 can each have an inner volume of about 20-60 or 30-50 in.sup.3
or preferably about 38 in.sup.3 and can each have an inner volume
of about 0.08-0.25, 0.12-0.21, or preferably about 0.17 gallons.
Together, the twenty-four manifold assemblies 680 can have a total
inner volume of about 6-13, 8-11, or preferably about 9.4 gallons.
The total inner volume of the cooling apparatus can be about 45-65,
50-60, or preferably about 55 gallons. In this example where the
cooling apparatus is configured to cool 240 standard servers, the
inner volume of the reservoir 200 can be equal to about 4-10, 8-15,
or 12-20% of the total inner volume of the cooling apparatus. This
percentage can be lower than the percentage for the 120-server
cooling system described above.
Flexible Tubing
[0392] FIG. 5 shows a top perspective view of a server 400 with its
lid removed and a portion of a cooling apparatus 1 having a primary
cooling loop 300 installed within the server housing. The cooling
loop 300 can include a cooling line 303 connected to two heat sink
modules 100 mounted on vertically oriented heat-generating
components (e.g. GPUs) within the server 400. The heat sink modules
100 are arranged in a series configuration and are fluidly
connected with sections of flexible tubing 225 to transport coolant
between neighboring heat sink modules, from an outlet port 105 of
the first heat sink module 100 to an inlet port 105 of the second
heat sink module. In some examples, others types of tubing can be
used, such as smooth tubing 225, as shown in FIGS. 4, 84, and 85.
More specifically, smooth nylon or fluorinated ethylene propylene
(FEP) tubing 225 can be used. In one example, the flexible tubing
225 can be FEP tubing from Cole-Parmer of Vernon Hills, Ill. and
can have a maximum temperature rating of about 400 degrees F., an
inner diameter of about 0.25-0.375 inches, and a maximum working
pressure of about 210 psi. In another example, the flexible tubing
225 of the cooling lines 303 can be fluoropolymer tubing from SMC
Corporation of Tokyo, Japan and can have a maximum operating
pressure of about 60-75 psi at 100 degrees C., an inner diameter of
about 0.165-0.185 inches, and a minimum bend radius of about
2.0-2.5 inches. The flexible tubing 225 can be chemically inert,
nontoxic, heat resistant, and have a low coefficient of friction.
In addition, the flexible tubing 225 may not noticeably deteriorate
with age.
[0393] Traditional two-phase cooling systems employ a
vapor-compression cycle to move heat. A vapor-compression cycle
requires a compressor that produces high operating pressures
adequate to compress a refrigerant from a vapor state back to a
liquid state. High pressures (e.g. greater than 100, 200, or 300
psi) associated with vapor-compression cycles necessitate
high-pressure tubing for safety. High-pressure tubing, such as
metal tubing used in refrigerators and freezers, is not flexible,
and must be pre-bent and customized for each new application.
Consequently, high-pressure tubing is not well suited for
retrofitting thousands of servers 400 in a data center 425 with a
two-phase cooling system, where the distance from each server to
each manifold assembly varies and where different makes and models
of servers (with different internal dimensions and processor
locations) may exist. By contrast, the low-pressure, flexible
tubing 225 described herein can easily be sized, cut, and routed
from a manifold assembly 680 into each server 400 in the data
center 425, regardless of make, model, or circuit board layout. The
installation process is quick and easy and does not require joining
(e.g. brazing), bending, or cutting metal tubing.
[0394] Unlike traditional two-phase systems, the cooling
apparatuses 1 described herein do not employ vapor-compression
cycles. Instead, the cooling apparatuses described herein take
advantage of a unique heat sink module 100 geometry and manifold
assembly 680 to control the pressure in the outlet chamber 150 of
the heat sink module to promote phase change heat transfer at a
surface to be cooled 12. Because the cooling system 1 operates at
relatively low pressures, low-pressure, flexible tubing can be used
to fluidly connect system components, such as heat sink modules
100. Low-pressure tubing with a maximum operating pressure of less
than about 35, 50, 75, 100, or 200 psi can be used. Although the
actual operating pressure of the cooling system 1 may be well below
75 or 100 psi, flexible tubing with a higher pressure rating (e.g.
a rating of 100 or 200 psi) may be selected to provide a suitable
safety factor (e.g. a safety factor of 1.5-2.5). Even at these
higher pressure ratings, the tubing is flexible and can be easily
routed within a standard server (see, e.g., FIG. 84) or a blade
server (see, e.g., FIG. 151). The flexible tubing 225 can have a
minimum bend radius (R) of less than about 3, 2.5, or 2 inches to
permit easy installation without risk of kinking.
[0395] Providing a cooling apparatus 1 that operates at low
pressures (e.g. less than 50 psi) as described herein, allows low
pressure, flexible tubing 225 to be used. Flexible tubing is
significantly less expensive than high pressure tubing, such as
braided stainless steel tubing. Moreover, operating at lower
pressures reduces power consumption by the pump 20, which provides
a more efficient cooling system 1. Low pressure, flexible lines 225
can have substantially smaller minimum bend radiuses (R) and
substantially smaller outer diameters than high pressure lines,
making them far easier to route within server housings 400 where
space is limited and where tight bends are commonly required to
route around server components, such as fans and power electronics,
as shown in FIG. 84.
[0396] In some applications, corrugated, flexible tubing 225 can
provide certain advantages. For instance, corrugated tubing can
resist kinking when routed in space-constrained applications, such
as within servers 400 as shown in FIGS. 5 and 6. Flexible,
corrugated tubing can be routed in configurations where the tubing
contains bends that result in 180-degree directional changes
without kinking, as shown in FIG. 6. In some examples, the
flexible, corrugated tubing 225 can be corrugated FEP tubing from
Cole-Parmer and can have a maximum temperature rating of about 400
degrees F. and a maximum working pressure of about 250 psi.
[0397] An advantage of corrugated tubing 225 is that, when
transporting two-phase bubbly flow, it may delay the onset of slug
flow by causing the breakdown of larger bubbles into smaller
bubbles and causing the breakdown of clusters of bubbles due to
frictional effects acting on the bubbles as they pass through the
corrugated tubing and contact the inner walls of the tubing. Slug
flow occurs when one or more large or bullet-shaped bubbles of
vapor form within the tubing 225. As shown in FIG. 58, large vapor
bubbles within slug flow may be nearly as wide as the inner
diameter of the tubing. Slug flow is undesirable, since it can
create flow instabilities in the cooling apparatus 1, resulting in
surging or chugging within the cooling loops 300, making it
difficult to maintain desired pressures in certain components of
the cooling system 1, such as the heat sink modules 100, and
thereby making it difficult to provide consistent and predictable
cooling of a heated surface 12. Slug flow can be combated by
increasing the flow rate through the heat sink modules 100 to
reduce flow quality (x) (due to less vapor formation), thereby
restoring two-phase bubbly flow, for example, between
series-connected heat sink modules 100. In some examples, the
cooling apparatus 1 can be configured to detect the onset of slug
flow (e.g. using a visual flow detection system) at an outlet port
110 of a heat sink module 100 or at some other point in the cooling
loop 300 and to automatically increase the coolant flow rate 51 to
restore two-phase bubbly flow at the outlets of the one or more
heat sink modules 100.
[0398] Another advantage of corrugated tubing 225 is that it can
resist collapse when vacuum pressure is applied to an inner volume
of the tubing. Vacuum pressure may be applied to the tubing 225
during servicing of the cooling apparatus 1. For example, when
draining coolant 50 from the system 1 to allow for repairs or
maintenance to be performed, vacuum pressure can be applied to a
location (e.g. a drain 245) in the cooling apparatus 1 to draw out
coolant 50 from the tubes and components of the apparatus. Portions
of the cooling apparatus 1 can then be safely disassembled without
having to make other arrangements for containment of the coolant.
Removing coolant 50 through the application of vacuum pressure can
allow the coolant to be captured in a vessel and reused to fill the
apparatus when servicing is complete, thereby reducing servicing
costs and waste that would otherwise be associated with discarding
and replacing the coolant.
[0399] FIG. 6 shows a top view of a server 400 with its lid removed
and a portion of a cooling apparatus 1 visible within the server.
This example of a server 400 includes a motherboard 405, two
microprocessors 415, and two sets of three memory modules 420. The
two microprocessors 415 are mounted parallel to the motherboard
405, and the memory modules 420 are mounted perpendicular to the
motherboard 405. The cooling apparatus 1 includes two heat sink
modules 100 arranged in a series configuration and fluidly
connected by flexible sections of flexible tubing 225. The first
heat sink module 101 is mounted on a first microprocessor, and the
second heat sink module 102 is mounted on a second microprocessor.
A first section of flexible tubing 225 delivers coolant the an
inlet port 105 of the first heat sink module 101, and a second
section of flexible tubing 225 delivers coolant from an outlet port
110 of the first heat sink module 101 to an inlet port 105 of the
second heat sink module 102. As, shown, due to its flexibility, the
second section of flexible tubing 225 can easily be routed around
server components for ease of installation. The flexible tubing 225
can be arranged in a variety of configurations, including
serpentine configurations, to allow any two heat sink modules 100
(e.g. within a server housing) to be fluidly connected regardless
of the orientation or placement of the two heat sink modules.
[0400] The heat sink modules 100 can be used within the server 400
to cool electrical components that produce the most heat, such as
the microprocessors 415. Other components within the server 400 may
also produce heat, but the amount of heat produced may not justify
installation of additional heat sink modules 100. Instead, to
remove heat generated by other electrical devices within the server
400, one or more fans 26 can be used to expel warm air from the
server 400 housing, as shown in FIG. 6. The fans can be configured
to draw cool room air into the server housing 400 and to expel warm
air from the housing.
[0401] In some examples, the length of a section of flexible tubing
225 between series-connected modules can be at least 4, 6, 12, 18,
or 24 inches in length. In some applications, increasing the length
of the section of tubing 225 can promote condensation of bubbles
275 within the bubbly flow between series-connected heat-sink
modules due to heat transfer from the liquid to the tubing 225 and
ultimately from the tubing to the ambient air, as well as heat
transfer within the coolant from the vapor portion of the flow to
the liquid portion of the flow, thereby elevating the bulk fluid
temperature as vapor bubbles collapse. In some applications,
increasing the length of the second section of flexible, corrugated
tubing 225 may promote breaking apart of clusters of bubbles that
may form in the two-phase flow, thereby delaying the onset of
plug/slug flow and maintaining two-phase bubbly flow.
Coolant Filter
[0402] FIG. 13 shows a schematic of a cooling apparatus 1 including
a filter 260 located between the reservoir 200 and the pump 20 in
the primary cooling loop 300. The filter 260 can trap and prevent
debris from entering and damaging the pump 20. Likewise, the filter
260 can trap and prevent debris from passing through the primary
cooling loop 300 to the one or more heat sink modules 100, where
the debris could potentially clog small orifices 155 in the heat
sink modules. The cooling apparatus 1 can include one or more
filters 260 placed upstream or downstream of the pump 20, or in any
other suitable locations. The filter 260 can be connected inline
using quick-connect fittings. The filter 260 can be a disposable
filter or a reusable filter. The filter can have a micron rating of
about 5, 10, or 20 microns.
[0403] In some examples, the heat sink module 100 can include a
filter 260 to ensure that no debris is permitted to enter the heat
sink module and clog orifices 155 within the heat sink module. The
filter 260 can be disposed within the heat sink module (e.g. a
removable filter that is inserted within the inlet port 105, inlet
passage 165, or inlet chamber 145), or can be attached in-line with
the heat sink module 100, such as a filter component that is
threaded onto the inlet port and that contains a filtration device.
By placing the filter 260 in or immediately upstream of the heat
sink module 100, clogging of orifices 155 within the heat sink
module can be avoided regardless of where debris originates from in
the cooling apparatus 1.
Heat Sink Module
[0404] The heat sink module 100 can be configured to mount on a
surface to be cooled 12 and provide a plurality of jet streams 16
(e.g. an array of jet streams 16) of coolant that impinge against
the surface to be cooled 12 to effectively remove heat from the
surface to be cooled. By removing heat from the surface to be
cooled 12, the heat sink module 100 can effectively maintain the
temperature of the surface to be cooled 12 at a suitable level so
that a device associated with the surface to be cooled 12 is able
to operate without overheating (i.e. operate below a threshold
temperature).
[0405] The heat sink module 100 can include a top surface 160 and a
bottom surface 135 opposite the top surface. The heat sink module
100 can be uniquely sized and shaped for a particular application.
For instance, where the heat sink module 100 is tasked with cooling
a square-shaped microprocessor, the heat sink module 100 can have a
square perimeter, as shown in FIGS. 21-24. In this example, the
heat sink module 100 can be defined by a front side surface 175, a
rear side surface 180, a left side surface 185, a right side
surface 190, the top surface 160, and the bottom surface 135. In
other applications, the perimeter shape of the heat sink module 100
can be round, polygonal, or non-polygonal. In some examples, the
heat sink module 100 can have dimensions that allow it to replace a
traditional finned heat sink. For instance, the heat sink module
100 can have a footprint of about 91.5.times.91.5 mm or 50.times.50
mm. In other examples, the heat sink module can be sized for a
specific CPU or GPU. The features of the heat sink module 100 are
scalable and can be rapidly manufactured using a 3D printing
process.
[0406] The heat sink module 100 can have any suitable sealing
feature located on the bottom surface 135 to facilitate sealing
against the surface to be cooled 12 or against an intermediary
surface, such as a surface of a thermally-conductive base member
(e.g. a copper plate 430) that is adhere to the surface to be
cooled 12. In some examples, the heat sink module 100 can include a
channel 140 along its bottom surface 135, as shown in FIG. 24. The
channel 140 can be configured to receive a suitable sealing member
125, such as a gasket or O-ring, as shown in FIG. 23. In some
examples, the channel 140 can be a continuous channel that
circumscribes an outlet chamber 150 of the heat sink module 100, as
shown in FIG. 24. In other examples, the heat sink module 100 can
include alternate or additional sealing materials, such as a liquid
gasket material, a die cut rubber gasket, an adhesive sealant, or a
3-D printed gasket provided on the bottom surface 135 of the heat
sink module 100.
[0407] Although the bottom surface 135 of the heat sink module
shown in FIG. 23 is flat, this is non-limiting. For applications
involving a contoured surface to be cooled 12, the bottom surface
135 of the heat sink module 100 can have a corresponding contour
that matches the contour of the surface to be cooled 12 and a
thereby allows a sealing member 125 disposed therebetween to
provide a liquid tight seal. In one example, the bottom surface 135
of the heat sink module can have a contour configured to match an
external surface contour of a cylindrical tube or vessel (e.g. a
metallic vessel) used in a chemical process, such as a condensation
process or cooling wort in a brewing process. The contoured bottom
surface 135 of the heat sink module 100 can allow the heat sink
module to be form a liquid-tight seal against the tube or vessel
and cool an external surface of the tube or vessel that is exposed
within the outlet chamber 150 of the heat sink module 100. Where
the contents of a large vessel must be cooled rapidly, such as when
chilling wort in a brewing process, a plurality of heat sink
modules 100 can be arranged on the external surface(s) of the large
vessel to remove heat from the vessel rapidly, thereby allowing the
cooling apparatus 1 to replace a glycol chiller system in a modern
brewery or a counterflow chiller (which uses a significant amount
of chilled water) in a more traditional brewery.
[0408] The heat sink module 100 can include mounting holes 130 or
locating holes, as shown in FIGS. 21 and 23, located near corners
of the module and/or along one or more perimeter portions of the
module. Fasteners 115 can be inserted through the mounting holes
130, as shown in FIG. 22, and installed into threaded holes
associated with a mounting surface to which the heat sink module
100 is mounted, such as a mounting surface of a thermally
conductive base member 430 (e.g. a copper base plate) or directly
to a mounting surface of an electrical device (e.g. a
microprocessor 415 or a motherboard 405). In some examples,
screw-type fasteners 115 can be replaced with alternate types of
fastening devices that allow for faster installation and/or removal
of the heat sink module 100. In one example, the heat sink module
100 can be fastened to a heat source using a buckle mechanism,
similar a ski boot buckle, to allow for rapid, tool-less
installation. In other examples, the heat sink module 100 can be
received by a snap fitting on the surface to be cooled 12, thereby
allowing the heat sink module to be installed and uninstalled with
ease by hand and without tools.
[0409] During installation of the heat sink module 100 on a surface
to be cooled 12, one or more fasteners 115 can be inserted through
one or more 130 holes in the heat sink module, and the one or more
fasteners can engage mounting holes in the surface 12 to permit
secure mounting of the heat sink module 100 to the surface 12. As
the fasteners 115 are tightened, the heat sink module 100 can be
drawn down tightly against the surface to be cooled 12, and the
sealing member 125 (e.g. o-ring or gasket) can be compressed
between the surface and the channel 140. Upon compression, the
sealing member 125 can provide a liquid-tight seal to ensure that
coolant 50 does not leak from the outlet chamber 150 during
operation of the cooling system 1 as coolant 50 flows from the
inlet port 105 to the outlet port 110 of the heat sink module
100.
[0410] The heat sink module 100 can include an inlet port 105, as
shown in FIG. 21. The inlet port 105 can have internal or external
threads 170 that allow a connector 120 to be connected to the inlet
port. Any suitable connector 120 can be used to connect the inlet
section of flexible tubing 225 to the inlet port 105. In some
examples, as shown in FIG. 22, a metal or polymer connector 120
from Swagelock Company of Solon, Ohio can be used to connect the
flexible tubing to the inlet port 105. The top surface 160 of the
heat sink module 100 can include visual markings 132 to identify a
preferred flow direction through the heat sink module to ensure
proper routing of tubing to and from the heat sink module 100 to
ensure that coolant flow 51 is delivered to the inlet port 105 and
exits from the outlet port 110 and is not accidentally
reversed.
[0411] As shown in FIG. 25, the heat sink module 100 can include an
inlet passage 165 that fluidly connects the inlet port 105 to an
inlet chamber 145 of the heat sink module. The heat sink module 100
can include a dividing member 195 that separates the inlet chamber
145 from the outlet chamber 150. The dividing member 195 can have a
top surface and a bottom surface and can include one or more
orifices 155 passing from the top surface to the bottom surface of
the dividing member. The orifices 155 permit jet streams 16 of
coolant 50 to be emitted from the bottom surface of the dividing
member 195 and into the outlet chamber 150 when pressurized coolant
54 is delivered to the inlet chamber 145, as shown in FIG. 26.
[0412] As shown in the cross-sectional view of FIG. 25, the inlet
chamber 145 can have a geometry that tapers in cross-sectional area
from the front side surface 175 of the heat sink module 100 toward
the rear side surface 180 of the heat sink module. The tapered
cross-sectional area of the inlet chamber 145 can ensure that all
orifices 155 receive coolant 50 at a similar pressure. Similarly,
the outlet chamber 150 can increase in cross-sectional area in a
direction from the rear surface 180 of the heat sink module toward
the front surface 175 of the heat sink module 100. The increase in
cross-sectional area of the outlet chamber 150 can provide suitable
volume for expansion of the coolant that may occur as a portion of
the liquid coolant transitions to vapor, as shown in FIG. 30, and
exits the outlet port 110 of the heat sink module 100.
[0413] The heat sink module 100 can include one or more inlet
passages 165 to permit fluid to enter the inlet chamber 145 and one
or more outlet passages 166 to permit fluid to exit the outlet
chamber 150. In this manner, the heat sink module 100 can be
configured to permit fluid to flow through the outlet chamber 150.
A dividing member 195 can at least partially separate the inlet
chamber 145 from the outlet chamber 150. A plurality of orifices
155 can be formed in the dividing member as shown in FIGS. 24 and
25. The plurality of orifices 155 can be configured to each project
a stream 16 of coolant 50 against the surface to be cooled 12. In
some examples, the streams 16 of fluid projected against the
surface 12 can be jet streams. As used herein, a "jet" or "jet
stream" refers to a substantially liquid fluid filament that is
projected through a substantially liquid or fluid medium or a
mixture thereof. As used herein, a "jet stream" can include a
single-phase liquid fluid filament or a two-phase bubbly flow
filament. "Jet" or "jet stream" is contrasted with "spray" or
"spray stream," where "spray" or "spray stream" refers to a
substantially atomized liquid fluid projected through a
substantially vapor medium.
[0414] The inlet chamber 145 and the outlet chamber 150 can be
formed within the heat sink module 100. The heat sink module 100
can be made from any suitable material and manufactured by any
suitable manufacturing process. In some examples, the heat sink
module 100 can be made of a polymer material and formed through a
3D printing process, such as stereolithography (SLA) using a
photo-curable resin. Printers capable of producing heat sink
modules as shown in FIGS. 21-54 are available from 3D Systems
Corporation of Rock Hill, S.C. In other examples, a module body can
be injection molded to reduce cost and manufacturing time and an
insertable orifice plate can be 3-D printed and attached to the
module body to complete the heat sink module 100.
[0415] The heat sink module 100 can be configured to cool a surface
12 of a heat source. The heat sink module 100 can include an inlet
chamber 145 formed within the heat sink module and an outlet
chamber 150 formed within the heat sink module. In some examples,
the outlet chamber 150 can have an open portion along the bottom
side surface 135 of the heat sink module 100, as shown in FIG. 23.
The open portion of the outlet chamber 150 can be enclosed by the
surface 12 of a heat source when the heat sink module 100 is
installed on the surface 12 of the heat source, as shown in FIG.
26. The heat sink module 100 can include a dividing member 195
disposed between the inlet chamber 145 and the outlet chamber 150.
The dividing member 195 can include a first plurality of orifices
155 formed in the dividing member. The first plurality of orifices
155 can pass from a top side of the dividing member 195 to a bottom
side of the dividing member and can be configured to deliver a
plurality of jet streams 16 of coolant 50 into the outlet chamber
150 when pressurized coolant 54 is provided to the inlet chamber
145, as shown in FIG. 26.
[0416] The first plurality of orifices 155 can have any suitable
diameter that allows the orifices to provide well-formed jets
streams 16 of coolant 50 when pressurized coolant 54 is delivered
to the inlet chamber 145 of the heat sink module 100. In some
examples, the orifices 155 may all have uniform diameters, and in
other examples, the orifices may not all have uniform diameters. In
either case, the average diameter of the orifices 155 can be about
0.001-0.020, 0.001-0.2, 0.001-0.150, 0.001-0.120, 0.001-0.005,
0.020-0.045, 0.030-0.050 in, or 0.040 in. An orifice 155 diameter
of about 0.040 in. can be preferable to ensure that orifice
clogging does not occur.
[0417] In some examples, to ensure that well-formed jet streams 16
of coolant 50 are provided by the orifices 155, the length of the
orifice can be selected based on the diameter of the orifice. For
instance, where the first plurality of orifices 155 are defined by
a diameter D and an average length L, in some cases L divided by D
can be greater than or equal to one, about 1-10, 1-8, 1-6, 1-4,
1-3, or 2. In the configuration shown in FIG. 26, the length of
each orifice 155 can be determined based on an angle of the orifice
with respect to the surface to be cooled 12 and based on the
thickness of the dividing member 195. In some examples the dividing
member 195 can have a thickness of about 0.005-0.25, 0.020-0.1,
0.025-0.08, 0.025-0.075, 0.040-0.070, 0.1-0.25, 0.040-0.070, or
0.080 in. The thickness of the dividing member 195 can be selected
to provide a desired length for the orifices 155 to ensure columnar
jet streams 16 of coolant. The thickness of the dividing member can
also be selected to ensure structural integrity of the heat sink
module 100 when receiving pressurized coolant 54 in the inlet
chamber 145 and to withstand vacuum pressure when coolant 50 is
purged from the cooling system 1. To minimize the height of the
heat sink module 100 (e.g. to provide greater freedom when dealing
with tight packaging constraints), it can be desirable to select a
minimal dividing member thickness that still provides well-formed
columnar jet streams 16 and adequate structural integrity.
[0418] The heat sink module 100 can be made of any suitable
material or process (e.g. a three-dimensional printing process) and
can have any suitable color or can be colorless. In some examples,
it may be desirable to visually inspect the operation of the heat
sink module 100 to ensure that boiling is occurring within the heat
sink module proximate the surface to be cooled 12. To permit visual
inspection, at least a portion of the heat sink module 100 can be
made of a transparent or translucent material. In some examples,
the transparent or translucent material can form the entire heat
sink module 100, and in other examples, the transparent or
translucent material can form only a portion of the heat sink
module, such as a window into the outlet chamber 150 of the heat
sink module or a side wall of the heat sink module. In these
examples, the window or side wall can permit boiling coolant within
the outlet chamber 150 to be observed when the heat sink module 100
is installed on the surface to be cooled 12.
Orifices within Heat Sink Module
[0419] Each orifice 155 within the heat sink module 100 can include
a central axis 74, as shown in FIG. 30. The central axis 74 of the
orifice 155 may either be angled perpendicularly with respect to
the surface to be cooled 12 or angled non-perpendicularly with
respect to the surface to be cooled 12, the latter of which is
shown in FIG. 30. FIG. 20 shows a cross-sectional view of a heat
sink module with orifices 155 arranged at a 45-degree angle with
respect to the surface to be cooled 12. If angled
non-perpendicularly with respect to the surface to be cooled 12,
the central axis 74 of the orifice 155 may define any angle between
0.degree. and 90.degree. with respect to the surface 12, such as
about 5.degree., about 10.degree., about 15.degree., about
20.degree., about 25.degree., about 30.degree., about 35.degree.,
about 40.degree., about 45.degree., about 50.degree., about
55.degree., about 60.degree., about 65.degree., about 70.degree.,
about 75.degree., about 80.degree. or about 85.degree. or any range
therebetween (e.g. 5-15.degree., 10-20.degree., 15-25.degree.,
20-30.degree., 25-35.degree., 30-40.degree., 35-45.degree.,
40-50.degree., 45-55.degree., 50-60.degree., 55-65.degree.,
60-70.degree., 65-75.degree., 70-80.degree., or 75-85.degree.). The
orifice 155 can have any cross-sectional shape when viewed along
its central axis 74. Various examples include a circular shape, an
oval shape (to generate a fan-shaped jet stream), a polygonal
shape, or any other suitable cross-sectional shape.
[0420] FIG. 31 shows a top cross-sectional view of the heat sink
module of FIG. 21 taken along section C-C shown in FIG. 25. Section
C-C passes through the dividing member 195 and exposes the array 76
of orifices 155 within the heat sink module 100. In this example,
because the central axes 74 of the plurality of orifices are
arranged at a 45-degree angle with respect to the dividing member
195, the orifices appear as ovals in FIG. 31 despite the orifice
being cylindrical coolant passageways through the dividing
member.
[0421] The heat sink module 100 preferably includes an array 76 of
orifices 155. The central axes 74 of the orifices 155 in the array
76 may define different angles with respect to the surface to be
cooled 12. Alternately, the central axis 74 of each orifice 155 in
the array 76 may have the same angle with respect to surface 12, as
shown in FIG. 30. In some examples, providing neighboring orifices
with central axes 74 with the same angle with respect to the
surface to be cooled 12 can be preferable to avoid interaction
(i.e. interference) of the jet streams 16 prior to impingement on
the surface to be cooled 12. By providing jet streams 16 of coolant
that do not interfere with each other prior to impingement, the
heat sink module 100 can provide jet streams 16 with sufficient
momentum to disrupt vapor formation on the surface to be cooled 12,
thereby increasing the three-phase contact line 58 length on the
surface to be cooled 12 and allowing higher heat fluxes to be
effectively dissipated without reaching critical heat flux (see,
e.g. FIG. 63).
[0422] The array 76 of orifices 155 may be arranged in any
configuration suitable for cooling the surface to be cooled 12.
FIG. 62 shows possible orifice 155 configurations including (a) a
regular rectangular jet array 76, (b) a regular hexagonal jet array
76, and (c) a circular jet array 76. In the regular hexagonal array
76, shown in FIGS. 23, 31 and 62(b), the arrays 76 can be organized
into staggered columns 77 and rows 78. The staggering of orifices
155 in the array 76 is such that a given orifice 155 in a given
column 77 and row 78 does not have a corresponding orifice in a
neighboring row 78 in the given column 77 or a corresponding
orifice 155 in a neighboring column 77 in the given row 78. If the
orifices 155 are configured to induce a substantially same
direction of flow 90 along the surface to be cooled 12 (as shown in
FIGS. 30 and 32), the columns 77 and the rows 78 are preferably
oriented substantially parallel and perpendicular, respectively, to
the substantially same direction of flow 90. Arrays of orifices 155
in non-staggered arrangements can be used in other examples of the
heat sink module 100.
[0423] The orifice 155 can be configured to project a jet stream 16
having any of a variety of shapes and any of a variety of
trajectories. With regard to shape, the stream 16 is preferably a
symmetrical stream. As used herein, "symmetrical stream," refers to
a jet stream 16 that is symmetrical in cross section. Examples of
symmetrical streams include linear streams, fan-shaped streams, and
conical streams. Linear streams have a substantially constant cross
section along their length. Conical streams have a round cross
section that increases along their length. Fan-shaped streams have
a cross section along their length with a first cross-sectional
axis being significantly longer than a second, perpendicular
cross-sectional axis. In some versions of the conical jet streams
16, at least one and possibly both of the cross-sectional axes
increase in length along the length of the stream. With regard to
trajectory, the jet stream 16 preferably includes a central axis
17. For the purposes herein, the "central axis 17 of the stream 16"
is the line formed by center points of a series of transverse
planes taken along the length of the stream 16, where each
transverse plane is oriented to overlap with the smallest possible
surface area of the stream 16, and each center point is the point
on the transverse plane that is equidistant from opposing edges of
the stream 16 along the transverse plane. In preferred versions,
the orifice 155 projects a jet stream 16 having a central axis 17
that is substantially collinear with the central axis 74 of the
orifice 155. However, the orifice 155 may also project a stream 16
having a central axis 17 that is angled with respect to the central
axis 74 of the orifice 155. The angle of the central axis 17 of the
stream 16 with respect to the central axis 74 of the orifice 155
may be any angle between 0.degree. and 90.degree., such as about
1.degree., about 2.degree., about 3.degree., about 4.degree., about
5.degree., about 7.degree., about 10.degree., about 15.degree.,
about 20.degree., about 25.degree., about 30.degree., about
35.degree., about 40.degree., about 45.degree., about 50.degree.,
about 55.degree., about 60.degree., about 65.degree., about
70.degree., about 75.degree., or about 80.degree. or any range
therebetween. In such versions, the orifice 155 preferably projects
a jet stream 16 where at least one portion of the jet stream 16 is
projected along the central axis 74 of the orifice 155. However,
the orifice 155 may also project a jet stream 16 where no portions
of the jet stream 16 are projected along the central axis 74 of the
orifices 155.
[0424] Similarly, the orifice 155 may be configured to project a
jet stream 16 that impinges on the surface 12 at any of a variety
of angles. In some versions, the orifice 155 projects a stream 16
at the surface 12 such that the entire stream (in the case of a
linear stream), or at least the central axis 17 of the stream 16
(in the case of conical or fan-shaped streams), impinges
perpendicularly on the surface 12 (i.e., at a 90.degree. angle with
respect to the surface). Perpendicular impingement upon a surface
12 induces radial flow of coolant 50 from contact points along the
surface 12. While arrays 96 of perpendicularly impinging streams 16
are suitable for some applications, they are not optimal in
efficiency. This is because opposing coolant flow from neighboring
contact points interacts to form stagnant regions. Heat transfer
performance in these stagnant regions can fall to nearly zero,
which in high heat flux applications (e.g. cooling high performance
microprocessors or power electronics) can pose risks associated
with critical heat flux.
[0425] In a preferred examples shown in FIGS. 30 and 32, the
orifices 155 are configured to project jet streams 16 of coolant
that impinge the surface to be cooled 12 such that at least the
central axis 17 of each jet stream 16, and more preferably the
entire jet stream 16, impinges non-perpendicularly on the surface
to be cooled 12 (i.e. at an angle other than 90.degree. with
respect to the surface), as shown in FIGS. 30-32. As a non-limiting
example, the central axis 17 of the jet stream 16 may impinge on
the surface 12 at any angle between 0.degree. and 90.degree., such
as about 1.degree., about 2.degree., about 3.degree., about
4.degree., about 5.degree., about 7.degree., about 10.degree.,
about 15.degree., about 20.degree., about 25.degree., about
30.degree., about 35.degree., about 40.degree., about 45.degree.,
about 50.degree., about 55.degree., about 60.degree., about
65.degree., about 70.degree., about 75.degree., or about 80.degree.
or any range there between.
[0426] FIG. 32 depicts a top view of a surface 12 on which jet
streams 16 of an array 76 of jet streams impinges
non-perpendicularly on the surface 12. The non-perpendicular
impingement creates a flow pattern 90 to the right in which all the
coolant 50 flows along the surface 12 in substantially the same
direction 90. In some versions of patterns flowing in substantially
the same direction 90, flow of coolant 50 at each portion of the
surface 12 has a common directional vector component along a plane
defined by the surface to be cooled 12. In other versions, coolant
50 at no two points on the surface 12 flows in opposite directions.
In yet other versions, coolant 50 at no two points on the surface
12 flows in opposite directions or flows in perpendicular
directions. Flowing coolant 50 in the substantially same direction
eliminates stagnant regions on the surface being cooled 12, which
helps avoid the onset of critical heat flux.
[0427] The plurality of orifices 155 in the array 76 are preferably
configured to provide impinging jet streams 16 of coolant on the
surface 12 in an array 96 of contact points 91 (i.e. where each
contact point 91 is a jet stream 16 impingement location on the
surface to be cooled 12) having staggered columns 97 and rows 98,
as shown in FIG. 32. The staggering is such that a given contact
point 91 in a given column 97 and row 98 does not have a
corresponding contact point 91 in a neighboring column 97 in the
given row 98 or a corresponding contact point 91 in a neighboring
row 98 in the given column 97. If the coolant 50 is induced to flow
across the surface 12 in substantially the same direction 90, as
shown in FIG. 32, either the columns 97 or the rows 98 are
preferably oriented substantially perpendicularly to the
substantially same direction 90 of flow. Arrays 96 of contact
points 91 arranged in this manner permit coolant 50 emanating from
each contact point 91 in a given column 97 or row 98 to flow
substantially between contact points 91 in a neighboring column 97
or row 98, respectively, as shown in FIG. 32. The heat sink module
100 shown in FIGS. 21 and 30 provides even, consistent flow of
coolant 50 over the surface to be cooled 12, without formation of
stagnation regions, and thereby encourages bubble 275 generation
and evaporation, which dramatically increases the heat transfer
rate from the surface to be cooled 12.
[0428] The heat sink module 100 can include an array 76 of orifices
155 with each orifice 155 having a central axis 74 angled
non-perpendicularly with respect to the surface 12, where each
orifice 155 projects a jet stream 16 of coolant 50 having a central
axis 17 collinear with the central axis 74 of the orifice 155. In
some examples, all the orifices 155 can have central axes 74
oriented at about the same angle and can project jet streams 16 of
coolant having about the same trajectory and shape and can impinge
against the surface 12 at about the same angle of impingement.
[0429] The array 76 of orifices 155 can be provided within the heat
sink module 100 as illustrated and described with respect to FIGS.
23-31. The plurality of jet streams 16 emitted from the plurality
of orifices 155 can promote bubble generation and evaporation at
the surface to be cooled 12, thereby achieving higher heat transfer
performance than conventional single-phase liquid cooling systems.
Other implementations may promote bubble 275 generation using
structures within the orifices 155, such as structures that
encourage cavitation or degassing of non-condensable gasses
absorbed in the liquid. Similarly boiling-inducing members 196 can
be included in the heat sink module 100, as shown in FIGS. 45-50,
or can be included on the surface to be cooled 12, as shown in FIG.
55.
Jet Streams with Entrained Bubbles
[0430] In some examples, it can be desirable provide jet streams 16
that contain entrained bubbles 275 to seed nucleation sites on the
surface to be cooled 12. Seeding nucleation sites on the surface to
be cooled 12 can promote vapor formation and can increase a heat
transfer rate from the surface to be cooled 12 to the coolant 50.
FIG. 73 shows a first heat sink module 100 fluidly connected to a
second heat sink module 100. A section of flexible tubing 225
transports coolant from an outlet port 110 of the first heat sink
module 100 to an inlet port 105 of the second heat sink module 100.
Within the first heat sink module 100, a plurality of jet streams
16 of coolant are shown impinging a first surface to be cooled 12.
Due to heat transferring from the first surface to be cooled 12 to
the coolant 50 within in the outlet chamber 150 of the first heat
sink module 100, vapor bubbles 275 form in the coolant 50. The
bubbles 275 can be dispersed within the liquid coolant as it exits
the outlet port 110 of the heat sink module 100. As the coolant 50
flows within the tubing 225 toward the inlet port 105 of the second
heat sink module, some of the bubbles 275 may coalesce and form
larger bubbles. The small and large bubbles 275 can be transported
to an inlet chamber 145 of the second heat sink module. The small
bubbles may be sufficiently small to travel through the orifices
155 and become entrained in a jet stream that impinges against the
surface to be cooled. When the small bubbles impinge the surface to
be cooled 12, they may seed nucleation sites on the surface to be
cooled 12 and promote vapor formation, which can provide higher
heat transfer rates. In some examples, as shown in FIG. 73, the
larger bubbles 276 may be too large to pass through the orifices
155. But pressure and flow forces may draw the larger bubbles 276
toward the orifices 155, where upon contacting the orifice inlets,
the larger bubbles 276 break into smaller bubbles that can pass
through the orifices 155 and be entrained in the jet streams 16. In
this way, the size of the orifice 155 determines the maximum bubble
size that will be entrained in the jet stream 16 and will impinge
the surface to be cooled 12. To provide jet streams 16 with
entrained bubbles 275 that provide desirable seeding of nucleation
sites on the surface to be cooled 12, the orifice 155 diameters
within the heat sink module 100 can be about 0.001-0.020,
0.001-0.2, 0.001-0.150, 0.001-0.120, 0.001-0.005, or 0.030-0.050
in.
Anti-Pooling Orifices
[0431] Pooling of coolant 50 within the outlet chamber 150 of the
heat sink module 100 is undesirable, since it can create stagnation
regions or other undesirable flow patterns that result in
non-uniform cooling of the surface to be cooled 12, which can lead
to critical heat flux issues. To avoid pooling of coolant 50 in the
outlet chamber 150, the heat sink module 100 can include a second
plurality of orifices 156 extending from the inlet chamber 145 to a
rear wall (or proximate the rear wall) of the outlet chamber 150,
as shown in FIGS. 33-38. The second plurality of orifices 156 can
be configured to deliver a plurality of anti-pooling jet streams 16
of coolant to a rear portion of the outlet chamber 150 when
pressurized coolant 54 is provided to the inlet chamber 145. As
shown in FIG. 33, the second plurality of orifices 156 can be
arranged in a column along the rear wall of the outlet chamber 150
thereby preventing coolant from pooling near the rear wall of the
outlet chamber 150.
[0432] FIG. 35 shows a detailed view of one anti-pooling orifice
156 taken from the cross-sectional view of FIG. 34. The
anti-pooling orifice 156 can be configured to deliver an
anti-pooling jet stream 16 of coolant to a rear region of the
outlet chamber 150 to prevent coolant from pooling or stagnating
near the rear wall of the outlet chamber 150. The central axes 75
of the anti-pooling orifice 156 can be arranged at an angle of
about 0-90, 40-80, 50-70, or 60 degrees respect to the surface to
be cooled 12. In some examples, the central axes 75 of the
anti-pooling orifice 156 can be at a larger angle than the central
axes 74 of the plurality of orifices 155, as shown in FIG. 35. This
arrangement can prevent interaction of the anti-pooling jet stream
with a neighboring jet stream 16 prior to impingement on the
surface to be cooled 12, thereby decreasing the likelihood of
stagnation points on the surface to be cooled 12 near the rear wall
of the outlet chamber 150.
Boiling-Inducing Features
[0433] As described above, achieving boiling of coolant 50
proximate the surface to be cooled 12 can dramatically increase the
heat transfer rate and overall performance of the cooling apparatus
1. To encourage boiling of coolant 50 within the outlet chamber
150, the heat sink module 100 can include one or more
boiling-inducing members 196 extending from the bottom surface of
the dividing member 195 toward the surface to be cooled 12, as
shown in FIG. 46. The one or more boiling-inducing members 196 can
be slender members extending from the bottom surface of the
dividing member 195. In some examples, the one or more
boiling-inducing members 196 can be configured to contact the
surface to be cooled 12. In other examples, the one or more
boiling-inducing members 196 can be configured to extend toward the
surface to be cooled but not contact the surface to be cooled.
Rather, a clearance can be provided between the one or more
boiling-inducing members 196 and the surface to be cooled 196, such
that coolant 50 can flow between the surface to be cooled 12 and
the tips of the boiling-inducing members, thereby ensuring that no
hot spots or stagnation regions are created on the surface to be
cooled 12. The clearance distance can be any suitable distance, and
in some examples can be 0.001-0.0125, 0.001-0.05, 0.001-0.02,
0.001-0.01, or 0.005-0.010 in.
Angled Inlet and Outlet Ports
[0434] The inlet port 105 and outlet port 110 of the heat sink
module 100 can be angled to provide ease of installation in a wide
variety of applications. For instance, when installing the heat
sink module 100 on a microprocessor 415 that is mounted on a
motherboard 405, as shown in FIG. 27, if the inlet port 105 of the
heat sink module is arranged at an angle (a) that is greater than
zero, a clearance distance is provided between a bottom surface of
the inlet port 105 and the microprocessor 415 and motherboard 405.
This clearance distance can allow a connector 120, such as a
compression fitting, to be easily installed (e.g. threaded) on the
inlet port 105) without interfering with or contacting the
microprocessor or motherboard. In addition, angling the port
upwards at a moderate angle reduces the likelihood that the heat
sink module 100 (and flexible tubing 225 connected to the inlet
port 105) will interfere with any motherboard devices (e.g.
capacitors, resistors, inductors), while still maintaining a
compact height that allows the heat sink module 100 to be used
between two expansion cards. In the example shown in FIG. 21, a
height measured from the bottom surface 135 to the top surface 160
of the heat sink module 100 can be about 0.36 inches, and a height
measured from the bottom surface 135 to the highest surface of the
angled inlet and outlet ports (105, 110) can be about 0.42 inches.
As shown in FIGS. 5, 6, 56, and 57, free space can be limited on a
motherboard 405 and in a server 400, and experimental installations
have shown that angled inlet and outlet ports (105, 110) and
compact external dimensions can be very helpful in making heat sink
modules 100 fit in tight spaces where competing heat sinks are
unable to fit.
[0435] The heat sink module 100 can include an inlet port 105 that
is fluidly connected to the inlet chamber 145 by an inlet passage
165. The heat sink module 100 can include a bottom plane 19
associated with the bottom surface 135, as shown in FIG. 26. The
inlet port 105 can be defined by a central axis 23. The central
axis 23 of the inlet port 105 can be non-parallel and
non-perpendicular to the bottom plane 19 of the heat sink module
100. For instance, the central axis 23 of the inlet port 105 can
define an angle of about 10-80, 20-70, 30-60, or 40-50 degrees with
respect to the bottom plane 19 of the heat sink module 100.
[0436] The heat sink module 100 can include an outlet port 110 that
is fluidly connected to the outlet chamber 150 by an outlet passage
166. The outlet port 110 can be defined by a central axis 24, as
shown in FIG. 29. The central axis 24 of the outlet port 110 can be
non-parallel and non-perpendicular to the bottom plane 19 of the
heat sink module 100. For instance, the central axis 24 of the
outlet port 110 can define an angle of about 10-80, 20-70, 30-60,
or 40-50 degrees with respect to the bottom plane 19 of the heat
sink module 100.
Insertable Orifice Plate
[0437] In some instances, the heat sink module 100 can include two
or more components that are assembled to construct the heat sink
module. Since the plurality of orifices 155 disposed in the
dividing member 195 can be the most intricate and costly portion of
the heat sink module 100 to manufacture (due to the relatively
small diameters of the orifices 155 requiring a tighter tolerance
manufacturing process than the rest of the module), it may be
desirable to manufacture an orifice plate 198 (e.g. that includes a
dividing member 195 and a plurality of orifices 155) separately
from the rest of the heat sink module (i.e. the module body 104)
and subsequently assemble the module body 104 and the orifice plate
198. FIG. 65 shows an insertable orifice plate 198 attached to a
module body 104 to form heat sink module 100.
[0438] In some examples, the orifice plate 198 can be manufactured
by a first manufacturing method and the module body 104 can be
manufactured by a second manufacturing method where the second
manufacturing method is, for example, a lower cost and/or lower
precision manufacturing method than the first manufacturing method.
In some examples, the orifice plate 198 can be manufactured using a
3-D printing process, and the module body 104 can be manufactured
by an injection molding process. In other examples, the orifice
plate 198 can be manufactured by an injection molding process, a
casting process, or a machining or drilling process, and the module
body 104 can be manufactured by any other suitable process.
[0439] FIG. 65 shows a heat sink module 100 with a module body 104
and an insertable orifice plate 198 installed therein. The
insertable orifice plate 198 can be attached to the heat sink
module 100 by any suitable method of assembly (e.g. fasteners,
press fit, or snap fit). As shown in FIG. 65, the insertable
orifice plate 198 can be pressed into the body 104 of the heat sink
module 100 and can include a sealing member 126 that is configured
to form a liquid-tight seal between the inlet chamber 145 and the
outlet chamber 150. In some examples, the insertable orifice plate
198 can be removable, and in other examples the insertable orifice
plate 198 may not be easily removable once installed in the body of
the heat sink module 100. The plurality of orifice 155 in the
orifice plate 198 can be optimized to cool a certain device, such
as a certain brand and model of microprocessor 415 having a
particular non-uniform heat distribution. When the microprocessor
415, motherboard 405, or entire server 400 is upgraded to a newer
model, a first insertable orifice plate 198 in the heat sink module
100 can be replaced by a second insertable orifice plate 198 that
has been optimized to cool the newer model processor that will
replace the older one. Consequently, instead of needing to replace
the entire heat sink module 100, only the insertable orifice plate
198 needs to be replaced to ensure adequate cooling of the newer
model processor. This approach can significantly reduce costs
associated with upgrading servers 400 in data centers 425. It can
also significantly reduce the cost of optimizing the cooling
apparatus 1 when replacing servers 400 in a datacenter 425, since
the original cooling apparatus 1, including the pump 20, manifolds
(210, 215), heat exchangers 40, flexible tubing 225, and fittings
235, can continue to be used.
[0440] A heat sink module 100 can be configured to cool a heat
source, such as a surface 12 of a heat source. The heat sink module
100 can include an inlet chamber 145 formed within the heat sink
module. The heat sink module 100 can include an insertable orifice
plate 198 and a module body 104, as shown in FIG. 65, where the
insertable orifice plate is configured to attach within the module
body 104. The insertable orifice plate 198 can separate the inlet
chamber 145 from an outlet chamber 150. The insertable orifice
plate 198 can include a first plurality of orifices 155 passing
from a top side of the insertable orifice plate 198 to a bottom
side of the insertable orifice plate 198. The first plurality of
orifices 155 can be configured to deliver a plurality of jet
streams 16 of coolant 50 into the outlet chamber 150 when
pressurized coolant 54 is provided to the inlet chamber 145 of the
heat sink module 100. The outlet chamber 150 can have an open
portion proximate a bottom surface of the heat sink module 100, and
the open portion can be configured to be enclosed by a surface 12
of a heat source when the heat sink module is installed on the
surface of the heat source. In this example, the first plurality of
orifices 155 can have an average diameter of about 0.001-0.020,
0.001-0.2, 0.001-0.150, 0.001-0.120, 0.001-0.005, or 0.030-0.050
in. The insertable orifice plate 198 can have a thickness of about
0.005-0.25, 0.020-0.1, 0.025-0.08, 0.025-0.075, 0.040-0.070,
0.1-0.25, or 0.040-0.070 in.
Jet Height
[0441] The heat sink module 100 can have a bottom plane 19
associated with the bottom surface 135 of the heat sink module, as
shown in FIG. 26. The distance between the bottom plane 19 of the
heat sink module and the bottom side of the insertable orifice
plate 198 (i.e. where orifice 155 outlets are located) defines a
"jet height" 18, which can be an important factor affecting heat
transfer rates attainable from the surface to be cooled 12 in
response to impinging jets 16 of coolant 50 being delivered from
the plurality of orifices 155. In some examples, the distance
between the orifice 155 outlets and the surface to be cooled 12 can
be about 0.01-0.75, 0.05-0.5, 0.05-0.25, 0.020-0.25, 0.03-0.125,
0.04-0.08, or about 0.050 in. In some examples, the jet height 18
can define the height of the outlet chamber 150 of the heat sink
module 100.
[0442] As shown in FIG. 26, the outlet chamber 150 can have a
tapered profile that permits for expansion of the coolant 50 as the
coolant flows towards the outlet port 110 and as the quality (x) of
the coolant increases in response to vapor formation proximate the
surface to be cooled 12. To provide this tapered volume, the bottom
surface of the dividing member may be arranged at an angle with
respect to the surface to be cooled. Consequently, a jet height 18
of a first orifice 155 located near a front side of the heat sink
module 100 may be less than a jet height 18 of a second orifice 155
located near a rear side of the heat sink module. In these
examples, a non-uniform jet height 18 may be defined as falling
within a suitable range, such as about 0.01-0.75, 0.05-0.5,
0.05-0.25, 0.020-0.25, 0.03-0.125, or 0.04-0.08 in. In other
examples, an average jet height can be calculated based on the
non-uniform jet height values, and the average jet height can be
about 0.01-0.75, 0.05-0.5, 0.05-0.25, 0.020-0.25, 0.03-0.125, or
0.04-0.08 in.
[0443] In some examples, the distance between the bottom surface of
the insertable orifice plate 198 (or dividing member 195) and the
bottom surface 135 of the heat sink module 100 can define the jet
height 18. The jet height (H) can be selected based on the average
diameter (d.sub.n) of the plurality of orifices 155. The
relationship between the jet height 18 and the average diameter of
the plurality of orifices 155 can be expressed as a ratio
(H/d.sub.n). Examples of suitable values for H/d.sub.n can be about
0.25-30, 0.25-10, 5-20, 15-25, or 20-30 for the heat sink module
100 described herein.
Jet Spacing
[0444] The orifices 155 within the heat sink module 100 can have
any suitable configuration forming an array 76. FIGS. 62(a), (b),
and (c) show configurations of orifices 155 having a rectangular
jet array, a hexagonal jet array, and a circular jet array,
respectively. Spacing (S) of the orifices 155 can be selected based
on the average diameter (d.sub.n) of the plurality of orifices 155.
As shown in FIG. 62(b), for a hexagonal jet array 76, spacing
between jets from left to right (i.e. in a streamwise direction for
oblique jet impingement as shown in FIG. 32) is identified as
S.sub.col, and spacing between jets from top to bottom (i.e.
cross-stream direction for oblique impingement as shown in FIG. 32)
is identified as S.sub.row. Where S.sub.col is set equal to S, and
S.sub.row is set equal to (2.sub.col/ 3), a relationship between
jet spacing S and the average diameter of the plurality of orifices
155 can be expressed as S/d.sub.n. Suitable values for S/d.sub.n
can be about 1.8-330, 1.8-50, 25-125, 100-200, 150-250, 200-300, or
275-330 for the rectangular, hexagonal, and circular jet arrays 76
shown in FIGS. 62(a), (b), and (c), respectively.
Jet Stream Momentum Flux
[0445] In some examples, coolant pressure, coolant temperature,
coolant mass, and/or orifice diameter can be selected to provide a
jet stream 16 with sufficient momentum flux to penetrate through
the coolant 50 in the outlet chamber 150 and to impinge the surface
to be cooled 12, as shown in FIG. 26. By impinging the surface to
be cooled 12, the jet stream 16 can disrupt vapor bubbles or
pockets forming on the surface to be cooled 12, thereby increasing
the length of the three-phase contact line 58 (see, e.g. FIG. 63)
and thereby increasing the heat transfer rate from the surface to
be cooled 12 to the coolant 50 and delaying the onset of critical
heat flux.
[0446] To provide desirable heat transfer from the surface to be
cooled 12, experimental testing demonstrated that jet stream 16
momentum flux should be at least 23 kg/m-s.sup.2 when using R245fa
as the coolant 50 and should be at least 24 kg/m-s.sup.2 when using
HFE-7000 as the coolant 50. Suitable values of jet stream 16
momentum flux from each orifice include 24-220, 98-390, 220-611,
390-880, 611-1200, 880-1566, and greater than 1566 kg/m-s.sup.2.
Although a high jet stream 16 momentum flux can be desirable to
increase heat transfer rates, reducing the jet stream momentum flux
can be desirable to reduce power consumption by the pump 20, and
thereby increase efficiency of the cooling apparatus 1.
Experimental tests showed that jet stream 16 momentum fluxes of
about 95-880, 220-615, and about 390 kg/m-s.sup.2 produced a
desirable balance of high heat transfer rates and low power
consumption by the pump 20.
Internal Threads on Inlet and Outlet Ports
[0447] In some examples, corrugated, flexible tubing 225 can be
used to fluidly connect heat sink modules 100 to the cooling
apparatus. The corrugated, flexible tubing 225 can include spiral
corrugations extending along the length of the tubing 225, similar
to course threads on a screw. To facilitate fast connection of a
section of flexible tubing 225 to the heat sink module 100,
corresponding corrugation-mating features can be provided on the
interior surfaces of the inlet and outlet ports (105, 110) of the
heat sink module. The corresponding corrugation-mating features can
be molded into the inlet and outlet ports (105, 110) thereby
serving as internal threads. As a result, fluidly connecting a
section of flexible corrugated tubing 225 to a port (105 or 110) of
the heat sink module 100 can be as simple as threading the section
of tubing 225 into the port. In some examples the diameter of the
port (105, 110) can taper inward, thereby ensuring a liquid-tight
fit as the section of tubing 225 is threaded into the port. To
further ensure a liquid-tight seal, a thread sealant, such as a
Teflon tape or a spreadable thread sealant can be provided between
the interior surface of the port (105, 110) and the outer surface
of the section of flexible tubing 225. In other examples, an
adhesive, such as epoxy, can be provided between the interior
surface of the port (105, 110) and the outer surface of the section
of flexible tubing 225 to further ensure a liquid-tight seal and to
prevent inadvertent disconnection of the section of tubing from the
port.
Non-Threaded Connections
[0448] To speed installation of the heat sink module 100, for
example, into a server 400, the threaded ports 105, 110 of the heat
sink module 100 can be replaced with non-threaded ports. In one
example, the non-threaded ports can be quick-connect ports are
configured to mate with a corresponding quick connect coupler, such
as a corresponding quick connect coupler attached to a section of
flexible tubing 225. In this example, the quick-connect features of
the quick-connect ports can be manufactured using a 3D printer. In
another example, the non-threaded ports can be configured to
receive smooth, flexible tubing 225 within in inner diameter of
each port or over an outer diameter of each port. An epoxy or other
suitable adhesive can be used to bond the flexible tubing 225 to
the port (105, 110) of the heat sink module 100 to form a
connector-less fluid coupling.
Leakproof Coating
[0449] The heat sink module 100 can be manufactured from a plastic
material through, for example, an injection molding process or an
additive manufacturing process. Depending of the properties of the
plastic material used to manufacture the heat sink module 100, and
the type of coolant 50 used with the cooling apparatus 1 (and the
molecular size of the coolant), leakage of coolant through the
walls of the heat sink module 100 may occur. To avoid leakage, the
heat sink module 100 can be coated with a leakproof coating. In
some examples, the leakproof coating can be a metalized coating,
such as a nickel coating deposited on an outer surface of the heat
sink module 100 or along the inner surfaces of the heat sink module
(e.g. inner surfaces of the inlet and outlet ports, inlet and
outlet passages, and inlet and outlet chambers). The leakproof
coating can be made of a suitable material and can have a suitable
thickness to ensure that coolant does not migrate through the walls
of the heat sink module 100 and into the environment. The leakproof
coating can be applied to surfaces of the heat sink module 100 by
any suitable application method, such as arc or flame spray
coating, electroplating, physical vapor deposition, or chemical
vapor deposition.
Internal Bypass in Heat Sink Module
[0450] To promote condensing of two-phase bubbly flow upstream of
the reservoir 200, and thereby reduce the likelihood of vapor being
drawn into the pump 20 from the reservoir, the heat sink module 100
can include an internal bypass that routes a portion of the coolant
50 flow delivered to the inlet port 105 of the module around the
heated surface 12. The internal bypass can be formed within the
heat sink module 100. For instance, the internal bypass can be a,
injection molded, cast, or 3D printed internal bypass formed within
the heat sink module 100 and configured to transport coolant from
the inlet port 105 to the outlet port 110 without bringing the
fluid in contact with the surface to be cooled 12. The coolant that
flows through the internal bypass can remain single-phase liquid
coolant that is below the saturation temperature of the coolant.
Near the outlet port 110 of the heat sink module 100, the
single-phase liquid coolant that is diverted through the internal
bypass can be mixed with two-phase bubbly flow (i.e. two-phase
bubbly flow generated by jet stream impingement against the surface
to be cooled 12) that was not diverted. Mixing of the single-phase
liquid coolant with the two-phase bubbly flow can result in
condensation and collapse of vapor bubbles 275 within the mixed
flow 50, thereby reducing the void fraction of the coolant 50 flow
delivered to the reservoir 200 and, in turn, reducing the
likelihood of vapor bubbles being delivered to the pump 20.
[0451] In some examples, as shown in FIG. 12E, the internal bypass
65 in the heat sink module can include a valve 60. The valve 60 can
be disposed at least partially within the internal bypass 65 and
can serve to restrict flow through the internal bypass 65, thereby
controlling the proportion of coolant flow through the internal
bypass, and as a result, the proportion of coolant flow through the
plurality of orifices 155 along a standard flow path 66 through the
heat sink module. The internal valve 60 can be an active or passive
regulator. In some examples, the valve can be a thermostatic valve
that increases flow through the internal bypass 65 as the
temperature of the coolant increases or decreases. In other
examples, the valve 60 can be computer controlled valve where flow
is adjusted based on a temperature and/or a pressure of the coolant
upstream or downstream of the heat sink module 100. In other
examples, the valve 60 can be a simple flow constriction (e.g. a
physical neck) in the internal bypass that effectively restricts
flow by providing flow resistance.
Flow-Guiding Lip
[0452] The heat sink module 100 can include a flow-guiding lip 162,
as shown in FIG. 30. The flow-guiding lip 162 can guide a
directional flow 51 of coolant from the outlet chamber 150 to the
outlet passage 166. Preferably, the flow-guiding lip 162 can have
an angle of less than about 45 or less than about 30 degrees with
respect to the surface to be cooled 12 to avoid creating a flow
restriction or stagnation region proximate the exit of the outlet
chamber 150. By avoiding formation of a stagnation region, the
flow-guiding lip 162 can prevent onset of critical heat flux near
the exit of the outlet chamber 150.
Cooling Line Assembly
[0453] FIG. 7 shows a cooling line assembly 303 including a heat
sink module 100 fluidly connected to two sections of flexible
tubing 225. The heat sink module 100 has an inlet port 105 and an
outlet port 110. One end of the first section of flexible tubing
225 is fluidly connected to the inlet port 105 by a first connector
120, and one end of the second section of flexible tubing 225 is
fluidly connected to the outlet port 110 by a second connector 120.
In some examples, the connectors 120 can be liquid-tight fittings,
such as compression fittings. The cooling line assembly 303 can be
used to cool any heat generating surface 12 associated with a
device, such as an electrical or mechanical device. As shown in
FIG. 6, the cooling line assembly 303 can include additional heat
sink modules 100 and sections of flexible tubing 225 to facilitate
two-phase cooling of two or more electronic devices within a
computer 400.
[0454] A cooling line assembly 303 can be adapted to fluidly
connect to a two-phase cooling apparatus 1. As shown in FIGS. 113,
114, 132, 133, and 143-151, the cooling line assembly 303 can be
hot-swappable, meaning that it can be connected to and disconnected
from the manifold assembly 680 while the cooling apparatus 1 is
operating and while coolant 50 is flowing through the manifold
assembly. To facilitate hot-swapping, the cooling line assembly 303
can include a pair of quick-connect fittings 235, as shown in FIGS.
113, 114, 143, 147, and 151. Each quick-connect fitting 235 can
include a non-spill shut-off valve 723 and a first connection
feature 735 as shown, for example, in FIGS. 107 and 110. The
quick-connect fittings 235 can be male or female depending on the
mating fittings provided on the manifold assembly 680 and depending
on whether two or more cooling line assemblies 303 are
daisy-chained together, as shown in FIGS. 134 and 135.
[0455] As shown in FIGS. 133, 143, and 151, a hot-swappable cooling
line assembly 303 can include a first section of flexible tubing
225-1 having a first end and a second end. The first end of the
first section of tubing can be fluidly connected to the first
connection feature 735-1 of the first quick-connect fitting 235-1.
The cooling line assembly 303 can include a first heat sink module
100-1 (see, e.g., the heat sink module shown in FIGS. 23-25),
having a first inlet port 105-1 fluidly connected to a first inlet
chamber 145-1, a first plurality of orifices 155-1 fluidly
connecting the first inlet chamber 145-1 to a first outlet chamber
150-1, and a first outlet port 110-1 fluidly connected to the first
outlet chamber. The second end of the first section of flexible
tubing 225-1 can be fluidly connected to the first inlet port 105.
The cooling line assembly 303 can include a second section of
flexible tubing 225-2 comprising a first end and a second end. A
first end of the second section of flexible tubing 225-2 can be
fluidly connected to the first outlet port 110-1 of the first heat
sink module 100-1, as shown in FIGS. 133, 143, and 148. The cooling
line assembly 303 can include a second heat sink module 100-2
having a second inlet port 105-2 fluidly connected to a second
inlet chamber 145-2, a second plurality of orifices 155-2 fluidly
connecting the second inlet chamber 145-1 to a second outlet
chamber 150-2, and a second outlet port 110-2 fluidly connected to
the second outlet chamber 150-2. The second end of the second
section of flexible tubing 225-2 can be fluidly connected to the
second inlet port 110-2. The cooling line assembly 303 can include
a third section of flexible tubing 225-3 having a first end and a
second end. The first end of the third section of flexible tubing
225-3 can be fluidly connected to the second outlet port 110-2 of
the second heat sink module 100-2. The cooling line assembly 303
can include a second quick-connect fitting 235-2 having a second
non-spill shut-off valve 723-2 and a second connection feature 735
(see, e.g., FIG. 107) fluidly connected to the second end of the
third section of flexible tubing 235-3.
[0456] The cooling line assembly 303 can include a first thermally
conductive base member 430-1, as shown in FIG. 145. The first heat
sink module 100 can be mounted against a surface 12-1 of the first
thermally conductive base member 430-1. A first sealing member 125
can be disposed and compressed between a bottom surface 135-1 of
the first heat sink module and the surface of the first thermally
conductive base member 430-1 to provide a first liquid-tight seal
around a perimeter of the first outlet chamber 150-1 (see, e.g.,
FIG. 38). During installation, a layer of thermal interface paste
435 can be applied to a top surface of a first processor 415-1 in
the server 400. The bottom surface of the first thermally
conductive base member 430-1 can then be mounted on top of the
first processor 415-1, as shown in FIG. 28. The layer of thermal
interface paste 435 can improve heat transfer between the first
processor 415-1 and the first thermally conductive base member
430-1.
[0457] The cooling line assembly 303 can include a second thermally
conductive base member 430-2, as shown in FIG. 145. The second heat
sink module 100-2 can be mounted against a surface 12-2 of the
second thermally conductive base member 430-2. A second sealing
member 125 can be disposed and compressed between a bottom surface
135-2 of the second heat sink module 100-2 and the surface of the
second thermally conductive base member 430-2 to provide a second
liquid-tight seal around a perimeter of the second outlet chamber
150-2 (see, e.g., FIG. 38). During installation, a layer of thermal
interface paste 435 can be applied to a top surface of a second
processor 415-1 in the server 400. The bottom surface of the second
thermally conductive base member 430-2 can then be mounted on top
of the second processor 415-2, as shown in FIG. 28. The layer of
thermal interface paste 435 can improve heat transfer between the
second processor 415-2 and the second thermally conductive base
member 430-2.
[0458] In the examples shown in FIGS. 133, 143, and 151, the first
section of flexible tubing 225-1 can have a maximum operating
pressure of less than about 35, 50, 75, 100, or 200 psi rated at
100 degrees C. The first section of flexible tubing 225-1 can have
an outer diameter less about 0.25, 0.3, or 0.35 in. and a minimum
bend radius of less than or equal to 3, 2.5, or 2 in. The second
section of flexible tubing 225-2 can have a maximum operating
pressure of less than about 35, 50, 75, 100, or 200 psi rated at
100 degrees C. The second section of flexible tubing 225-2 can have
an outer diameter less about 0.25, 0.3, or 0.35 in. and a minimum
bend radius of less than or equal to 3, 2.5, or 2 in. The third
section of flexible tubing 225-3 can have a maximum operating
pressure of less than about 35, 50, 75, 100, or 200 psi rated at
100 degrees C. The third section of flexible tubing 225-3 can have
an outer diameter less about 0.25, 0.3, or 0.35 in. and a minimum
bend radius of less than or equal to 3, 2.5, or 2 in.
[0459] The first plurality of orifices 155-1 in the first heat sink
module 100 can have an average diameter of about 0.001-0.020,
0.001-0.2, 0.001-0.150, 0.001-0.120, 0.001-0.005, 0.020-0.045,
0.030-0.050 in, or 0.040 in., where the average diameter is
determined by summing the diameters (D) of all orifices in the
plurality of orifices and dividing by the number of orifices. The
diameter (D) for one orifice 155 is shown in FIG. 35. A second
plurality of orifices 155-2 in the second heat sink module can have
an average diameter of about 0.001-0.020, 0.001-0.2, 0.001-0.150,
0.001-0.120, 0.001-0.005, 0.020-0.045, 0.030-0.050 in, or 0.040
in.
[0460] The first plurality of orifices 155-1 can have an average
jet height 18 of about 0.01-0.75, 0.05-0.5, 0.05-0.25, 0.020-0.25,
0.03-0.125, or 0.04-0.08 in., where each jet height is measured as
a shortest distance from an exit of an orifice 155 to the surface
12 of the first thermally conductive base member 430-1 or a surface
to be cooled 12 (see, e.g., FIG. 35), and average jet height is
determined by summing jet heights for all orifices 155 and dividing
by the number of orifices. The second plurality of orifices 155-2
can have an average jet height 18 of about 0.01-0.75, 0.05-0.5,
0.05-0.25, 0.020-0.25, 0.03-0.125, or 0.04-0.08 in., where each jet
height is measured as a shortest distance from an exit of an
orifice 155-2 to the surface of the second thermally conductive
base member 430-2.
[0461] The first plurality of orifices 155-1 can have an average
diameter of D.sub.1 and an average length of L.sub.1. L.sub.1
divided by D.sub.1 can be greater than or equal to one or about
1-10, 1-8, 1-6, 1-4, or 1-3. The second plurality of orifices can
have an average diameter of D.sub.2 and an average length of
L.sub.2. L.sub.2 divided by D.sub.2 can be greater than or equal to
one or about 1-10, 1-8, 1-6, 1-4, or 1-3.
[0462] The first connection feature can be a first barbed fitting
735, as shown in FIGS. 107 and 110, that is configured to engage
with an interior cylindrical surface of the first end of the first
section of flexible tubing 225-1. The second connection feature can
be a second barbed fitting 735 configured to engage with an
interior cylindrical surface of the second end of the third section
of flexible tubing 225-3.
[0463] As shown in FIGS. 115, 143, 151, the cooling line assembly
303 can include any type of sensor 880 (e.g. T, P, x, etc.)
described herein. The cooling line assembly 303 can include more
than one sensor 880, as shown in FIGS. 143 and 151 to allow an
outlet condition at each heat sink module 100 to be determined and
conveyed to the electronic control system 850 for process
monitoring or to serve as an input signal to allow the electronic
control system 850 to dynamically adjust system parameters (e.g.
pump speed, chilled water flow rate through an external heat
rejection loop, etc.) to improve system performance, efficiency, or
stability. In some examples, the sensor can be a vapor quality (x)
sensor 880, as shown in FIGS. 115, 143, 151. The vapor quality
sensor 880 can be an ultrasonic sensor capable of detecting density
variations between vapor coolant and liquid coolant. The vapor
quality sensor 880 can be attached to the first section of flexible
tubing 225-1 to monitor coolant inlet flow conditions of the
cooling line assembly 303. The vapor quality sensor 880 can be
attached to the second section of flexible tubing 225-2 to monitor
coolant outlet flow conditions from the first heat sink module
100-1, as shown in FIG. 151. The vapor quality sensor 880 can be
attached to the third section of flexible tubing 225-2 to monitor
coolant outlet flow conditions from the second heat sink module
100-2, as shown in FIG. 151. Alternately, or in addition to the
previously mentioned sensors, a vapor quality sensor 880 can be
attached to the return line 230 of the primary cooling loop 300 to
monitor the flow conditions of coolant 50 returning to the
reservoir 200, as shown in FIG. 115. In any example herein where a
vapor quality (x) sensor is described, a combination of potentially
lower cost temperature and pressure sensors can be substituted to
provide a signal that can be correlated to vapor quality (x) and
used as an input signal by the electronic control system 850 when
adjusting system parameters to improve cooling system 1
performance, efficiency, and/or stability.
[0464] When adding additional cooling line assemblies 303 to an
operating cooling system 1, such as when connecting additional
hot-swappable servers 400 (see, e.g. FIG. 151) to a manifold
assembly 680, it can be desirable to avoid introducing air into the
cooling system 1. This can be accomplished by providing
cooling-line assemblies 303 that are prefilled with coolant 50.
Prefilling can be accomplished by orienting the cooling line
assembly 303 vertically and filling the assembly with coolant from
the lower quick-connect fitting 235 while venting the assembly from
the upper quick-connect fitting 235. Gravitational forces will
cause the assembly to fill with coolant 50 from the lower
quick-connect fitting upward, while forcing air out from the upper
fitting, similar to the way air is purged from a syringe filled
with liquid. Once filled, the non-spill shut-off valves on each end
of the apparatus can be allowed to close, thereby providing a
sealed, prefilled cooling line assembly 303. In some examples, it
may be desirable to pressurize the coolant in the cooling line
assembly 303 to match an anticipated operating pressure of the
cooling system 1 (e.g. 10-25 psi) to avoid decreasing the level of
coolant in the reservoir 200 when connecting additional cooling
line assemblies 303. This can be accomplished be forcing additional
coolant 50 into the cooling line assembly 303 after all air has
been purged. In some examples, prior to introducing coolant 50 to
the cooling line assembly 303, the assembly can be connected to a
vacuum pump to evacuate all air from the assembly to ensure no
residual air is left, for example, in cavities within the heat sink
module(s) 100.
[0465] The cooling line assembly 303 can have an inner volume
consisting of inner volumes of all cooling line assembly 303
components, including inner volumes of the sections of flexible
tubing (e.g. 225-1, 225-2, 225-3), heat sink modules (e.g. 100-1,
100-2), and fittings (e.g. 235-1, 235-2). The inner volume of the
flexible cooling line assembly 303 can be filled with dielectric
coolant. The dielectric coolant can be a hydrofluorether, such as
Novec 7000, or a pentafluoropropane, such as R-245fa. In some
examples, the inner volume of the flexible cooling line assembly
303 can be filled with a compressible gas, such as nitrogen or
argon. The inner volume of the flexible cooling line assembly 303
can be filled with a mixture of dielectric coolant 50 and
compressible gas, such as a mixture of hydrofluoroether and
nitrogen. Adding nitrogen to the coolant 50 may promote formation
of bubbles 275 proximate the surface to be cooled 12 within the
outlet chamber 150 of the heat sink module 100, which can be
desirable for increasing the heat transfer rate from the surface to
be cooled. In some examples, the mixture can consist of about 2-10,
5-15, 10-20% nitrogen by volume, which may be dissolved in the
dielectric coolant.
[0466] As shown in FIGS. 74, 113, 114, 132, 133, 143, and 151, a
modular cooling line assembly 303 can be adapted to fluidly connect
to a low pressure, two-phase cooling apparatus 1. The cooling line
assembly 303 can include a first fitting 235-1 having a first
connection feature. The first fitting 235 can be a threaded
fitting, compression fitting, or a quick-connect fitting with a
non-spill shut-off valve 723. The cooling line assembly 303 can
include a first section of flexible tubing 225-1 having a first end
and a second end. The first end of the first section of tubing
225-1 can be fluidly connected to the first connection feature of
the first fitting. The first connection feature can be a first
barbed fitting 735 configured to engage with an interior
cylindrical surface of the first end of the first section of
flexible tubing 225-1. A first heat sink module 100-1 can include a
first inlet port 105-1 fluidly connected to a first inlet chamber
145-1, a first plurality of orifices 155-1 fluidly connecting the
first inlet chamber to a first outlet chamber 150-1, and a first
outlet port 110-1 fluidly connected to the first outlet chamber
150-1. The first plurality of orifices 155-1 can have an average
diameter of about 0.001-0.020, 0.001-0.2, 0.001-0.150, 0.001-0.120,
0.001-0.005, 0.020-0.045, 0.030-0.050 in, or 0.040 in. The second
end of the first section of flexible tubing 225-2 can be fluidly
connected to the first inlet port 105-1. The cooling line assembly
303 can include a second section of flexible tubing 225-2 having a
first end and a second end. A first end of the second section of
flexible tubing 225-2 can be fluidly connected to the outlet port
105-1 of the first heat sink module 100-1.
[0467] The cooling line assembly 303 can include a second fitting
235-1 having a second connection feature. The second end of the
second section of flexible tubing 225-2 can be fluidly connected to
the second connection feature. Alternately, the cooling line
assembly 303 can include a second heat sink module 100-2 having a
second inlet port 105-2 fluidly connected to a second inlet chamber
145-2, a second plurality of orifices 155-2 fluidly connecting the
second inlet chamber 145-2 to a second outlet chamber 150-2, and a
second outlet port 110-2 fluidly connected to the second outlet
chamber. The second end of the second section of flexible tubing
225-2 can be fluidly connected to the second inlet port 105-2. The
cooling line assembly 303 can include a third section of flexible
tubing 225-3 having a first end and a second end. The first end of
the third section of flexible tubing 225-3 can be fluidly connected
to the second outlet port 110-2 of the second heat sink module
100-2. The cooling line assembly 303 can include a second fitting
235-2 having a second connection feature fluidly connected to the
second end of the third section of flexible tubing 225-3. The
second fitting 235-2 can be a threaded fitting, compression
fitting, or a quick-connect fitting with a non-spill shut-off valve
723-2.
[0468] The first inlet chamber 145-1 and the first outlet chamber
150-1 can be formed within the first heat sink module 100-1, as
shown in FIG. 25. The first outlet chamber 150-1 can have an open
portion configured to be enclosed by a heat-providing surface when
the first heat sink module 100-1 is installed on the heat-providing
surface 12. The first heat sink module 100-1 can include a dividing
member 195 disposed between the first inlet chamber 145-1 and the
first outlet chamber 150-1. The first plurality of orifices 155-1
can be formed in the dividing member 195. The first plurality of
orifices 155-1 can extend from a top surface of the dividing member
to a bottom surface of the dividing member. The first plurality of
orifices 155-1 can be configured to deliver a plurality of jet
streams 16 of coolant 50 into the first outlet chamber 150-1 and
against the heat-providing surface 12 when the first heat sink
module is installed on the first heat-providing surface 12 and when
pressurized coolant is provided to the first inlet chamber, as
shown in FIG. 26.
[0469] The first section of flexible tubing 225-1 can be made of
nylon or fluorinated ethylene propylene tubing. The first section
of flexible tubing 225-1 can have a maximum operating pressure of
less than about 35, 50, 75, 100, or 200 psi rated at 100 degrees C.
The second section of flexible tubing 225-2 can be made of nylon or
fluorinated ethylene propylene tubing. The second section of
flexible tubing 225-2 can have a maximum operating pressure of less
than about 35, 50, 75, 100, or 200 psi rated at 100 degrees C. The
third section of flexible tubing 225-3 can be made of nylon or
fluorinated ethylene propylene tubing. The third section of
flexible tubing 225-3 can have a maximum operating pressure of less
than about 35, 50, 75, 100, or 200 psi rated at 100 degrees C.
[0470] The cooling line assembly 303 can include a first thermally
conductive base member 430-1, as shown in FIG. 145. The first heat
sink module 100-1 can be mounted against a surface 12 of the first
thermally conductive base member 430-1. A first sealing member
125-1 can be disposed and compressed between a bottom surface 135
of the first heat sink module 100-1 and the surface 12 of the first
thermally conductive base member 430-1 to provide a first
liquid-tight seal around a perimeter of the first outlet chamber
145-1, as shown in FIG. 38. The first inlet chamber 145-1 can be
formed within the first heat sink module 100-1. The first outlet
chamber 150-1 can be formed within the heat sink module 100-1. The
first outlet chamber 150 can have an open portion. The open portion
can be enclosed by the surface 12 of the thermally conductive base
member 430-1. The first heat sink module 100-1 can include a
dividing member 195 disposed between the first inlet chamber 145-1
and the first outlet chamber 150-1 within the heat sink module. The
first plurality of orifices 155-1 can be formed in the dividing
member, as shown in FIGS. 23, 24, and 38. The first plurality of
orifices 155-1 can extend from a top surface of the dividing member
195 to a bottom surface of the dividing member. The first plurality
of orifices 155-1 can be configured to deliver a plurality of jet
streams 16 of coolant 50 into the first outlet chamber 150-1 and
against the surface 12 of the first thermally conductive base
member 430-1 when pressurized coolant 50 is provided to the first
inlet chamber 145-1, as shown in FIG. 26.
[0471] The first plurality of orifices 155-1 can have an average
jet height of about 0.01-0.75, 0.05-0.5, 0.05-0.25, 0.020-0.25,
0.03-0.125, or 0.04-0.08 in, where each jet height is measured as a
shortest distance from an exit of an orifice 155 to the surface 12
of the first thermally conductive base member 430-1 or a surface to
be cooled 12 (see, e.g., FIG. 35), and average jet height is
determined by summing jet heights for all orifices 155 and dividing
by the number of orifices.
[0472] As shown in FIGS. 6, 7, 15, 74, 113, 114, 132, 133, 143, and
151, a cooling line assembly 303 can be adapted to fluidly connect
to a cooling apparatus 1. The cooling line assembly 303 can include
a first section of flexible tubing 225-1 having a first end and a
second end. The cooling line assembly 303 can include a heat sink
module 100-1 mounted to a surface of a thermally conductive base
member 430-1. As shown in FIG. 26, the heat sink module 100-1 can
include an inlet port 105 fluidly connected to an inlet chamber 145
formed within the heat sink module 100 and an outlet chamber 150
formed within the heat sink module. The outlet chamber 150 can be
fluidly connected to an outlet port 110 of the heat sink module.
The outlet chamber 150 can have an open portion that is enclosed by
the surface 12 of the thermally conductive base member 430 when the
heat sink module 100 is mounted on the thermally conductive base
member. The heat sink module 100 can include a dividing member 195
disposed between the inlet chamber 145 and the outlet chamber 150.
The dividing member 195 can include a first plurality of orifices
155 formed in the dividing member. The first plurality of orifices
155 can extend from a top surface of the dividing member to a
bottom surface of the dividing member. The first plurality of
orifices 155 can be configured to deliver a plurality of jet
streams 16 of coolant 50 into the outlet chamber 150 and against
the surface 12 of the thermally conductive base member 430 when
pressurized coolant 50 is provided to the inlet chamber 145, as
shown in FIG. 26. The second end of the first section of flexible
tubing 225-1 can be fluidly connected to the first inlet port 105.
The cooling line assembly 303 can include a second section of
flexible tubing 225-2 having a first end and a second end. The
first end of the second section of flexible tubing 225-2 can be
fluidly connected to the outlet port 110 of the heat sink module
100.
[0473] FIG. 143 shows a top view of a cooling line assembly 303
with two series-connected heat sink module assemblies 107 as show
in FIG. 141A connected with flexible tubing 225 that extends to a
pair of quick-connect fittings. More specifically, the cooling line
assembly 303 of FIG. 143 shows a first section of flexible tubing
225-1 fluidly connecting a first quick-connect fitting 235 to an
inlet port 105-1 of a first heat sink module 100-1, a second
section of flexible tubing 225-2 fluidly connecting an outlet port
110-1 of a first heat sink module to an inlet port 105-2 of a
second heat sink module 100-2, and a third section of flexible
tubing 225-3 fluidly connecting an outlet port 110-2 of a second
heat sink module 100-2 to a second quick-connect fitting 235. The
cooling line assembly 303 can include one or more sensors 880 that
can be connected to an electronic control system 850 associated
with a two-phase cooling apparatus 1. The quick-connect fittings
235 can include non-spill shut-off valves 723 to permit
hot-swapping of the cooling line assembly 303. FIG. 144 shows an
enlarged top view of a cooling line assembly 303 of FIG. 143. FIG.
145 shows an enlarged bottom view of a cooling line assembly of
FIG. 143.
[0474] FIG. 148 shows a fluid distribution unit of FIG. 125 mounted
to a base member of a server rack 410 and fluidly connected to a
manifold assembly 680. The server rack 410 is populated with a
plurality of blade servers 400. FIG. 147 shows a plurality of blade
servers 400 mounted in an upper portion of the server rack 410 of
FIG. 148. Two of the blade servers 400 are fluidly connected to the
manifold assembly 680 of the cooling apparatus 1 by a pair of
cooling line assemblies 303 with quick-connect fittings 235. FIG.
150 shows a variation of the cooling apparatus of FIG. 148 having
redundant manifold assemblies 680 vertically connected to the
server rack 410. The redundant manifold assemblies 680 can be
connected to separate fluid distribution units 10.
[0475] FIG. 151 shows a top view of a hot-swappable blade server
400 with its lid removed and a cooling line assembly 303 routed
into and out of the blade server through access holes 87 in a front
faceplate 401, as shown in detail in FIG. 149. The cooling line
assembly 303 can have two series-connected heat sink module
assemblies 107, each mounted on a processor 415 of the server. The
cooling line assembly 303 can have a first section of flexible
tubing 225-1 extending from a first quick-connect fitting 235-1 to
an inlet port 105-1 of a first heat sink module 100-1, a second
section of flexible tubing 225-2 extending from an outlet port
110-1 of the first heat sink module 100-1 to an inlet port 105-1 of
a second heat sink module 100-2, and a third section of flexible
tubing 225-2 extending from an outlet port 110-2 of the second heat
sink module 100-2 to a second quick-connect fitting 235. The
cooling line assembly 303 can include one or more sensors 880 that
can be connected to an electronic control system 850 associated
with a two-phase cooling apparatus 1. FIG. 149 shows a front
perspective view of the blade server 400 of FIG. 151 with access
holes (87-1, 87-2) provided in a faceplate 401 of the server to
permit routing of the sections of flexible tubing 225.
Series-Connected Heat Sink Modules
[0476] FIG. 14A shows a schematic of a cooling apparatus 1 having
three heat sink modules 100 arranged in a series configuration on
three surfaces to be cooled 12. As shown by way of example in FIG.
15, the three heat sink modules 100 can be fluidly connected with
tubing, such as flexible tubing 225. The three surfaces to be
cooled 12 can be three separate surfaces to be cooled or can be
three different locations on the same surface to be cooled 12.
[0477] FIG. 15 shows a portion of a cooling line assembly 303 of a
cooling apparatus 1 where the cooling line assembly includes three
series-connected heat sink modules 100 mounted on three
heat-providing surfaces 12 (see, e.g. FIG. 14A). The heat sink
module 100 can be connected by sections of flexible tubing 225. A
single-phase liquid coolant 50 can be provided to a first heat sink
module 100 by a section of tubing 225-0, and due to heat transfer
occurring within the first heat sink module 100-1 (i.e. heat being
transferred from the first heat-generating surface 12 to the flow
of coolant), two-phase bubbly flow can be generated and transported
in a first section of flexible tubing 225-1 extending from the
first heat sink module 100-1 to the second heat sink module 100-2.
The two-phase bubbly flow contains a plurality of bubbles 275
having a first number density. Due to heat transfer occurring
within the second heat sink module 100-2 (i.e. heat being
transferred from the second heat-generating surface 12 to the flow
of coolant), higher quality (x) two-phase bubbly flow can be
generated and transported from the second module 100-2 to the third
heat sink module 100-3 through a second section of flexible tubing
225-2. In the second section of flexible tubing 225, the two-phase
bubbly flow contains a plurality of bubbles 275 having a second
number density, where the second number density is higher than the
first number density. Due to heat transfer occurring within the
third heat sink module 100 (i.e. heat being transferred from the
third heat-generating surface 12 to the flow of coolant), even
higher quality (x) two-phase bubbly flow can be generated and
transported out of the third heat sink module 100-3 through a third
section of tubing 225-3. In the third section of tubing 225-3, the
two-phase bubbly flow contains a plurality of bubbles 275 having a
third number density, where the third number density is higher than
the second number density.
[0478] FIG. 14B shows a representation of coolant flowing through
three heat sink modules (100-1, 100-2, 100-3) connected in series
by four lengths of tubing (225-1, 225-2, 225-3, 225-4), similar to
the configurations shown in FIGS. 14A and 15. FIG. 14B also shows
corresponding plots of saturation temperature (T.sub.sat), liquid
coolant temperature (T.sub.liquid), pressure (P), and quality (x)
of the coolant versus distance along a flow path through the
series-connected heat sink modules. In the example, a flow 51 of
single-phase liquid coolant 50 enters the first heat sink module
100-1 through a first section of tubing 225-1 at a temperature that
is slightly below the saturation temperature of the liquid coolant
50. Within the first heat sink module 100-1, the single-phase
liquid coolant 50 is projected against a first surface to be cooled
12-1 by way of a plurality of jet streams 16 of coolant. A first
portion of the liquid coolant 50 changes phase and becomes vapor
bubbles 275 dispersed in the liquid coolant 50, thereby producing
two-phase bubbly flow having a first quality (x.sub.1). The
two-phase bubbly flow having the first quality is transported from
the first heat sink module 100-1 to a second heat sink module 100-2
by a second section of tubing 225-2. Within the second heat sink
module 100-2, the two-phase bubbly flow having a first quality is
projected against a second surface to be cooled 12-2 by way of a
plurality of jet streams 16 of coolant. A second portion of the
liquid coolant 50 changes phase and becomes vapor bubbles 275
dispersed in the liquid coolant 50, thereby producing two-phase
bubbly flow having a second quality (x.sub.2) that is greater than
the first quality (i.e. x.sub.2>x.sub.1). The two-phase bubbly
flow having the second quality is transported from the second heat
sink module 100-2 to a third heat sink module 100-3 by a third
section of tubing 225-3. Within the third heat sink module 100-3,
the two-phase bubbly flow having a second quality is projected
against a third surface to be cooled 12-3 by way of a plurality of
jet streams 16 of coolant. A third portion of the liquid coolant 50
changes phase and becomes vapor bubbles 275 dispersed in the liquid
coolant 50, thereby producing two-phase bubbly flow having a third
quality (x.sub.3) that is greater than the second quality (i.e.
x.sub.3>x.sub.2). As shown in FIG. 14B, along the distance of
the flow path, quality of the coolant increases, pressure
decreases, liquid coolant temperature (T.sub.liquid) decreases, and
T.sub.sat decreases through successive series-connected heat sink
modules.
[0479] Through each successive heat sink module 100, the flow of
coolant 51 experiences a pressure drop, as shown in FIG. 14B. In
some examples, the pressure drop across each heat sink module 100
can be about 0.5-5.0, 0.5-3, 1-3, or 1.5 psi. The pressure drop
across each heat sink module 100 causes a corresponding decrease in
saturation temperature (Tsat) of the coolant. Accordingly, the
temperature of the liquid coolant component of the two-phase bubbly
flow also decreases in response to decreasing saturation
temperature at each pressure drop at each module. Consequently, the
third heat sink module 100-3 receives two-phase bubbly flow
containing liquid coolant 50 that is cooler than liquid coolant 50
in the two-phase bubbly flow received by the second heat sink
module 100-2. As a result of this phenomenon, the cooling apparatus
1 is able to maintain the third surface to be cooled 12-3 at a
temperature below the temperature of a second surface to be cooled
12-2 when the second and third surfaces to be cooled have equal
heat fluxes. Because of this behavior, additional series connected
heat sink modules 100 can be added to the series configuration. In
some examples four, six, or eight or more heat sink modules 100 can
be connected in series with each successive module receiving
two-phase bubbly flow containing liquid coolant 50 that is slightly
cooler than the liquid coolant received by the previous module
connected in series. The only limitation on the number of
series-connected modules that can be used a threshold quality (x)
value, which if exceeded, could result in unstable flow. However,
if the cooling system 1 is on the verge of exceeding the threshold
quality (x) value, the coolant flow rate can be increased to
decrease the flow quality.
[0480] HFE-7000 can be used as coolant 50 in the cooling apparatus
1. HFE-7000 has a boiling temperature of about 34 degrees Celsius
at a pressure of 1 atm. In the example shown in FIGS. 14A, 14B, and
15, HFE-7000 can be introduced to the series configuration as
single-phase liquid coolant at a pressure of about 1 atmosphere and
a temperature slightly below 34 degrees Celsius. A flow rate of
about 0.1-10, 0.2-5, 0.3-2.5, 0.6-1.2, or 0.8-1.1 liters per minute
of single-phase coolant can be provided. As the coolant flows
through the first, second, and third heat sink modules, the coolant
may experience a total pressure drop of about 5-10, 8-12, or 10-15
psi. At each heat sink module, the coolant may experience a
pressure drop of about 0.5-5.0, 0.5-3, 1-3, or 1.5 psi. As shown in
FIG. 14B, a drop in saturation temperature accompanies each
pressure drop, and a drop in liquid temperature follows each
decrease in saturation temperature. Consequently, the temperature
of the liquid component 50 of the two-phase bubbly flow continues
to decrease through the series connection and exits the third heat
sink module 100-3 at a temperature below 34 degrees Celsius, where
the temperature depends on pressure and quality of the exiting flow
51. In this example, through the first heat sink module 100-1, heat
transfer occurs via sensible and latent heating of the coolant, and
through the second and third heat sink modules (100-2, 100-3), heat
transfer occurs primarily by latent heating of the coolant.
[0481] In competing pumped liquid cooling systems, such as those
that use pumped single-phase water as a coolant, the coolant
becomes progressively warmer (due to sensible heating) as it passes
through each successive series-connected heat sink module. For this
reason, competing single-phase cooling systems typically cannot
support more than two series connected heat sink modules, because
the coolant temperature at the outlet of the second heat sink
module is too hot to properly cool a third heat sink module. Where
competing pumped liquid cooling systems include multiple
series-connected heat sink modules, the cooling system is unable to
maintain sensitive devices, such as microprocessors, at uniform
temperatures, and the last device in series may experience
sub-optimal performance or premature failure in response to
operating at elevated temperatures.
[0482] FIG. 14C shows a representation of coolant flowing through
three heat sink modules (100-1, 100-2, 100-3) connected in series
by lengths of tubing (225-1, 225-2, 225-3, 225-4), similar to FIG.
14B, except that the coolant does not reach its saturation
temperature until the second heat sink module 100-2. Consequently,
single-phase liquid coolant 50 flows through the first heat sink
module 100-1 (where no vapor is formed) and travels to the second
heat-sink module 100-2 at an elevated temperature due to sensible
heating. Within the second heat sink-module 100-2, a pressure drop
occurs, as does a corresponding drop in saturation temperature.
Heat transfer from the second surface to be cooled 12-2 to the
single-phase liquid coolant 50 causes a portion of the coolant to
vaporize. Consequently, heat transfer within the second heat sink
module 100-2 can be a combination of latent heating and sensible
heating. Two-phase bubbly flow can then be transported from the
second heat sink module 100-2 to the third heat sink module 100-3
in a third section of tubing 225-3. Within the third heat sink
module 100-3, since the temperature of the liquid component 50 of
the coolant is at or nearly at its saturation temperature, heat
transfer may occur primarily by latent heating, as evidenced by an
increase in quality (x), as shown in FIG. 14C.
[0483] The method shown in FIG. 14C can be less efficient than the
method shown in FIG. 14B, since it does not employ latent heating
within the first heat sink module 100-1 and may therefore require
higher flow rates and more pump work to adequately cool the first
surface to be cooled 12-1. However, the method in FIG. 14C can be
easier to achieve and maintain, since the temperature of the
incoming single-phase liquid coolant 50 does not need to be
controlled as carefully as the method shown in FIG. 14B (e.g. with
respect to providing a temperature that is slightly below the
saturation temperature). In some examples, an operating method can
alternate between the methods shown in FIGS. 14B and 14C depending
on the temperature of the incoming single-phase coolant 50. For
instance, where the system is undergoing transient operation, due
to changing heat loads or changing chiller loop conditions, the
operating method can alternate from the method shown in FIG. 14B to
the method shown in FIG. 14C for safety until the transient
condition subsides. Once the transient condition is over, the
microcontroller 850 of the cooling apparatus 1 can begin to ramp up
the temperature of the incoming single-phase liquid coolant 50 to a
temperature that is slightly below its saturation temperature. By
employing this control strategy, the cooling system 1 can avoid
instabilities caused by excess vapor formation during transient
conditions. One strategy for decreasing the temperature of the
incoming single-phase liquid coolant 50 can include increasing the
flow rate through the heat exchanger 40 to reduce the temperature
of the coolant in the reservoir 200, which is then delivered to the
series-configuration by the pump 20.
[0484] In one example, a method of cooling two or more processors
415 of a server 400 can include providing a cooling apparatus 1
having two or more series-connected heat sink modules 100, as shown
in FIG. 15, and in FIGS. 14A, 14B, 14C, 16, 74, and 78-80. The
method can include providing a flow 51 of dielectric single-phase
liquid coolant 50 to an inlet port 105 of a first heat sink module
100-1 in thermal communication with a first processor 415 of a
server 400. A first amount of heat can be transferred from the
first processor (12, 415) to the dielectric single-phase liquid
coolant 50 resulting in vaporization of a portion of the dielectric
single-phase liquid coolant thereby changing the flow of dielectric
single-phase liquid coolant to two-phase bubbly flow made of
dielectric liquid coolant with dielectric vapor coolant dispersed
as bubbles 275 in the dielectric liquid coolant 50. Consequently,
heat from the processor 415 is absorbed to the coolant across the
coolant's heat of vaporization, which is a far more efficient
method for absorbing heat. For a dielectric coolant, such as NOVEC
7000, the latent heat of vaporization is 142,000 J/kg, whereas the
specific heat for sensible warming the coolant is only 1,300
J/(kg-K). Therefore, by vaporizing a portion of the liquid coolant
50 within the heat sink module 100-1, that portion of coolant is
able to absorb significantly more heat (on an order of 100 times
more heat) from the processor (12, 415) than if the liquid coolant
50 were simply warmed inside the heat sink module 100-1 by one or
two degrees without experiencing any vaporization. The two-phase
bubbly flow that is formed within the first heat sink module 100-1
can have a first quality (x.sub.1). The method can include
transporting the two-phase bubbly flow from an outlet port 110 of
the first heat sink module 100 to an inlet port 105 of a second
heat sink module 100-2 connected in series with the first heat sink
module 100-1. The second heat sink module 100-2 can be in thermal
communication with a second processor (12, 415) of the server 400.
A second amount of heat can be transferred from the second
processor (12, 415) to the two-phase bubbly flow resulting in
vaporization of a portion of the dielectric liquid coolant within
the two-phase bubbly flow thereby resulting in a change from the
first quality (x.sub.1) to a second quality (x.sub.2). The second
quality (x.sub.2) can be greater than the first quality (x.sub.1).
The first quality (x.sub.1) can be about 0-0.1, 0.05-0.15, 0.1-0.2,
0.15-0.25, 0.2-0.3, 0.25-0.35, 0.3-0.4, 0.35-0.45, 0.4-0.5,
0.45-0.55, and the second quality (x.sub.2) can be about 0-0.1,
0.05-0.15, 0.1-0.2, 0.15-0.25, 0.2-0.3, 0.25-0.35, 0.3-0.4, or
0.4-0.45 greater than the first quality.
[0485] Energy from the first amount of heat and the second amount
of heat can be stored, at least in part, as latent heat in the
two-phase bubbly flow and transported out of the server through a
flexible cooling line. The liquid coolant in the two-phase bubbly
flow 51 that is transported between the first heat sink module
100-1 and the second heat sink module 100-2 can have a temperature
at or slightly below its saturation temperature. The pressure of
the two-phase bubbly flow can be about 0.5-5.0, 0.5-3, or 1-3 psi
less than the predetermined pressure of the flow of dielectric
single-phase liquid coolant provided to the inlet port of the first
heat sink module, as shown in the pressure versus distance plots of
FIGS. 14B and 14C.
[0486] A saturation temperature of the two-phase flow 51 having the
second quality (x.sub.2) can be less than a saturation temperature
of the two-phase flow having the first quality (x.sub.1), thereby
allowing the second processor (12, 415) to remain at a slightly
lower temperature than the first processor (12, 415) when a first
heat flux from the first processor is approximately equal to a
second heat flux from the second processor, as shown in the
temperature versus distance plots of FIGS. 14B and 14C. Providing
the flow 51 of dielectric single-phase liquid coolant to the inlet
port 105 of the first heat sink module 100-1 can include providing
a flow rate of about 0.1-10, 0.2-5, 0.3-2.5, 0.6-1.2, or 0.8-1.1
liters per minute of dielectric single-phase liquid coolant to the
first inlet port of the first heat sink module. The flow of
single-phase liquid coolant can have a boiling point of about
15-35, 20-45, 30-55, or 40-65 degrees C. determined at a pressure
of 1 atm. The dielectric coolant can be a hydrofluoroether, a
hydrofluorocarbon, or a combination thereof. Providing the flow of
dielectric single-phase liquid coolant to the first heat sink
module 100-1 can include providing the flow 51 of dielectric
single-phase liquid coolant at a predetermined temperature and a
predetermined pressure, where the predetermined temperature is
slightly below the saturation temperature (T.sub.sat) of the flow
of dielectric single-phase liquid coolant at the predetermined
pressure. The predetermined temperature can about 0.5-20, 0.5-15,
0.5-10, 0.5-7, 0.5-5, 0.5-3, 0.5-1, 1-20, 1-15, 1-10, 1-7, 1-5,
1-3, 3-20, 3-15, 3-10, 3-7, 3-5, 5-20, 5-15, 5-10, 5-7, 7-20, 7-15,
7-10, 10-20, 10-15, or 15-20 degrees C. below the saturation
temperature (T.sub.sat) of the flow of dielectric single-phase
liquid coolant at the predetermined pressure.
[0487] The method can include providing a pressure differential of
about 0.5-5.0, 0.5-3, or 1-3 psi between the inlet port 105 of the
first heat sink module 100-1 and the outlet port 110 of the first
heat sink module. The pressure differential can be suitable to
promote the flow 51 of coolant to advance from the inlet port 105
of the first heat sink module 100-1 to the outlet port 110 of the
first heat sink module. The method can include transporting the
two-phase bubbly flow 51 from an outlet port 110 of the second heat
sink module 100-2 to an inlet port of a third heat sink module
100-3 connected in series with the first and second heat sink
modules. The third heat sink module 100-3 can be in thermal
communication with a third processor (12, 415) of the server 400. A
third amount of heat can be transferred from the third processor
(12, 415) to the two-phase bubbly flow 51 resulting in vaporization
of a portion of the dielectric liquid coolant 50 within the
two-phase bubbly flow thereby resulting in a change from the second
quality (x.sub.2) to a third quality (x.sub.3). The third quality
(x.sub.3) can be greater than the second quality (x.sub.2).
[0488] In another example, a method of cooling two or more
processors 415 in an electronic device can include providing a
cooling apparatus 1 with two or more fluidly connected heat sink
modules arranged in a series configuration, as shown in FIG. 15.
The method can include providing a flow 51 of dielectric
single-phase liquid coolant to a first heat sink module 100-1. The
first heat sink module 100-1 can include a first thermally
conductive base member 430 in thermal communication with a first
processor 415 in an electronic device. The dielectric single-phase
liquid coolant can have a predetermined pressure and a
predetermined temperature at a first inlet 105 of the first heat
sink module 100-1. The predetermined temperature can be slightly
below a saturation temperature (T.sub.sat) of the dielectric
single-phase liquid coolant at the predetermined pressure. The
method can include projecting the flow of dielectric single-phase
liquid coolant against the thermally conductive member (e.g. in the
form of impinging jet streams 16 of coolant) within the first heat
sink module 100-1. A first amount of heat can be transferred from
the processor 415 through the thermally conductive base member 430
and to the flow 51 of dielectric single-phase liquid coolant
thereby inducing phase change in a portion of the flow of
dielectric single-phase liquid coolant and thereby changing the
flow of dielectric single-phase liquid coolant to two-phase bubbly
flow having a dielectric liquid coolant 50 and a plurality of vapor
bubbles 275 dispersed in the dielectric liquid coolant.
Consequently, heat from the processor 415 is absorbed to the
coolant 50 across the coolant's heat of vaporization, which is a
far more efficient method for absorbing heat. For a dielectric
coolant, such as NOVEC 7000, the latent heat of vaporization is
142,000 J/kg, whereas the specific heat for sensible warming the
coolant is only 1,300 J/(kg-K). Therefore, by vaporizing a portion
of the liquid coolant 50 within the heat sink module 100-1, that
portion of coolant is able to absorb significantly more heat (on an
order of 100 times more heat) from the processor 415 than if the
liquid coolant 50 were simply warmed inside the heat sink module
100-1 by one or two degrees without experiencing any vaporization.
The plurality of vapor bubbles 275 in the two-phase bubbly flow can
have a first number density.
[0489] The method can include providing a second heat sink module
100-2 having a second thermally conductive base member 430 in
thermal communication with a second processor 415. The second heat
sink module 100-2 can have a second inlet 105. The method can
include providing a first section of tubing 225-1 having a first
end connected to the first outlet 110 of the first heat sink module
100-1 and a second end connected to the second inlet 105 of the
second heat sink module 100-2. The first section of tubing 225-1
can transport the two-phase bubbly flow 51 having the first number
density from the first outlet 105 of the first heat sink module
100-1 to the second inlet 110 of the second heat sink module 100-2.
The method can include projecting the two-phase bubbly flow having
the first number density against the second thermally conductive
base member (e.g. in the form of impinging jet streams 16 of
coolant) within the second heat sink module 100-2. A second amount
of heat can be transferred from the second processor 415 through
the second thermally conductive base member 430 and to the
two-phase bubbly flow having a first number density thereby
changing two-phase bubbly flow having a first number density to a
two-phase bubbly flow having a second number density greater than
the first number density.
[0490] A saturation temperature (T.sub.sat) and pressure of the
two-phase flow having a second number density can be less than a
saturation temperature and pressure of the two-phase flow having a
first number density, thereby allowing the second processor 415 to
be maintained at a slightly lower temperature than the first
processor when a first heat flux from the first processor is
approximately equal to a second heat flux from the second
processor, as shown in the temperature versus distance plots of
FIGS. 14b and 14C. The predetermined temperature of the flow 51 of
dielectric single-phase liquid coolant at the first inlet 105 of
the first heat sink module 100-1 can be about 0.5-20, 0.5-15,
0.5-10, 0.5-7, 0.5-5, 0.5-3, 0.5-1, 1-20, 1-15, 1-10, 1-7, 1-5,
1-3, 3-20, 3-15, 3-10, 3-7, 3-5, 5-20, 5-15, 5-10, 5-7, 7-20, 7-15,
7-10, 10-20, 10-15, or 15-20 degrees C. below the theoretical
saturation temperature (T.sub.sat) of the flow of dielectric
single-phase liquid coolant at the predetermined pressure of the
flow of dielectric single-phase liquid coolant at the first inlet
105 of the first heat sink module 100-1. Providing the flow 51 of
dielectric single-phase liquid coolant to the inlet of the first
heat sink module includes providing a flow rate of about 0.1-10,
0.2-5, 0.3-2.5, 0.6-1.2, or 0.8-1.1 liters per minute of
single-phase liquid coolant to the first inlet 105 of the first
heat sink module 100-1. The liquid in the two-phase bubbly flow 51
being transported between the first heat sink module 100-1 and the
second heat sink module 100-2 can have a temperature at or slightly
below its saturation temperature (T.sub.sat), where a pressure of
the two-phase bubbly flow having a first number density can be
about 0.5-5.0, 0.5-3, or 1-3 psi less than the predetermined
pressure of the flow of single-phase liquid coolant provided to the
first heat sink module 100-1.
[0491] The electronic device can be, for example, a server 400, a
personal computer, a tablet computer, a power electronics device, a
workstation, a smartphone, a network switch, a telecommunications
system, an automotive electronic control unit, a battery management
device, a progressive gaming device for a casino, a high
performance computing (HPC) system, a server-based gaming device,
an avionics system, or a home automation control unit. The first
processor can be a central processing unit (CPU) or a graphics
processing unit (GPU). Likewise, the second processor can be a CPU
or a GPU.
[0492] In yet another example, a method of cooling three or more
processors 415 on a motherboard 405 can employ a two-phase cooling
apparatus having three or more fluidly-connected and
series-connected heat sink modules, as shown in FIG. 15. The method
can include providing a flow 51 of dielectric single-phase liquid
coolant to an inlet port 105 of a first heat sink module 100-1
mounted on a first thermally conductive base member 430. The first
thermally conductive base member 430 can be mounted on a first
processor 415 on a motherboard 405, as shown in FIGS. 84-89. Heat
can be transferred from the first processor 415 through the first
thermally conductive base member 430 and to the flow of dielectric
single-phase liquid coolant resulting in boiling of a first portion
of the dielectric single-phase liquid coolant, thereby changing the
flow of dielectric single-phase liquid coolant to two-phase bubbly
flow having a first quality, as shown in FIG. 99. Consequently,
heat from the first processor 415 is absorbed to the coolant across
the coolant's heat of vaporization, which is a far more efficient
method for absorbing heat than sensible heating. For a dielectric
coolant, such as NOVEC 7000, the latent heat of vaporization is
142,000 J/kg, whereas the specific heat for sensible warming the
coolant is only 1,300 J/(kg-K). Therefore, by vaporizing a portion
of the liquid coolant 50 within the heat sink module 100-1, that
portion of coolant is able to absorb significantly more heat (on an
order of 100 times more heat) from the processor 415 than if the
liquid coolant 50 were simply warmed inside the heat sink module
100-1 by one or two degrees without experiencing any
vaporization.
[0493] The method can include transporting the two-phase bubbly
flow 51 from an outlet port of 110 the first heat sink module 100-1
to an inlet port 105 of a second heat sink module 100-2 through a
first section of flexible tubing 225-1, as shown in FIG. 99. The
second heat sink module 100-2 can be mounted on a second thermally
conductive base member 430. The second thermally conductive base
member 430 can be mounted on a second processor 415 on the
motherboard 405. Heat can be transferred from the second processor
415 through the second thermally conductive base member 430 and to
the two-phase bubbly flow 51 resulting in vaporization of a portion
of dielectric liquid coolant 50 within the two-phase bubbly flow,
thereby resulting in a change from the first quality (x.sub.1) to a
second quality (x.sub.2), where the second quality is higher than
the first quality. The method can include transporting the
two-phase bubbly flow 51 from an outlet port 110 of the second heat
sink module 100-2 to an inlet port 105 of a third heat sink module
100-3 through a second section of flexible tubing 225-2. The third
heat sink module 100-3 can be mounted on a third thermally
conductive base member 430. The third thermally conductive base
member 430 can be mounted on a third processor 415 on the
motherboard 405. Heat can be transferred from the third processor
415 through the third thermally conductive base member 430 and to
the two-phase bubbly flow 51 resulting in vaporization of a portion
of dielectric liquid coolant within the two-phase bubbly flow,
thereby resulting in a change from the second quality (x.sub.2) to
a third quality (x.sub.3), where the third quality is higher than
the second quality. The motherboard 405 can be associated with a
server 400, a personal computer, a tablet computer, a power
electronics device, a smartphone, an automotive electronic control
unit, a battery management device, a high performance computing
system, a progressive gaming device, a server-based gaming device,
a telecommunications system, an avionics system, or a home
automation control unit.
[0494] In one example, a method of cooling two or more processors
415 of a server 400 can involve absorbing sensible heat and latent
heat in coolant 50 flowing through two or more series-connected
heat sink modules 100. The method can include providing a flow 51
of subcooled single-phase liquid coolant to an inlet 105 of a first
heat sink module 100-1 in thermal communication with a first
processor 415 of a server 400, as shown in FIG. 98. The subcooled
single-phase liquid coolant can absorb a first amount of heat from
the first processor 415 as sensible heat. The method can include
transporting the flow 51 of subcooled single-phase liquid coolant
from an outlet 110 of the first heat sink module 100-1 to an inlet
105 of a second heat sink module 100-2 in thermal communication
with a second processor 415 of the server 400. The subcooled
single-phase liquid can absorb a second amount of heat from the
second processor 415 as sensible heat resulting in the flow of
subcooled single-phase liquid coolant reaching its saturation
temperature and becoming a flow of saturated single-phase liquid
coolant. The flow of saturated single-phase liquid coolant can
absorb a third amount of heat from the second processor as latent
heat resulting in vaporization of a first portion of the flow of
saturated single-phase liquid coolant thereby changing the flow of
saturated single-phase liquid coolant to two-phase bubbly flow
including saturated liquid coolant 50 with vapor coolant dispersed
as bubbles 275 in the saturated liquid coolant, as shown in FIG.
98.
[0495] The method can include transporting the flow 51 of two-phase
bubbly flow containing the first amount of heat, the second amount
of heat, and the third amount of heat out of the server through a
flexible cooling line 303, as shown in FIG. 98. The method can
include rejecting the first amount of heat, the second amount of
heat, and the third amount of heat from the flow of two-phase
bubbly flow by directing the flow of two-phase bubbly flow through
a heat exchanger 40 fluidly connected to an external heat rejection
loop 43. The external heat rejection loop 43 can then reject the
first, second, and third amounts of heat to a chilled water supply
or to ambient air outside of a data center facility 425 where the
server 400 is located.
[0496] The method can include projecting the flow 51 of subcooled
single-phase liquid coolant 50, in the form of impinging jet
streams 16, against a first surface to be cooled 12 within the
first heat sink module 100-1, as shown in FIGS. 26 and 27.
Similarly, the method can include projecting the flow 51 of
subcooled single-phase liquid coolant 50, in the form of impinging
jet streams 16, against a second surface to be cooled 12 within the
second heat sink module 100-2.
[0497] Providing the flow of subcooled single-phase liquid coolant
to the inlet 105 of the first heat sink module 100-1 can include
providing a flow rate of about 0.1-10, 0.2-5, 0.3-2.5, 0.6-1.2, or
0.8-1.1 liters per minute of subcooled single-phase liquid coolant
to the first inlet 105 of the first heat sink module 100-1.
Providing the flow 51 of subcooled single-phase liquid coolant 50
to the inlet 105 of the first heat sink module 100-1 can include
providing a subcooled single-phase liquid coolant with a boiling
point of about 15-35, 20-45, 30-55, or 40-65 degrees C. determined
at a pressure of 1 atm. Providing the flow 51 of subcooled
single-phase liquid coolant to the inlet 105 of the first heat sink
module 100-1 can include providing a dielectric coolant 50
including a hydrofluoroether, a hydrofluorocarbon, or a combination
thereof. Providing the flow 51 of subcooled single-phase liquid
coolant 50 to the first heat sink module 100-1 can include
providing a flow 51 of subcooled single-phase liquid coolant at a
predetermined temperature and a predetermined pressure. The
predetermined temperature can be below the saturation temperature
of the flow of subcooled single-phase liquid coolant at the
predetermined pressure. The predetermined temperature can be about
0.5-20, 0.5-15, 0.5-10, 0.5-7, 0.5-5, 0.5-3, 0.5-1, 1-20, 1-15,
1-10, 1-7, 1-5, 1-3, 3-20, 3-15, 3-10, 3-7, 3-5, 5-20, 5-15, 5-10,
5-7, 7-20, 7-15, 7-10, 10-20, 10-15, or 15-20 degrees C. below the
saturation temperature of the flow of subcooled single-phase liquid
coolant at the predetermined pressure. The method can include
providing a pressure differential of about 0.5-5.0, 0.5-3, or 1-3
psi between the inlet 105 of the first heat sink module 100-1 and
the outlet 110 of the first heat sink module. The pressure
differential can be suitable to promote the flow 51 of subcooled
single-phase liquid coolant to advance from the inlet 105 of the
first heat sink module 100-1 to the outlet 110 of the first heat
sink module.
[0498] The method can include transporting the two-phase bubbly
flow having a first quality (x.sub.1) from an outlet 110 of the
second heat sink module 100-2 to an inlet 105 of a third heat sink
module 100-3 connected in series with the first and second heat
sink modules. The third heat sink module 100-3 can be in thermal
communication with a third processor 415 of the server 400. The
two-phase bubbly flow having the first quality (x.sub.1) can absorb
a fourth amount of heat from the third processor 415 as latent heat
resulting in vaporization of a second portion of the saturated
single-phase liquid coolant thereby changing the flow from
two-phase bubbly flow with a first quality to two-phase bubbly flow
with a second quality (x.sub.2) greater than the first quality.
[0499] The method can include directing the flow 51 of subcooled
single-phase liquid coolant 50 through one or more series-connected
heat sink modules prior to providing the flow of subcooled
single-phase liquid coolant to the inlet 105 of the first heat sink
module 100-1. This arrangement can allow the coolant 50 to absorb
sensible heat as it flows through the one or more heat sink modules
100 before reaching the first heat sink module 100-1. The one or
more heat sink modules 100 can effectively serve as preheaters,
thereby allowing the cooling apparatus 1 to achieve vaporization in
subsequent heat sink modules in the series connection without
requiring sophisticated temperature control system to deliver the
coolant at a specific number of degrees below its saturation
temperature. This allows the range of suitable temperatures for
coolant stored in the reservoir 200 to be wider than if
vaporization were required within the first heat sink module. This
arrangement can allow a lower cost and potentially more reliable
control system to be used, which can be desirable in many
applications.
[0500] In another example, a method of absorbing heat from two or
more processors 415 in an electronic device can involve flowing
coolant 50 through two or more fluidly connected heat sink modules
100 arranged in a series configuration. The method can include
providing a flow 51 of subcooled single-phase liquid coolant 50 to
a first heat sink module 100-1, as shown in FIG. 98. The first heat
sink module 100-1 can include a first thermally conductive base
member 430 in thermal communication with a first processor in an
electronic device. The subcooled single-phase liquid coolant 50 can
have a predetermined pressure and a predetermined temperature at a
first inlet 105 of the first heat sink module 100-1. The
predetermined temperature can be below a saturation temperature of
the subcooled single-phase liquid coolant at the predetermined
pressure. The method can include projecting the flow 51 of
subcooled single-phase liquid coolant 50 against the thermally
conductive base member 430 within the first heat sink module 100-1.
The flow of subcooled single-phase liquid coolant can absorb a
first amount of heat from the first processor 415 through the
thermally conductive base member 430 as sensible heat. Despite
absorbing the first amount of heat, the flow can remain subcooled
single-phase liquid coolant 50 at a temperature below the coolant's
saturation temperature. The method can include providing a second
heat sink module 100-2 including a second thermally conductive base
member 430 in thermal communication with a second processor 415.
The second heat sink module 100-2 can include a second inlet 105.
The method can include providing a first section of tubing 225
having a first end connected to the first outlet 110 of the first
heat sink module 100-1 and a second end connected to the second
inlet 105 of the second heat sink module 100-2, as shown in FIG.
98. The method can include transporting through the first section
of tubing 225 the flow of subcooled single-phase liquid coolant
from the first outlet 110 of the first heat sink module 100-1 to
the second inlet 105 of the second heat sink module 100-2. The
method can include projecting the flow 51 of subcooled single-phase
liquid coolant 50 against the second thermally conductive base
member 430 within the second heat sink module 100-2. The subcooled
single-phase liquid coolant can absorb a second amount of heat from
the second processor 415 through the second thermally conductive
base member 430 as sensible heat resulting in the subcooled
single-phase liquid coolant reaching its saturation temperature and
becoming saturated single-phase liquid coolant. The saturated
single-phase liquid coolant can absorb a third amount of heat from
the second processor 415 through the second thermally conductive
base member 430 as latent heat resulting in vaporization of a first
portion of the saturated single-phase liquid coolant thereby
changing the flow 51 of saturated single-phase liquid coolant to
two-phase bubbly flow comprising saturated liquid coolant with
vapor coolant dispersed as bubbles 275 in the saturated liquid
coolant 50.
[0501] The method can include directing the flow 51 of subcooled
single-phase liquid coolant through one or more series-connected
heat sink modules 100 prior to providing the flow of subcooled
single-phase liquid coolant to the inlet 105 of the first heat sink
module 100-1. The method can include transporting the flow 51 of
two-phase bubbly flow containing the first amount of heat, the
second amount of heat, and the third amount of heat out of the
electronic device through a flexible cooling line 225 where it can
be rejected to an external heat rejection loop 43. Providing a
first section of tubing 225 can include providing a section of
flexible tubing having a minimum bend radius of less than 3, 2.5,
or 2 inches to permit routing within the electronic device.
Likewise, providing a flexible cooling line 303 can include
providing a flexible cooling line having a minimum bend radius of
less than 3, 2.5, or 2 inches to permit routing within the
electronic device.
[0502] The electronic device can be a server 400, a personal
computer, a tablet computer, a power electronics device, a
smartphone, an automotive electronic control unit, a battery
management device, a progressive gaming device, a
telecommunications system, a high performance computing system, a
server-based gaming device, an avionics system, or a home
automation control unit. The first processor 415 can be a central
processing unit (CPU) or a graphics processing unit (GPU).
Likewise, the second processor 415 can be a CPU or GPU.
[0503] In yet another example, a method of absorbing heat from two
or more devices can involve using a two-phase cooling apparatus
configured to pump low-pressure coolant 50 through two or more
fluidly-connected and series-connected heat sink modules 100. The
method can include providing a flow 51 of subcooled single-phase
liquid coolant 50 to an inlet 105 of a first heat sink module 100-1
in thermal communication with a first device. The flow 51 of
subcooled single-phase liquid coolant 50 can absorb a first amount
of heat from the first device as sensible heat within the first
heat sink module 100-1. The method can include transporting the
flow 51 of subcooled single-phase liquid coolant 50 from an outlet
110 of the first heat sink module 100-1 to an inlet 110 of a second
heat sink module 100-2. The flow 51 of subcooled single-phase
liquid coolant 50 absorbs a second amount of heat from the second
device partially as sensible heat and partially as latent heat
within the second heat sink module 100-2. As a result, the flow 51
of subcooled single-phase liquid coolant can become two-phase
bubbly flow having saturated liquid coolant with vapor bubbles 275
of coolant dispersed in the saturated liquid coolant. The method
can include transporting the two-phase bubbly flow including the
first amount of heat and the second amount of heat away from the
first and second devices. The first and second amounts of heat can
be rejected to an external heat rejection loop 43 by directing the
two-phase bubbly flow through a heat exchanger 40 in thermal
communication with the external heat rejection loop 43.
[0504] FIG. 113 shows a quick-connect cooling line assembly 303 for
a cooling apparatus 1. The cooling line assembly 303 includes three
heat sink modules 100 fluidly connected in series by sections of
flexible tubing 225. Specifically, a first inlet section of
flexible tubing 225-0 has a first end connected to a first
quick-connect fitting 235-1, similar to the female fitting shown in
FIG. 107, and a second end of the inlet section of flexible tubing
225-0 can be connected to an inlet port 105 of a first heat sink
module 100-1. A first section of flexible tubing 225-1 fluidly
connects an outlet port 110 of the first heat sink module 100-1 to
an inlet port 105 of a second heat sink module 100-2. Similarly, a
second section of flexible tubing 225-2 fluidly connects an outlet
port 105 of the second heat sink module 100-2 to an inlet port of a
third heat sink module 100-3. An outlet section of flexible tubing
225-3 fluidly connects an outlet port 110 of the third heat sink
module 100-3 to a second quick-connect fitting 235-2, similar to
the female fitting show in FIG. 107. The quick-connect fittings 235
can allow the cooling line assembly 303 to be rapidly connected to
or disconnected the manifold assemblies 680 shown in FIG. 100 or
106 or any other suitable manifold assemblies with mating
quick-connect fittings 235. The quick-connect fittings 235 allow a
server 400 to which the heat sink modules 100 are mounted to be
hot-swapped (i.e. rapidly connected to or disconnected from a
manifold assembly 680 of an operating cooling apparatus 1).
Although three heat sink modules are shown in FIG. 113, this is not
limiting. The cooling line assembly 303 can include one, two,
three, four, five, six, or more than six heat sink modules 100
fluidly connected in series. The number of heat sink modules can be
selected based upon, among other factors, the number of surfaces to
be cooled 12, the heat load of the surfaces to be cooled, and the
heat removal capacity of the cooling system 1.
[0505] FIG. 114 shows a quick-connect cooling line assembly 303 for
a cooling apparatus 1. The cooling line assembly 303 includes three
heat sink modules 100 fluidly connected in series by sections of
flexible tubing 225. Specifically, a first inlet section of
flexible tubing 225-0 has a first end connected to a first
quick-connect fitting 235-1, similar to the male fitting shown in
FIG. 110, and a second end of the inlet section of flexible tubing
225-0 can be connected to an inlet port 105 of a first heat sink
module 100-1. A first section of flexible tubing 225-1 fluidly
connects an outlet port 110 of the first heat sink module 100-1 to
an inlet port 105 of a second heat sink module 100-2. Similarly, a
second section of flexible tubing 225-2 fluidly connects an outlet
port 105 of the second heat sink module 100-2 to an inlet port 105
of a third heat sink module 100-3. An outlet section of flexible
tubing 225-3 fluidly connects an outlet port 110 of the third heat
sink module 100-3 to a second quick-connect fitting 235-2, similar
to the male fitting show in FIG. 110. The quick-connect fittings
235 can allow the cooling line assembly 303 to be rapidly connected
to or disconnected from the manifold assemblies 680 that are shown
in FIG. 100 or 106 or any other suitable manifold assemblies with
mating quick-connect fittings 235. The quick-connect fittings 235
allow a server 400 to which the heat sink modules 100 are mounted
to be hot-swapped (i.e. rapidly connected to or disconnected from a
manifold assembly 680 of an operating cooling apparatus 1).
Although three heat sink modules are shown in FIG. 114, this is not
limiting. The cooling line assembly 303 can include one, two,
three, four, five, six, or more than six heat sink modules 100
fluidly connected in series. The number of heat sink modules 100
can be selected based upon, among other factors, the number of
surfaces to be cooled 12, the heat load of the surfaces to be
cooled, and the heat removal capacity of the cooling system 1.
Parallel-Connected Heat Sink Modules
[0506] FIG. 16 shows a schematic of a cooling apparatus 1 having a
primary cooling loop 300 that includes three parallel cooling line
assemblies 303 where each parallel cooling line includes three heat
sink modules 100 fluidly connected in series. The cooling apparatus
1 shown in FIG. 16 can be configured to cool nine independent
heat-generating surfaces 12, such as nine microprocessors 415.
Other variations of the cooling apparatus 1 shown in FIG. 16 can
include more than three parallel cooling line assemblies 303, and
each cooling line assembly can include more than three
series-connected modules 100. As shown in FIG. 129, a first cooling
line assembly 303-1 can include five series-connected heat sink
modules 100, and a second cooling line assembly 303-2 can include
eight series-connected heat sink modules 100.
[0507] As shown in the schematic of FIG. 16, additional heat sink
modules 100 can be added to the cooling apparatus 1 in parallel
cooling loops 300 that they are serviced by, for example, the same
pump 20, reservoir 200, and heat exchanger 40. Alternatively, as
shown in FIG. 17, the cooling apparatus 1 can include additional
reservoirs 200, pumps 20, and/or heat exchangers 40 in parallel for
the purpose of redundancy and reliability. As used herein, an
additional component "in parallel" refers to a component in fluid
communication with the other components in a manner that bypasses
only components of the same type without bypassing different types
of components. An example of an additional component added in
parallel is shown with the additional heat sink modules 100 in FIG.
16, where three parallel cooling loops 300 are provided that each
are serviced by the same reservoir 200 and pump 20.
Mounting Bracket for Heat Sink Module
[0508] In some examples, it can be desirable to secure the heat
sink module 100 to a device using a mounting bracket 500. For
instance, it can be desirable to secure the sink module 100 tightly
to a heat-providing surface 12 to reduce thermal resistance and
improve heat transfer rates. More specifically, when installing a
heat sink module 100 on a microprocessor 415, it can be desirable
to use a mounting bracket 500 to secure the heat sink module 100
firmly in place, as shown in FIGS. 84-89. FIG. 84 shows a top
perspective view of two series-connected heat sink modules 100
installed on top of microprocessors 415 in a server 400. The
mounting bracket 500 can attach to existing mounting holes 406 in
the motherboard 405 originally intended for an air-cooled heat
sink. Threaded fasteners 115 can secure the mounting bracket 500 to
the threaded holes 406 in the motherboard 405. When the threaded
fasteners 115 are secured in the mounting holes 406, the mounting
bracket 500 can contact and apply a clamping force to a top surface
160 of the heat sink module 100, as shown in FIG. 84, thereby
preventing the heat sink module 100 from shifting out of place
during use.
[0509] The mounting brackets 500 shown in FIG. 84 are suitable for
installations where the heat sink modules 100 can be aligned with
the microprocessor 415 and where there is ample room to route
flexible cooling lines 303 that transport coolant (i.e. working
fluid) 50 to and from the heat sink modules. However, in many
instances, routing the flexible cooling lines 303 can be difficult
due to space constraints. In some installations, greater mounting
flexibility may be required. FIG. 85 shows a top view of an
S-shaped mounting bracket 500 that can connect to two holes in a
motherboard 405 and can permit the heat sink module 100 to be
mounted in any suitable orientation, independent of the orientation
of the microprocessor 415. By reducing mounting constraints and the
number of fasteners required, the S-shaped mounting bracket 500 can
allow for much shorter installation times and can alleviate stress
on flexible cooling lines assemblies 303 and the potential for
kinking by reducing the need for tight bend radiuses that may be
otherwise be required. Having greater options for orienting the
heat sink module 100 can also allow less flexible tubing 225 to be
used in an installation, since routing options can be more direct
than the configuration shown in FIG. 84 where the heat sink module
100 is aligned with the microprocessor 415.
[0510] The S-shaped bracket 500 can include a bracket member having
a first end and a second end, as shown in FIGS. 85-91. The S-shaped
bracket member can include a first curvilinear portion 510 located
between the first end and a midpoint. The S-shaped bracket can
include a second curvilinear portion 510 located between the
midpoint and the second end. The first curvilinear portion can have
a radius of curvature of about 1.0-4.0, 1.0-2.5, or 1.5-2.0 inches.
Similarly, the second curvilinear portion can have a radius of
curvature of about 1.0-4.0, 1.0-2.5, or 1.5-2.0 inches.
[0511] The bracket 500 can include a first slot 505 proximate the
first end and a second slot 505 proximate a second end. The first
and second slots 505 can be elongated openings that allow for
imperfect alignment with the mounting holes in the motherboard 405.
In some examples, the fasteners 115 that mount the S-shaped bracket
500 to the mounting holes in the motherboard 405 can each include a
washer to distribute a clamping load across a larger surface area
of the bracket near the first and second slots 505.
[0512] In some examples, the first slot 505 can be substantially
parallel to the second slot 505. The first slot 505 can have a
first midpoint located a first distance from the midpoint of the
bracket 500. Similarly, the second slot can have a second midpoint
located a second distance from the midpoint of the bracket 500. The
first distance and the second distance can be about equal, thereby
providing a bracket that is symmetrical so that an installer does
not have to be concerned with properly orienting the bracket during
assembly.
[0513] The S-shaped bracket can provide a larger contact area
against the top surface 160 of the heat sink module 100 than a
linear mounting bracket, thereby allowing the clamping force to be
distributed over a greater percentage of the top surface 160 of the
heat sink module 100 and thereby mitigating risks of cracking or
crushing the polymer heat sink module 100 during installation if
the fasteners are over-tightened.
[0514] In another example, it can be desirable to provide a
mounting bracket 500 that permits rotation of the heat sink module
100 relative to the mounting bracket 500 but prevents lateral
movement of the heat sink module relative to the mounting bracket.
This can allow for ease of installation without concern for the
heat sink module 100 becoming misaligned with, for example, a
processor 415. FIG. 141A shows a top perspective view of a heat
sink assembly 107 with a heat sink module 100 mounted to a
thermally-conductive base member 430 and a mounting bracket 500
configured to secure the heat sink module against a surface to be
cooled 12 while permitting rotation of the heat sink module
relative to the mounting bracket for ease of installation. FIG.
141B shows an exploded perspective view of the heat sink assembly
of FIG. 141A. FIG. 142A shows a side cross-sectional view of the
heat sink assembly of FIG. 141A taken along section A-A. The
mounting bracket 500 can have a bevel 85-1 circumscribing a central
opening in the mounting bracket. The bevel 85-1 of the mounting
bracket can contact one or more bevels 85-2 of the thermally
conductive base member 430. The bevel can circumscribe a perimeter
of the thermally conductive base member or, as shown in FIG. 141B,
can include discrete beveled portions 85 that contact the bevel of
the mounting bracket 85-1 and permit rotation of the thermally
conductive base member 430 relative to the mounting bracket 430.
FIG. 142B shows an alternative embodiment of FIG. 141A, where the
bevels are replaced with step features. More specifically, the
mounting bracket 500 can have a first step feature 86-1 in contact
with a second step feature 86-2 of the thermally conductive base
member 430. Together the first and second step features (86-1,
86-2) can prevent lateral movement of the thermally conductive base
member 430 relative to the mounting bracket 500 while permitting
rotation of the thermally conductive base member. Other suitable
mating features can be used to permit rotation of the thermally
conductive base member 430 relative to the mounting bracket while
preventing lateral movement of the thermally conductive base
member.
[0515] Although the mounting brackets shown in FIG. 141A has four
mounting holes, this is not limiting. The mounting bracket 500 can
have two or more mounting holes. FIG. 146 shows a top view of a
cooling line assembly 303 with two series-connected heat sink
modules (100-1, 100-2) mounted on processors 415 within a server
100. Each heat sink module 100 is mounted to a processor by a
mounting bracket 500 having two holes.
Single Heat Sink Module for Multiple Heat Sources
[0516] To reduce installation costs, it can be desirable to cool
more than one heat source 12 using a single heat sink module 100.
Example installations are shown in FIGS. 66 and 67. FIG. 66 shows
an example of an existing server 400 with a heat sink module
retrofitted thereon. The server 400 includes a motherboard 405, two
microprocessors 415 mounted on the motherboard, and a finned heat
sink 440 mounted on each microprocessor 415. Rather than spend time
and effort removing the finned heat sink modules 440 already
installed on the microprocessors 415, instead, a thermally
conductive base member 430 can be placed in thermal contact with
both finned heat sinks 440, as shown in FIG. 66. The thermally
conductive base member 430 can extend from a first finned heat sink
440 to a second finned heat sink 440. A heat sink module 100 can be
mounted on a surface 12 of the thermally conductive base member
430. By directing a plurality of jet streams 16 of coolant at the
surface to be cooled 12 of the thermally conductive base member
430, the configuration shown in FIG. 66 can cool two
microprocessors simultaneously at a lower cost than installing two
heat sink modules and without having to uninstall any
factory-installed components of the server (e.g. the finned heat
sinks 440). By not uninstalling factory-installed hardware, this
cooling method can avoid potentially voiding a factory warranty on
the server 400 or computer.
[0517] FIG. 67 shows an arrangement where a thermally conductive
base member 430 extends from a first microprocessor 415 to a second
microprocessor 415 mounted on a motherboard 405. A heat sink module
100 can be mounted on a surface 12 of the thermally conductive base
member 430. By directing a plurality of jet streams 16 of coolant
at the surface to be cooled 12 of the thermally conductive base
member 430, the configuration shown in FIG. 67 can cool two
microprocessors 415 simultaneously at a lower cost than using two
heat sink modules. To ensure even cooling of each microprocessor,
it can be desirable for the thermally conductive base member 430 to
make contact with an entire, or substantially the entire, top
surface of each microprocessor, as shown in FIG. 67.
Surface to be Cooled
[0518] The surface to be cooled 12 can be exposed within the outlet
chamber 150 of the heat sink module 100, such that the jet streams
16 of coolant 50 impinge directly on the surface to be cooled 12
without thermal interference materials disposed between the surface
12 and the coolant 50. As used herein, "surface to be cooled"
refers to any electronic or other device having a surface that
generates or transfers heat and requires cooling. Non-limiting,
examples of surfaces to be cooled 12 include microprocessors 415
(e.g. CPUs, GPUs), batteries (e.g. lithium ion batteries and
battery terminals), memory modules 420, LED arrays, diode laser
arrays, microelectronic circuit chips in supercomputers, diode
laser packages, weapons systems, power electronics, mechanical
components, process containers, or any electronic circuits or
devices requiring cooling. The surface to be cooled 12 can be
exposed within the outlet chamber 150 of the heat sink module 100
by constructing the outlet chamber to include the surface 12 within
the chamber 150 or by constructing the outlet chamber such that the
surface to be cooled 12 serves as a bounding wall of the outlet
chamber 150, as shown in FIG. 26. In some examples, the heat sink
module 100 can form an enclosure, such as a sealed liquid-tight
enclosure, against the surface to be cooled 12 using one or more
sealing members (e.g. o-rings, gaskets, or adhesives). In some
examples, the heat sink module 100 can be permanently or
semi-permanently to the surface to be cooled 12. For instance, to
provide direct-to-silicon cooling of a microprocessor 415, a
microprocessor lid can be removed and replaced with an
appropriately-sized heat sink module to provide jet streams 16 of
coolant 50 directly against the silicon surface of the
microprocessor. Removing the lid of the microprocessor 415 can
significantly reduce the thermal resistance associated with cooling
the microprocessor, thereby allowing the cooling apparatus 1 to
maintain lower processor temperatures for a given processor
utilization rate. In this example, the heat sink module 100 can be
permanently or semi-permanently affixed to the processor using a
suitable adhesive, such as a layer of epoxy applied around a
perimeter of the heat sink module.
[0519] FIGS. 154-156 show three sequential steps of providing
direct-to-silicon cooling for a GPU of a graphics card 405. FIG.
154 shows a graphics card 405 with a GPU 415 having an exposed
silicon surface. FIG. 155 shows a heat sink module 100 mounted
directly against the exposed silicon surface of the GPU 415 of FIG.
154. FIG. 156 shows a mounting bracket 500 installed over the heat
sink module 100 of FIG. 155 and secured to the graphics card 405 by
fasteners that compress a sealing member 125 between the silicon
surface and the heat sink module to provide a liquid-tight seal
circumscribing an outlet chamber of the heat sink module, as shown
in FIG. 27. A first section of flexible tubing 225-1 is fluidly
connected to an inlet port 105 of the heat sink module 100, and a
second section of flexible tubing is fluidly connected to an outlet
port 110 of the heat sink module. The first and second sections of
flexible tubing (225-1, 225-2) can each include a fitting 235. Each
fitting 235 can be a quick-connect fitting with a non-spill
shut-off valve as shown in FIGS. 107-110. As shown in FIG. 156, one
fitting can be male and the other fitting can be female to allow
the cooling line assembly 303 to be daisy-chained with one or more
other cooling line assemblies. This arrangement is suitable for use
in home computers where users may prefer modular components that
allow them to connect two or more cooling line assemblies 303 to
meet specific cooling needs of their computer and to allow for
future expansion if the user purchases additional hardware that
requires cooling. In other examples, where the cooling line
assembly 303 is configured to fluidly connect to a manifold
assembly 680 with a common type of fitting (see, e.g., FIG. 106),
both fittings of the cooling line assembly 303 may be male or
female to facilitate connection with the manifold assembly
fittings.
[0520] In some examples of the cooling apparatus 1, coolant 50 can
be delivered to a heat sink module 100 that is mounted directly on
a surface to be cooled, such as a surface of a microprocessor 415
that is electrically connected to a motherboard 405. FIG. 27 shows
a side cross-sectional view of the heat sink module 100 of FIG. 24
taken along section B-B with the heat sink module mounted directly
on a computer processor located on a motherboard 405 and showing
central axes of several orifices 155. The heat sink module 100 is
capable of mounting directly on a lid of a processor 415 and
providing impinging jet streams 16 of coolant 50 against the lid
or, in another example, mounting directly on a processor without a
lid and providing direct-to-silicon cooling where jet streams 16 of
coolant 50 directly impinge a silicon surface of the processor.
Providing direct-to-silicon cooling eliminates thermal resistance
associated with the processor lid, thereby increasing heat transfer
rates and allowing the processor 415 to be maintained at a lower
operating temperate. In addition, hot spots on the processor 415
can be addressed by modifying the impingement pattern of the heat
sink module 100. For example, if thermal characterization of the
microprocessor 415 reveals hot spots, or if the processor has
certain cores that statistically are more heavily utilized than
other cores, orifices 155 of the heat sink module 100 can be
arranged to direct additional jet streams 16 of coolant 50 at or
near the hot spots to enhance heat transfer proximate the hot spots
and thereby achieve more consistent temperatures across the
processor.
[0521] In other examples, the heat sink module 100 can be mounted
on a thermally conductive intermediary object, such as a thermally
conductive base member 430, as shown in FIG. 26. The assembly of
the heat sink module 100 and the thermally conductive base member
430 can then be mounted on a heat source, such as a microprocessor
415 electrically connected to a motherboard 405, as show in FIG.
28. A layer of thermal interface material (e.g. solder thermal
interface material or polymer thermal interface material) can be
applied between a top surface of the heat source (e.g.
microprocessor) and a bottom surface of the thermally conductive
base member 430. The thermally conductive base member 430 can be
made of a material with a high thermal conductivity, such as
copper, silver, gold, aluminum, or tungsten.
[0522] The thermally conductive member 430 can be placed in thermal
communication with an electronic device, or other type of device,
that has a surface 12 that generates heat and requires cooling,
such as a microprocessor 415, microelectronic circuit chip in a
supercomputer, or any other electronic circuit or device requiring
cooling, such as diode laser packages.
Three-Phase Contact Line Length
[0523] FIG. 63 shows a top view of a heated surface 12 covered by
coolant 50, where the coolant has regions of vapor coolant 56 and
wetted regions of liquid coolant 57 in contact with the heated
surface 12. The dark areas in FIG. 63 show the vapor coolant
regions 56, and the light areas show the liquid coolant regions 57.
A length of a three-phase contact line 58 is measured as a sum of
all curves where liquid coolant 57, vapor coolant 56, and the solid
heated surface 12 are in mutual contact on the heated surface 12.
The three-phase contact line 58 length can be determined using
suitable image processing techniques.
[0524] The heat transfer rate from the surface to be cooled 12 to
the coolant 50 has been shown to strongly correlate with the length
of the three-phase contact line 58 on the surface to be cooled 12.
Consequently, increasing the length of the three-phase contact line
58 can be desirable when attempting to increase the heat transfer
rate from the surface to be cooled. Increasing the heat transfer
rate is desirable, since it increases the efficiency of the cooling
apparatus 1 and allows higher heat flux surfaces to be cooled by
the cooling apparatus.
[0525] By providing jet streams 16 of coolant that impinge the
surface to be cooled 12 from a suitable jet height 18, the heat
sink modules 100 described herein effectively increase the length
of the three-phase contact line 58. Consequently, the heat sink
modules 100 described herein provide much higher heat transfer
rates than competing cooling systems. By selecting orifice 155
diameters, jet heights 18, coolant pressures, and orifice
orientations from the ranges provided herein, the heat sink module
100 can provide jet streams 16 with sufficient momentum to disrupt
vapor formation on the surface to be cooled 12, thereby increasing
the length of the three-phase contact line 58 on the surface to be
cooled 12 and allowing higher heat fluxes to be effectively
dissipated without reaching critical heat flux.
Redundant Cooling Apparatus
[0526] In some examples, it can be desirable to have a fully
redundant cooling apparatus 2 where each heat-generating surface 12
is cooled by at least two completely independent cooling
apparatuses 1. In the event of failure of a first independent
cooling apparatus 1, a second independent cooling apparatus 1 can
be configured to provide sufficient cooling capacity to adequately
cool the heat-generating surface 12 and thereby avoid any downtime
or reduction in performance when the heat-generating surface 12 is,
for example, a microprocessor 415 or other critical system
component. In a fully redundant cooling apparatus 2, the
heat-generating component 12 can be adequately cooled by a first
cooling apparatus 1 (and can continue to operate normally) while
repairs are made on a failed component within a second cooling
apparatus 1 of the redundant cooling apparatus 2.
[0527] FIG. 9 shows a front perspective view of a fully redundant
cooling apparatus 2 installed on eight racks 410 of servers 400 in
a data center 425. The redundant cooling apparatus 2 includes a
first independent cooling apparatus 1 and a second independent
cooling apparatus, each similar to the cooling apparatus 1
described with respect to FIGS. 1-3. FIG. 10 shows a rear view of
the redundant cooling apparatus 2 of FIG. 9. In FIGS. 9 and 10, the
redundant cooling apparatus 2 has a first pump 20, a first
reservoir 200, a first set of inlet and outlet manifolds, and a
first heat exchanger 40 associated with the first independent
cooling apparatus 1. Likewise, the redundant cooling apparatus 2
has a second pump, a second reservoir, a second set of inlet and
outlet manifolds, and a second heat exchanger 40 associated with
the second independent cooling apparatus 1.
[0528] In some examples, the first and second cooling apparatuses 1
may not be fully independent and may share components that have a
very low likelihood of failure, such as a common reservoir 200
and/or a common heat exchanger 40. FIGS. 69 and 70 shows schematics
of redundant cooling apparatuses 2 that have a common reservoir
200. Such an arrangement may be useful where a redundant cooling
apparatus 2 is desired but where safety regulations restrict the
volume of coolant that can be used in a confined space. The
configuration shown in FIGS. 69 and 70 may also reduce system cost
by reducing the total number of components and by reducing the
volume of coolant used.
[0529] FIG. 17 shows a schematic of a redundant cooling apparatus 2
having a redundant heat sink module 700 mounted on a heat source
12. The redundant heat sink module 700 is connected to two a first
independent cooling apparatus 1 and a second independent cooling
apparatus 1. The first independent cooling apparatus includes a
primary cooling loop 300, a first bypass, and a second bypass 310.
Similarly, the second independent cooling apparatus includes a
primary cooling loop 300, a first bypass 305, and second bypass
310. As a result of this configuration, failure of a single
component in the first independent cooling apparatus 1 will not
disrupt operation of the second independent cooling apparatus 1.
The redundant cooling apparatus 2 is configured to provide adequate
cooling of the surface to be cooled 12 even if the first or second
independent cooling apparatus 1 fails.
[0530] Although the redundant cooling apparatus 2 shown in FIG. 17
incorporates two cooling apparatuses 1 like the one presented in
FIG. 11A, this is not limiting. Any of the non-redundant cooling
apparatuses 1 presented in FIGS. 11A, 12A-12T, 13, 14A, and 16 can
be used, in any combination, to provide a redundant cooling
apparatus 2 to cool one or more heat generating surfaces 12.
[0531] In any of the schematics described herein or shown in the
accompanying figures, each redundant heat sink module 700 can be a
combination of two heat sink modules 100 of the type shown in FIG.
21, or a redundant heat sink module 700 with integrated independent
coolant pathways, as shown in FIGS. 51A-51M. Therefore, the
redundant heat sink module(s) 700 in FIGS. 17 and 18 can be
exchanged for two heat sink modules 100 of the type shown in FIG.
21. In some examples, two non-redundant heat sink modules 100 can
be mounted to a thermally conductive base member 430 to provide a
redundant heat sink assembly, as shown in FIG. 52B.
[0532] FIG. 18 shows a schematic of a redundant cooling apparatus 2
that is more complex than the schematic shown in FIG. 17. The
redundant cooling apparatus 2 in FIG. 18 includes a first
independent cooling apparatus 1 and a second independent cooling
apparatus 1. Each independent cooling apparatus 1 includes two
parallel cooling lines where each parallel cooling line is fluidly
connected to three redundant heat sink modules 700 arranged in a
series configuration. As a result, the redundant cooling apparatus
2 shown in FIG. 17 is capable of redundantly cooling six surfaces
to be cooled 12. The redundant cooling apparatus 2 is scalable, and
additional parallel and series connected heat sink modules 700 can
be added to cool additional surfaces 12.
[0533] FIG. 19 shows a top view of a redundant cooling apparatus 2
installed in a data center or computer room 425 having twenty racks
410 of servers 400. Each independent cooling apparatus 1 of the
redundant cooling apparatus 2 can be fluidly connected to a heat
exchanger 40 located inside of the room 425 where the servers are
located. In some examples, the heat exchanger 40 can reject heat
into the room 425, and a CRAC can be used to remove the rejected
heat from the room.
[0534] FIG. 20 shows a top view of a redundant cooling apparatus 2
installed in a data center or computer room 425 having twenty racks
410 of servers 400. Each independent cooling apparatus 1 of the
redundant cooling apparatus 2 can be fluidly connected to any
suitable external heat exchanger 40 located outside of the room 425
where the servers are located. Each independent cooling apparatus 1
can be fluidly connected to the external heat exchanger 40 by an
external heat rejection loop 43 that circulates an external cooling
fluid, such as water or a water-glycol mixture. In some examples
the heat exchanger 40 can be connected to a chilled water system of
a building where the room 425 is located. In other examples, the
heat exchanger 40 can be an air-to-liquid dry cooler or a
liquid-to-liquid heat exchanger located outside of the room 425
(e.g. located outside of the building).
[0535] As noted above, FIGS. 69 and 70 shows schematics of
redundant cooling apparatuses 2 having a first and second cooling
apparatus where the first and second cooling apparatuses are not
fully independent, since they share a common reservoir. In FIG. 69,
the first and second cooling apparatuses 1 also share a common heat
rejection loop 43. The heat rejection loop 43 is fluidly connected
to the common reservoir 200 and includes a pump 20 and a heat
exchanger 40. The pump 20 is configured to circulate a flow 51 of
coolant from the reservoir 200 through the heat exchanger 40, where
heat is removed from the flow of coolant, thereby reducing the
temperature of the flow of coolant. The heat exchanger can be
located outside of a room 425 where the redundant cooling apparatus
2 is installed so that heat rejected from the flow of coolant is
not discharged back into the room 425. For instance, the heat
exchanger 40 can be located on a rooftop of a building where the
redundant cooling apparatus 2 is installed.
[0536] In FIG. 70, the first and second cooling apparatuses 1 share
a common reservoir 200, but have separate heat rejection loops 43,
also known as second bypasses 310. Each heat rejection loop 43
includes a valve 60 and a heat exchanger 40. In some examples, each
valve 60 can be adjusted (manually or automatically) to allow about
30-60 or 45-55% of the flow 51 leaving each pump 20 to circulate
through each heat rejection loop 43. This configuration can ensure
that the coolant stored in the reservoir 200 remains sufficiently
sub-cooled to allow for rapid condensing of any vapor delivered to
the reservoir form a first or second return line 230 carrying
bubbly flow. By rapidly condensing vapor within the reservoir 200
through direct interaction with a relatively large volume of
sub-cooled liquid, the redundant cooling apparatus 2 prevents vapor
from being delivered from the reservoir 200 outlets to either
pump.
Redundant Heat Sink Module
[0537] FIG. 51A shows a top perspective view of a redundant heat
sink module 700. The heat sink module 700 can be defined by a front
side surface 175, a rear side surface 180, a left side surface 185,
a right side surface 190, a top surface 160, and a bottom surface
135. FIG. 51B shows a top view of the redundant heat sink module of
FIG. 51A, where a first independent coolant pathway 701 and the
second independent coolant pathway 702 are represented by dashed
lines. In the example shown in FIG. 51B, the first independent
coolant pathway 701 passes through a first region near a middle of
the redundant heat sink module 700, and the second independent
coolant pathway 702 passes through a second region outside of the
perimeter of the first region. The first and second independent
coolant pathways (701, 702) can be completely independent, meaning
that no amount (or no substantial amount) of coolant 51 is
transferred from the first independent coolant pathway 701 to the
second independent coolant pathway 702 or vice versa. The first
independent coolant pathway can extend from a first inlet port
105-1 to a first outlet port 110-1 of the redundant heat sink
module 700. Similarly, a second independent coolant pathway 702 can
extend from a second inlet port 105-2 to a second outlet port 110-2
of the redundant heat sink module 700.
[0538] The first independent coolant pathway 701 can include a
first inlet passage 165-1 extending from the first inlet port 105-1
to a first inlet chamber 145-1, as shown in FIG. 51F, which shows a
cross-sectional view of FIG. 51 E taken along section A-A. The
first inlet chamber 145-1 can have a tapered geometry to provide an
even distribution of coolant to the plurality of orifices 155-1.
For a redundant heat sink module 700 configured to cool a
microprocessor 415, the first inlet chamber 145-1 can taper from a
maximum height of about 0.040-0.120 in. to a minimum height of
about 0.020-0.040 in. The first inlet chamber 145-1 can have a
width of about 0.75-1.5 in. and a length of about 0.75-1.5 in. The
volume of the first inlet chamber 145-1 can be about 0.01-0.02,
0.01-0.05, 0.04-0.08, 0.07-0.15, 0.1-0.2, 0.15-0.25, 0.2-0.4,
0.3-0.5 in.sup.3, or preferably about 0.15 in.sup.3. The first
outlet chamber 150-1 can be slightly larger than the first inlet
chamber 145-1 to accommodate expansion of a portion of the coolant
50 as it changes phase from liquid to vapor. For example, the first
outlet chamber 15 can have a volume of about 0.02-0.05, 0.04-0.08,
0.07-0.15, 0.1-0.2, 0.15-0.25, 0.2-0.4, 0.3-0.5, 0.4-0.75 in.sup.3,
or preferably about 0.25 in.sup.3. Although the first inlet and
outlet chambers (145-1, 150-1) can be made larger, the dimensions
provided above provide a high-performing, compact heat sink module
700.
[0539] As shown in the top view of the FIG. 51E, the second
independent coolant pathway 702 is bifurcated and circumscribes the
first independent coolant pathway 701. Consequently, the second
inlet chamber 145-2 and the second outlet chamber 150-2 are also
bifurcated, as shown in FIG. 51I. Despite having a different
geometry than the first inlet chamber 145-1, the bifurcated second
inlet chamber 145-2 can have about the same total volume as the
first inlet chamber 145-1. For example, the volume of the first
inlet chamber 145-1 can be about 0.01-0.02, 0.01-0.05, 0.04-0.08,
0.07-0.15, 0.1-0.2, 0.15-0.25, 0.2-0.4, 0.3-0.5 in.sup.3, or
preferably about 0.15 in.sup.3. Likewise, despite having a
different geometry than the first outlet chamber 150-1, the
bifurcated second outlet chamber 150-2 can have about the same
total volume as the first outlet chamber 150-1. For example, the
volume of the second outlet chamber 150-2 can be about 0.02-0.05,
0.04-0.08, 0.07-0.15, 0.1-0.2, 0.15-0.25, 0.2-0.4, 0.3-0.5,
0.4-0.75 in.sup.3, or preferably about 0.25 in.sup.3.
[0540] As shown in FIG. 51F, a first plurality of orifices 155-1
can extend from the first inlet chamber 145-1 to a first outlet
chamber 150-1 and can be configured to provide a plurality of jet
streams 16 of coolant into the first outlet chamber 150-1 when
pressurized coolant is provided to the first inlet chamber 145-1. A
first outlet passage 166-1 can extend from the first outlet chamber
150-1 to the first outlet port 110-1, as shown in FIG. 51G, which
is a cross-sectional view of FIG. 51E taken along section B-B.
[0541] A first plurality of anti-pooling orifices 156-1 can extend
from the first inlet chamber 145-1 to a location proximate a rear
wall of the first outlet chamber 150-1 and can be configured to
provide a plurality of jet streams 16 of coolant proximate a rear
wall of the first outlet chamber 150-1 when pressurized coolant is
provided to the first inlet chamber 145-1. The anti-pooling jet
streams 16 can be configured to impinge the surface to be cooled 12
at an angle near the rear wall and to prevent pooling of coolant
near a rear wall of the first outlet chamber 150-1 by promoting
directional flow away from the rear wall. By preventing pooling,
the anti-pooling jet streams can prevent the onset of critical heat
flux near the rear wall of the first outlet chamber 150-1, thereby
increasing a maximum thermal load the heat sink module is capable
of safely dissipating.
[0542] The second independent coolant pathway 702 can include a
second inlet passage 165-2 extending from the second inlet port
105-2 to a second inlet chamber 145-2, as shown in FIG. 51G. A
second plurality of orifices 155-2 can extend from the second inlet
chamber 145-2 to a second outlet chamber 150-2 and can be
configured to provide a plurality of jet streams 16 of coolant into
the second outlet chamber 150-2 when pressurized coolant is
provided to the second inlet chamber 145-2. A second outlet passage
166-2 can extend from the second outlet chamber 150-2 to the second
outlet port 110-2, as shown in FIG. 51 F. A second plurality of
anti-pooling orifices 156-2 can extend from the second inlet
chamber 145-2 to a location proximate a rear wall of the second
outlet chamber 150-2 and can be configured to provide a plurality
of jet streams 16 of coolant proximate the rear wall of the second
outlet chamber 150-2 when pressurized coolant is provided to the
second inlet chamber 145-2.
[0543] FIG. 51D shows a bottom view of the redundant heat sink
module 700 of FIG. 51A. The first independent coolant pathway 701
includes an array of orifices 155 arranged in a first region
located near a middle portion of the module 700. The second
independent coolant pathway 702 includes an array of orifices 155
arranged in a second region located beyond (e.g. outside of or
circumscribing) the perimeter of the first region. In other
examples, the first region can be located near a first half of the
module 700 and the second region can be located near a second half
of the module 700, as shown in the side-by-side coolant pathway
example of FIG. 53.
[0544] The first outlet chamber 150-1 of the redundant heat sink
module 700 can have an open portion that can be enclosed by a
surface to be cooled 12 when the redundant heat sink module 700 is
installed on the surface to be cooled 12. Similarly, the second
outlet chamber 150-2 of the redundant heat sink module 700 can have
an open portion that can be enclosed by a surface to be cooled 12
when the redundant heat sink module 700 is installed on the surface
to be cooled 12.
[0545] To facilitate sealing against the surface to be cooled 12,
the redundant heat sink module 700 can include a first sealing
member 125-1 and a second sealing member 125-2, as shown in FIG.
51D. The first sealing member 125-1 (e.g. o-ring, gasket, sealant)
can be disposed within a first channel 140-1 formed in a bottom
surface 135 of the redundant heat sink module 700. The first
channel 140-1 can circumscribe the first outlet chamber 150-1, and
the first sealing member 125-1 can be compressed between the first
channel 140-1 and the surface to be cooled 12 to provide a
liquid-tight seal therebetween. The redundant heat sink module 700
can include a second sealing member 125-2, as shown in FIG. 51D.
The second sealing member 125-2 (e.g. o-ring, gasket, sealant) can
be disposed within a second channel 140-2 formed in the bottom
surface 135 of the redundant heat sink module 700. The second
channel 140-2 can circumscribe the second outlet chamber 150-2, and
the second sealing member 125-2 can be compressed between the
second channel 140-2 and the surface to be cooled 12 to provide a
liquid-tight seal therebetween. In this example the first sealing
member 125-1 can provide a liquid-tight seal between the first
outlet chamber 150-1 and the second outlet chamber 150-2. The first
sealing member 125-1 can bound an inner perimeter of the second
outlet chamber 150-2, and the second sealing member 125-2 can bound
an outer perimeter of the second outlet chamber 150-2.
[0546] FIG. 51I shows a cross-sectional view of the redundant heat
sink module 700 taken along section C-C shown in FIG. 51H. FIG. 51I
shows relative positioning of a first inlet chamber 145-1, a first
outlet chamber 150-1, a bifurcated second inlet chamber 145-2, and
a bifurcated second outlet chamber 150-2. A first dividing member
195-1 separates the first inlet chamber 145-1 from the first outlet
chamber 150-1. The first plurality of orifices 155-1 extend from
the first inlet chamber 145-1 to the first outlet chamber 150-1 and
through the first dividing member 195-1. Similarly, the second
inlet chamber 145-2 is separated from the second outlet chamber
150-2 by a second dividing member 195-2. The second plurality of
orifices 155-2 extend from the second inlet chamber 145-2 to the
second outlet chamber 150-2 and through the second dividing member
195-2. The thickness of the first and second dividing members
(195-1, 195-2) can be selected to ensure that the orifices have
sufficient L/D ratios and that the heat sink module 700 is
structurally sound (i.e. capable of handling a flow 51 of
pressurized coolant).
[0547] FIG. 51K shows a side cross-sectional view of the redundant
heat sink module 700 of FIG. 51J taken along section D-D. The
nonlinear sectional view exposes a substantial portion of the first
independent coolant pathway 701, including the first inlet port
105-1, first inlet passage 165-1, first inlet chamber 145-1, the
first plurality of orifices 155-1, the first anti-pooling orifice
156-1, the first outlet chamber 150-1, the first outlet passage
166-1, and the first outlet port 110-1. The apparent blockages
between the first inlet passage 165-1 and the first inlet chamber
145-1 and between the first outlet chamber 150-1 and the first
outlet passage 166-1 are simply artifacts of the location of
section D-D. No such blockages exist in the first coolant pathway
701. The first coolant pathway 701 is designed to be free flowing
such that only a small pressure drop (e.g. about 1.5 psi) is
observed between the first inlet port 105-1 and the first outlet
port 110-1 when pressurized coolant is delivered to the first
coolant pathway 701.
[0548] As shown in FIG. 51K, the first inlet chamber 145-1 can have
a tapered geometry that ensures substantially similar flow through
each orifice 155. The first outlet chamber 150-1 can have an
expanding geometry that allows for expansion of the coolant as a
portion of the coolant changes phase from a liquid to a vapor as
heat is transferred from the surface to be cooled 12 to the flow of
coolant 50. The redundant heat sink module 700 can include a
flow-guiding lip 162, as shown in FIG. 51K. The flow-guiding lip
162 can guide the directional flow 51 from the outlet chamber 150-1
to the outlet passage 166-1. Preferably, the flow-guiding lip can
have an angle of less than about 45 degrees with respect to the
surface to be cooled 12 to avoid creating a flow restriction or
stagnation region proximate the exit of the outlet chamber
150-1.
[0549] FIG. 51M shows a side cross-section view of the redundant
heat sink module 700 of FIG. 51L taken along section E-E. The
nonlinear sectional view exposes a substantial portion of the
second independent coolant pathway 702, including the second inlet
port 105-2, second inlet passage 165-2, second inlet chamber 145-2,
the second plurality of orifices 155-2, the second anti-pooling
orifice 156-2, the second outlet chamber 150-2, the second outlet
passage 166-2, and the second outlet port 110-2.
[0550] The apparent discontinuity between the second outlet chamber
150-2 on the left and the second outlet chamber 150-2 on the right
is simply an artifact of the location of section E-E. No such
discontinuity exists in the second coolant pathway 702. The second
coolant pathway 702 is designed to be free flowing such that only a
small pressure drop (e.g. about 1.5 psi) is observed between the
second inlet port 105-2 and the second outlet port 110-2 when
pressurized coolant is delivered to the second coolant pathway
702.
[0551] FIG. 51 N shows flow vectors associated with the first
coolant pathway 701 and flow vectors associated with the second
coolant pathway 702. To provide an even flow distribution across
the inlets of the plurality of orifices 155-1 in the first inlet
chamber 145-1, the first coolant pathway 701 can include a flow
diverter 706, as shown in FIG. 51N. The flow diverter 706 can have
a shape similar to an airfoil with a curved surface 706. As a
result of fluid dynamics, the curved surface 706 causes incoming
coolant to flow in close proximity to the curvature of the curved
surface 706, similar to the way air flow follows the curvature of a
wing. Without the flow diverter 706, the incoming flow would hug a
left perimeter of the first coolant pathway 701 and potentially
starve orifices 155 located near a center or right perimeter of the
array of orifices.
[0552] FIG. 51O is a top view of the redundant heat sink module
700. The first coolant pathway 701 has a first inlet port 105-1 and
a first outlet port 110-1, and the second coolant pathway 702 has a
second inlet port 105-2 and a second outlet port 110-2. In some
examples, coolant can enter the first inlet port 105-1 as liquid
flow and exit the first outlet port 110-1 as two-phase bubbly flow.
Likewise, coolant can enter the second inlet port 105-2 as liquid
flow and exit the second outlet port 110-2 as two-phase bubbly
flow.
[0553] When cooling a heated surface 12 that experiences rapid
increases in heat flux, such as an electric motor of an electric
vehicle, it can be desirable to configure the redundant cooling
apparatus 2 to manage transient heat loads without experiencing
critical heat flux. In one example, the redundant heat sink module
700 can be operated as shown in FIG. 51Q. In this example, during
normal operation, when the heated surface is producing a moderate
heat flux, a first coolant pathway 701 can be operated so that
two-phase bubbly flow is formed therein, and a second coolant
pathway 702 can be operated so that little or no vapor is formed
therein. If the heat load increases rapidly, it will cause phase
change within the second coolant pathway 702, which will provide
additional cooling capacity for the increased heat load. Achieving
parallel flows of bubbly flow and liquid flow can be achieved in
several possible ways. Where both coolant pathways are transporting
the same type of coolant (e.g. HFE-7000), the flow rate of coolant
50 in the second cooling pathway 702 can be increased until no
vapor forms therein. Due to its higher flow rate, the second
cooling pathway 702 will have greater cooling capacity than the
first coolant pathway 701, and will be able to safely manage rapid
increases in heat flux and thereby avoid onset of critical heat
flux. In this example, the pressure of the flow 51 of coolant in
the second coolant pathway 702 can be set higher than the pressure
of the flow of coolant in the first coolant pathway 701 to provide
a higher saturation temperature in the second coolant pathway 702
than in the first coolant pathway 701. In another example, the
first coolant pathway 701 can transport a first coolant having a
first boiling point, and the second coolant pathway 702 can
transport a second coolant having a second boiling point, where the
second boiling point is higher than the first boiling point. In one
specific example, the first coolant can be HFE-7000 with a boiling
point of 34 degrees C. at one atmosphere, and the second coolant
can be HFE-7100 with a boiling point of 61 degrees C. at one
atmosphere. The flow rate and/or pressure of the second coolant can
be increased to provide excess cooling capacity in the second
coolant pathway to safely manage rapid increases in heat flux and
thereby avoid onset of critical heat flux.
[0554] FIG. 51P shows a top view of the redundant heat sink module
similar to FIG. 51Q, except that the first coolant pathway 701 is
transporting a flow of liquid coolant, and the second coolant
pathway 702 is transporting two-phase bubbly flow. For heat sources
that have non-uniform heat distributions, such as multi-core
processors, it can be desirable to select a configuration where the
coolant pathway with excess cooling capacity (i.e. the coolant
pathway that is transporting a flow of liquid coolant) is situated
over the portion of the heat source that is likely to experience a
rapid increase in heat flux.
[0555] Dimensions, volumes, and/or ratios associated with orifices
(155, 156), chambers (145, 150), ports (105, 110), passages (165,
166), jet heights 18, boiling inducing members 196, and dividing
members 195 described herein with respect to the non-redundant heat
sink modules 100 also apply to corresponding features of the
redundant heat sink modules 700. Coolant pressures and flow rates
described herein with respect to non-redundant heat sink modules
100 also apply to each independent coolant pathway (701, 702) in
the redundant heat sink modules 700.
Portable Servicing Unit
[0556] A portable servicing unit can be provided to aid in draining
the cooling apparatus 1, for example, when servicing or repairing
the cooling apparatus. The portable servicing unit can include a
vacuum pump. The portable servicing unit can include a hose, such
as a flexible hose, having a first end a second end. A first end of
the hose can be configured to fluidly connect to an inlet of the
vacuum pump of the portable servicing unit. A second end of the
hose can be configured to fluidly connect to a connection point
(e.g. a drain 245) of the cooling apparatus 1 through, for example,
a threaded fitting or a quick-connect fitting. The portable machine
can include a portable reservoir fluidly connected to an outlet of
the vacuum pump. When connected to the cooling apparatus 1 and
activated, the vacuum pump of the portable servicing unit can apply
vacuum pressure to the cooling apparatus 1 by way of the hose,
which results in coolant flowing from the cooling apparatus,
through the hose and vacuum pump, and into the portable reservoir.
When servicing is complete, fluid from the portable reservoir can
be pumped back into the cooling system or transported to an
appropriate disposal or recycling facility. In some examples, the
portable servicing unit can include one or more thermoelectric
heaters. The thermoelectric heaters can be placed in thermal
communication with components of the cooling apparatus 1, and by
transferring heat to coolant within the apparatus, the
thermoelectric heaters can promote evacuation of fluid from the
apparatus through a drain 245 or other access point in the
apparatus.
3D Printing
[0557] One or more components of the cooling apparatus 1 can be
manufactured by a three-dimensional printing process. The heat sink
module 100, redundant heat sink module 700, or portions of either
heat sink module, such as an insertable orifice plate 198 or module
body 104, can be manufactured by a three-dimensional printing
process. One example of a suitable 3D printer is a Form 1+ SLA 3D
Printer from Formlabs Inc. of Somerville, Mass. One example of a
suitable material for SLA 3D printing is Accura Bluestone Plastic
from 3D Systems.
[0558] In some examples, a three-dimensional manufacturing process
can be used to create tubing 225 used to fluidly connect a first
heat sink module 100 to a second heat sink module, such as the
section of tubing shown in FIG. 73. In some examples, a
three-dimensional printing process can be used to form a combined
heat sink module 100 and section of tubing 225 to eliminate
connectors 120 and potential leak points. In some examples, a
three-dimensional printing process can be used to form two heat
sink modules 100 fluidly connected by a section of tubing 225,
similar to the configuration shown in FIG. 73. This approach can
eliminate potential leak points that would typically exist, for
example, at threaded connections where fittings attach a section of
tubing 225 to an inlet or outlet port (105, 110) of the heat sink
modules. This approach can also reduce installation time and avoid
installation errors.
[0559] In some examples, components of the cooling apparatus 1 can
be formed by a stereolithography process that involves forming
layers of material curable in response to synergistic stimulation
adjacent to previously formed layers of material and successively
curing the layers of material by exposing the layers of material to
a pattern of synergistic stimulation corresponding to successive
cross-sections of the heat sink module. The material curable in
response to synergistic stimulation can be a liquid
photopolymer.
Coolant Temperature, Pressure, and Flow Rate
[0560] In some examples, it can be desirable to maintain coolant
surrounding a surface to be cooled 12 at a pressure that results in
the saturation temperature of the coolant being slightly above the
temperature of jet streams of coolant being projected at the
surface to be cooled 12. As used herein, "maintain" can mean
holding at a relatively constant value over a period of time.
"Coolant surrounding a surface" refers to a steady state volume of
coolant immediately surrounding and in contact with the surface to
be cooled 12, excluding jet streams 16 of coolant projected
directly at the surface to be cooled 12. "Saturation temperature"
is used herein as is it is commonly used in the art. The saturation
temperature is the temperature for a given pressure at which a
liquid is in equilibrium with its vapor phase. If the pressure in a
system remains constant (i.e. isobaric), a liquid at saturation
temperature evaporates into its vapor phase as additional thermal
energy (i.e. heat) is applied. Similarly, if the pressure in a
system remains constant, a vapor at saturation temperature
condenses into its liquid phase as thermal energy is removed. The
saturation temperature can be increased by increasing the pressure
in the system. Conversely, the saturation temperature can be
decreased by decreasing the pressure in the system. In specific
versions of the invention, a saturation temperature "slightly
above" the temperature of jet streams 16 of coolant projected at
the surface to be cooled 12 refers to a saturation temperature of
about 0.5.degree. C., about 1.degree. C., about 3.degree. C., about
5.degree. C., about 7.degree. C., about 10.degree. C., about
15.degree. C., about 20.degree. C., or about 30.degree. C. above
the temperature of coolant 50 projected against the surface.
Establishing a saturation temperature of coolant 50 surrounding a
surface 12 slightly above the temperature of the jet stream 16 of
coolant projected at the surface provides for at least a portion of
the coolant projected at the surface to heat and evaporate after
contacting the surface, thereby greatly increasing the heat
transfer rate and efficiency of the cooling apparatus 1.
[0561] The appropriate pressure at which to maintain the coolant to
achieve the preferred saturation temperatures can be determined
theoretically by rearranging the following Clausius-Clapeyron
equation to solve for P.sub.0:
T B = ( R ln ( P 0 ) .DELTA. H vaporization + 1 T 0 ) - 1
##EQU00001##
where: T.sub.B=normal boiling point (K), R=ideal gas constant
(J-K.sup.-1mol.sup.-1), P.sub.0=vapor pressure at a given
temperature (atm), .DELTA.H.sub.vaporization=heat of vaporization
of the coolant (J/mol), T.sub.0=given temperature (K), and
ln=natural log to the base e.
[0562] In the above equation, the given temperature (T.sub.0) is
the temperature of coolant 50 in contact with, and heated by, the
surface to be cooled 12. The normal boiling point (T.sub.B) is the
boiling point of the coolant at a pressure of one atmosphere. The
heat of vaporization (.DELTA.H.sub.vaporization) is the amount of
energy required to convert or vaporize a given quantity of a
saturated liquid (i.e., a liquid at its boiling point) into a
vapor. As an alternative to determining the appropriate pressure
theoretically, the appropriate pressure can be determined
empirically by adjusting the pressure and detecting evaporation or
bubble generation at a surface to be cooled 12, as shown in FIG.
30. Bubble generation can be visually detected with a human eye
when transparent components, such as a transparent heat sink module
100 or transparent flexible tubing 225, is used to construct the
cooling apparatus 1. In some examples, the heat sink module 100 or
the flexible tubing 225 can be transparent throughout, and in other
examples, at least a portion of the heat sink module 100 or
flexible tubing 225 can be transparent to provide a transparent
window portion that permits a system operator or electronic eye to
visually detect the presence of bubbles 275 within the coolant 50
flow and to make system adjustments based on that visual detection.
For instance, if no bubbles 275 are visually detected exiting the
outlet chamber 150 of the heat sink module 100, the coolant flow
rate can be reduced by reducing the pump 20 speed, thereby reducing
energy consumed by the pump 20 and reducing overall energy
consumption and operating cost. Conversely, if slug or churn flow
is detected (see, e.g. FIGS. 58 and 59B), the coolant flow rate 51
can be increased to eliminate the presence of those unwanted flow
regimes and restore the system to two-phase bubbly flow.
[0563] During operation of the cooling apparatus 1, coolant 50 can
be flowed into an outlet chamber 150 of the heat sink module 100.
The surface to be cooled 12 can be exposed within the outlet
chamber 150 or, as shown in FIG. 30, the surface to be cooled 12
can serve as a bounding surface of the outlet chamber 150 when the
heat sink module 100 is installed on the surface to be cooled 12.
The coolant 50 can be introduced to the outlet chamber 150 at a
predetermined pressure that promotes a phase change upon the liquid
coolant 50 contacting, and being heated by, the surface to be
cooled 12. One example of such a cooling apparatus 1 for performing
various cooling methods described herein is shown in FIG. 11A. The
cooling apparatus 1 can include a heat sink module 100, as shown in
FIGS. 26 and 30. The heat sink module 100 can include an outlet
chamber 150 with a surface 12 to be cooled exposed within the
outlet chamber 150. The pump 20, as shown in FIG. 11A, can provide
coolant 50 at a predetermined pressure to an inlet 21 of the heat
sink module 100.
[0564] The cooling apparatus 1 as described above and as shown in
FIG. 11A can include several steady-state zones having either
liquid flow or two-phase bubbly flow. The nature of the coolant 50
in each zone can depend on the temperature and pressure of the
coolant in each zone. In the example in FIG. 11A, a zone having
high-temperature coolant 52 includes the coolant 50 surrounding the
surface to be cooled 12 within the outlet chamber 150 (excluding
the jet streams 16 of coolant 50 projected into the outlet chamber
150 through the orifices 155 of the heat sink module 100) of the
heat sink module 100 and extends downstream to the heat exchanger
40 (see FIG. 11A for direction of flow 51). Portions of the
high-temperature coolant 52 within the outlet chamber 150 are
preferably at a temperature approximately equal to or above the
saturation temperature. A zone of low-temperature coolant 53
extends from downstream of the reservoir 200 to at least the inlet
port 105 of the first heat sink module 100 and includes the jet
streams 16 of coolant 50 injected into the outlet chamber 150 of
the first heat sink module 100. The low-temperature coolant 53 is
preferably at a temperature slightly below the saturation
temperature of the coolant 50 surrounding the surface 12, wherein
"slightly below" can include 0.5-1, 0.5-3, 1-3, 1-5, 3-7, 5-10,
7-10, 7-15, 10-15, 15-20, 15-30, about 0.5, about 1, about 3, about
5, about 7, about 10, about 15, about 20, or about 30.degree. C. or
more below the saturation temperature of coolant 50 surrounding the
surface to be cooled 12. Heat transfer from the surface to be
cooled 12 to the coolant 50 with the outlet chamber 150 of the heat
sink module 100 serves to transition the low-temperature coolant 53
to high-temperature coolant 52. In some examples, the surface to be
cooled 12 heats a portion of the coolant 50 contacting the surface
12 to its saturation temperature, thereby promoting evaporation and
formation of two-phase bubbly flow, which exits the heat sink
module through the outlet port 110.
[0565] A zone of low-pressure coolant 55 includes the coolant 50
surrounding the surface to be cooled 12 within the outlet chamber
150 (which excludes the jet streams 16 of coolant 50 projecting
into the outlet chamber 150 through the orifices 155 of the heat
sink module) and extends downstream to an inlet 21 of the pump 20.
The low-pressure coolant 55 is preferably at a pressure that
promotes evaporation of coolant 50 when heated at the surface 12.
Therefore, the pressure of the low-pressure coolant 55 preferably
determines a saturation temperature to be about equal to the
temperature of the high-temperature coolant 52. A zone of
high-pressure coolant 54 includes a portion downstream of the pump
outlet 22 and extends to at least the inlet port 105 of the first
heat sink module 100. The high-pressure coolant 54 is preferably at
a pressure suitable for generating jet streams 16 of coolant that
are capable of penetrating liquid present in the outlet chamber 150
and impinging the surface to be cooled 12. In some examples, the
pump 20 can provide high-pressure coolant 54 at a pressure of about
1-20, 10-30, 25-50, 40-60, or 50-75, 60-80, or 75-100 psi. In other
examples, the pump 20 can provide high-pressure coolant 54 at a
pressure of about 85-120, 100-140, 130-160, 150-175, 160-185,
175-200, or greater than 200 psi.
[0566] The pump 20 serves to transition low-pressure coolant 55 to
high-pressure coolant 54 as the coolant passes from the pump inlet
21 to the pump outlet 22. In some examples, the pump 20 can provide
high-pressure coolant 54 at a pressure that is about 10-20, 15-30,
20-40, 30-45, or 40-60 psi or greater above the pressure of the
low-pressure coolant 55. The high-pressure coolant 54 in the
cooling apparatus 1 applies a positive pressure against the
plurality of orifices 155 in the heat sink module 100, and the
plurality of orifices 155 serve to transition the high-pressure
coolant 54 to low-pressure coolant 55, as the coolant 50
equilibrates to the pressure of the low-pressure coolant 55 after
passing through the plurality of orifices as jet streams 16 and
mixing with the coolant in the outlet chamber 150 of the heat sink
module 100.
[0567] With the apparatus 1 described above, a flow rate is set by
the pump 20 to handle the expected heat load produced by the
surface to be cooled 12. A specific pressure for the low-pressure
coolant 55 is set and maintained by one or more pumps 20 and by one
or more valves 60, as shown in the various schematics presented in
FIGS. 11A-14, 16-18, and 68-72 to establish a saturation
temperature for the coolant 50 surrounding the surface to be cooled
12 to be slightly above the saturation temperature of the
low-temperature coolant 53. Relatively high-pressure 54
low-temperature 53 coolant 50 is projected as jet streams 16 from
the plurality of orifices 155 against the surface to be cooled 12,
whereby the coolant 50 undergoes a pressure drop upon equilibrating
with fluid present in the outlet chamber 150 and a portion of the
fluid may heat to its saturation temperature upon contacting the
surface 12 and absorbing heat from the surface. A portion of the
heated coolant 50 undergoes a phase transition at the surface to be
cooled 12, which causes highly efficient cooling of the surface 12.
Downstream of the heat sink module 100, the relatively low-pressure
55, high-temperature 52 coolant flow is then mixed with
low-pressure 55, low-temperature 54 coolant from the second bypass
310 to promote condensing of vapor bubbles 275 within the
low-pressure 55, high temperature 52 coolant by cooling it below
its saturation temperature, which produces a flow of low-pressure
55, low-temperature 53 coolant in the return line 230 that returns
the coolant 50 to the reservoir 200. Upon being drawn form the
lower portion of the reservoir 200 to the pump inlet 21, the
low-pressure 55, low-temperature 53 coolant is then transitioned to
high-pressure 54, low-temperature 53 coolant as it passes through
the pump 20. The high-pressure 54, low-temperature 53 coolant is
then circulated back to the inlet port 105 of the first heat sink
module 100 and the above-described process is repeated.
Cooling System Preparation and Operation
[0568] In some applications, it can be desirable to fill the
cooling apparatus 1 with a dielectric coolant 50 that is at a
pressure below atmospheric pressure (e.g. less than about 14.7
psi). For example, when cooling microprocessors 415, it can be
desirable fill the cooling apparatus 1 with HFE-7000 (or a coolant
mixture containing HFE-7000 and, for example, R-245fa) that is at a
pressure below atmospheric pressure to reduce the boiling point of
the dielectric fluid. To accomplish this, the portable servicing
unit (or other vacuum source) can be used to apply a vacuum to the
cooling apparatus 1 to purge the contents of the cooling apparatus.
Upon reducing the pressure within the cooling apparatus 1 to about
0-3, 0-5, 1-5, 4-8, 5-10, or 8-14.5 psi, the dielectric coolant 50
can be added to the cooling apparatus 1. In some examples,
operation of the pump 20 may only increase the pressure of the
dielectric coolant about 1-15, 5-20, or 10-25 psi above the
baseline sub-atmospheric pressure. Consequently, the operating
pressure of the high pressure coolant 54 within the cooling
apparatus 1 may be about equal to atmospheric pressure (e.g. about
8-14, 10-16, 12-18, or 14-20 psi), thereby ensuring that that
saturation temperature of the dielectric coolant remains low enough
to ensure that boiling can be achieved when jet streams 16 of
coolant impinge the surface to be cooled 12 associated with a
microprocessor 415. Providing high-pressure coolant 54 at a
pressure near atmospheric pressure has other added benefits. First,
low pressure tubing 225 can be used, which is lightweight,
flexible, and low cost. Second, because of the minimal pressure
difference between the high-pressure coolant 54 and the surrounding
atmosphere, fluid leakage from fittings and other joints of the
cooling apparatus 1 may be less likely.
Temperature Conditioning of Coolant
[0569] The cooling apparatus 1 can include any suitable heat
exchanger 40 configured to promote heat rejection from the flow 51
of coolant to effectively sub-cool the coolant. By enabling heat
rejection from the coolant 50, the heat exchanger 40 can ensure the
reservoir 200 maintains a volume of subcooled liquid that can be
safely supplied to the pump 20 without risk of vapor lock or
instability. Any heat exchanger 40 capable of reducing the
temperature of the coolant 50 below its saturation temperature is
acceptable. For instance, the heat exchanger 40 can be any suitable
air-to-liquid heat exchanger or liquid-to-liquid heat exchanger.
Non-limiting types of suitable heat exchangers include
shell-and-tube, fin-and-tube, micro-channel, plate,
adiabatic-wheel, plate-fin, pillow-plate, fluid,
dynamic-scraped-surface, phase-change, direct contact, and spiral
type heat exchangers. The heat exchanger 40 can operate using
parallel flow, counter flow, or a combination thereof. In one
example, a liquid-to-liquid heat exchanger 40 can be a Standard
Xchange Brazepak brazed plate heat exchanger from Xylem, Inc. of
Rye Brook, N.Y.
[0570] A first liquid-to-liquid heat exchanger 40, as shown in
FIGS. 92-95 and 97, can be connected to an external heat rejection
loop 43, as shown in FIG. 77. The external heat rejection loop 43
can carry a flow of external cooling fluid 42, such as water or a
water-glycol mixture. A second pump 20 can circulate the flow of
external cooling fluid 42 through the heat rejection loop 43, as
shown in FIG. 77. As the flow of external cooling fluid 42 is
circulated through the first liquid-to-liquid heat exchanger 40,
heat can be transferred from the flow 51 of dielectric coolant 50
to the flow of external cooling fluid 42, thereby subcooling the
flow 51 of dielectric coolant 50 in the first bypass 305 and
heating the flow of external cooling fluid 42. The heated external
cooling fluid 42 is then circulated through a second
liquid-to-liquid heat exchanger 40 located outside of the room 425
where the cooling apparatus 1 is installed. The second
liquid-to-liquid heat exchanger 40 can be connected to a flow of
chilled water 46, such as a chilled water supply from a building.
As the heated external cooling fluid 42 circulates through the
second liquid-to-liquid heat exchanger 40, heat is transferred from
the flow of external cooling fluid 42 to the flow of chilled water,
thereby completing heat rejection from the cooling apparatus 1 to
the flow of chilled water by way of the heat rejection loop 43.
[0571] A cooling apparatus 1 as shown in FIG. 77 can use HFE-7000
as a primary coolant 50 circulating through one or more heat sink
modules 100, a heat rejection loop 43 circulating a flow of a
water-glycol mixture 42 as an external cooling fluid to transfer
heat from a first heat exchanger 40-1 to a second heat exchanger
40-2, and a flow of chilled water 46 from a building supply line as
a third heat exchange medium to carry heat away from the second
heat exchanger 40-2. In one example, during operation, the flow
51-1 of subcooled liquid coolant 50 can be about 25-30 degrees C.
and about 10-20 psia at an inlet of the first liquid-to-liquid heat
exchanger 40-1 and about 20-25 degrees C. at an outlet of the first
liquid-to-liquid heat exchanger. The liquid in the reservoir 200,
which can be a subcooled liquid with an average temperature of
about 25-30 degrees C., which is about 5-10 degrees below the
saturation temperature of HFE-7000 at the operating pressure. Where
a high heat load from heated surface 12 is expected, it can be
desirable to further subcool the flow 51-2 of liquid coolant
delivered to the inlet of the heat sink module 100. For instance,
it can be desirable to deliver a flow 51-2 of subcooled coolant to
the heat sink module that is about 15-25 degrees C., which is about
10-15 degrees below the saturation temperature of HFE-7000 at the
operating pressure. The flow of external cooling fluid 42 can be
about 10-15 degrees C. at an inlet of the first liquid-to-liquid
heat exchanger 40-1 and about 15-20 degrees C. at an outlet of the
first liquid-to-liquid heat exchanger 40-1. The flow of chilled
water 46 can be about 4-7 degrees C. at an inlet of the second
liquid-to-liquid heat exchanger 40-2 and about 9-12 degrees C. at
an outlet of the second liquid-to-liquid heat exchanger. The flow
of external cooling fluid 42 can be about 15-20 degrees at an inlet
of the second liquid-to-liquid heat exchanger and about 10-15
degrees at an outlet of the second liquid-to-liquid heat exchanger.
These values are provided as an example of one suitable operating
condition and are non-limiting. The temperatures can vary as flow
rates, pressures, and heat loads change or when different coolants
50, external cooling fluids 42, heat rejection loop 43
configurations, or system configurations are used.
[0572] In another example, a liquid-to-liquid heat exchanger 40 can
be connected to an external heat rejection loop 43, as shown in
FIG. 75. The external heat rejection loop 43 can carry a flow of
external cooling fluid 42, such as water or a water-glycol mixture.
A second pump 20-2 can circulate the flow of external cooling fluid
42 through the heat rejection loop 43. As the flow of external
cooling fluid 42 is circulated through the first liquid-to-liquid
heat exchanger 40-1, heat can be transferred from the flow 51-1 of
dielectric coolant 50 to the flow of external cooling fluid 42,
thereby subcooling the flow 51-1 of dielectric coolant 50 in the
first bypass 305 and heating the flow of external cooling fluid 42.
The heated external cooling fluid 42 is then circulated through an
air-to-liquid heat exchanger 40-2 located outside of the room 425
where the cooling apparatus 1 is installed. The air-to-liquid heat
exchanger 40-2 can be a radiator or a dry cooler having one or more
fans 26 configured to provide airflow across a structure of the
heat exchanger. As the heated external cooling fluid 42 circulates
through the air-to-liquid heat exchanger 40-2, heat is transferred
from the flow of external cooling fluid 42 to the flow of air,
thereby completing heat rejection from the cooling apparatus 1 to
ambient air by way of the heat rejection loop 43. As shown in FIG.
75, the air-to-liquid heat exchanger 40-2 can be located outside
the room 425 where the surface to be cooled 12 is located to avoid
rejecting the heat to the ambient air in the room 425 and thereby
increasing the air temperature in the room 425.
[0573] In some examples, the heat exchanger 40 can be a
liquid-to-liquid heat exchanger 40 that is directly connected to a
flow of external cooling fluid 46, such as chilled water from a
building supply line, as shown in FIG. 76. This configuration can
allow heat rejected from the cooling apparatus 1 to be removed from
the room 425 where the cooling apparatus 1 is installed and
transferred directly to a flow of chilled water 46 instead of being
rejected into the room air or through an intermediate heat
rejection loop 43, as shown in FIG. 77. In this example, care
should be taken to regulate the flow rate of chilled water 46
through the heat exchanger 40 to avoid cooling the dielectric
coolant 50 to a temperature at or below its dew point.
[0574] In any of the cooling apparatuses 1 described herein, the
flow rate of coolant 50-1 through the heat exchanger 40 can be
monitored and controlled to avoid reducing the temperature of the
low-temperature 53 coolant to or below the dew point of ambient air
in the room 425 where the surface to be cooled 12 is located.
Reaching or dropping below the dew point of the ambient air is
undesirable, since it can cause condensation to form on an outer
surface of the flexible tubing 225 or other components of the
cooling apparatus 1. If this occurs, water droplets can form on and
fall from the outer surface of the tubing 225 onto sensitive
electrical components within the server 400, such as the
microprocessor 415 or memory modules 420, which is undesirable.
Consequently, the low-temperature 53 coolant should be maintained
at a temperature above the dew point of ambient air in the room 425
to ensure that condensation will not form on any components of the
cooling apparatus 1 that are in close proximity to sensitive
electrical devices being cooled.
[0575] In some examples, if the low-temperature 53 coolant is
cooled below the dew point of ambient air in the room by the heat
exchanger 40, a preheater can be provided in line with, or upstream
of, the line (e.g. flexible tubing 225) that transports coolant 50
flow into the server 400 housing and into the heat sink module 100.
The preheater can be used to heat the flow of coolant 51 to bring
the coolant temperature above its dew point temperature, thereby
avoiding potential complications caused by condensation forming on
the lines within the server housing. In some examples, the
preheater can be configured to operate only when needed, such as
when the temperature of the low-temperature coolant drops below its
dew point.
[0576] The temperature of the low-temperature coolant 52 can be
monitored with one or more temperature sensors positioned in the
cooling lines, and data from the sensors can be input to the
controller. For instance, a first temperature sensor can be
positioned upstream of the preheater, and a second temperature
sensor can be positioned downstream of the preheater. When the
first temperature sensor detects a coolant temperature that is
below the dew point of ambient air in the room 425, the controller
can be configured to activate the preheater to heat the
low-temperature coolant 52 to bring the temperature of the
low-temperature coolant above the dew point of the ambient air in
the room 425. In some examples, the rate of heat addition can be
ramped up gradually, and once the temperature detected by the
second temperature sensor is above the dew point of the ambient
air, the controller can be configured to stop ramping the rate of
heat addition and instead hold the heat addition constant. The
controller can continue instructing the preheater to heat the
low-temperature coolant 52 until preheating is no longer needed.
For instance, the controller can continue instructing the preheater
to heat the low-temperature coolant 52 until the temperature
detected by the first temperature sensor is above the dew point of
the ambient air.
[0577] Although the preheating process described above includes
measuring the temperature of the low-temperature coolant 52
directly, in other examples the surface temperature of the outer
surface of the tubing (e.g. 225) can be measured instead of
measuring the coolant temperature directly. For instance,
temperature sensors can be affixed directly to the outer surface of
the tubing (e.g. 225) upstream and downstream of the preheater. In
some instances, this approach can permit faster installation of the
temperature sensors and can reduce the number of potential leak
points in the cooling apparatus 1. In other examples, a contactless
temperature-sensing device, such as an infrared temperature sensor,
can be used to detect the temperature of the coolant or the
temperature of the tubing 225 transporting the coolant.
[0578] To ensure the temperature of the low temperature coolant 52
remains above the dew point temperature of the ambient air, the
flow rate through the heat exchanger 40 can be decreased and/or the
fan speed of a fan 26 mounted on the heat exchanger 40 can be
reduced to lower the heat rejection rate from the heat exchanger 40
if a low temperature threshold is detected in the low-temperature
coolant. This step can be taken instead of, or in conjunction with,
using the preheater to avoid dew formation on any components of the
cooling apparatus 1.
[0579] In some examples, the heat exchanger 40 can be upstream of
the valve 60 in the first bypass 305 (see, e.g. FIG. 12A) and in
other examples, the heat exchanger 40 can be downstream of the
valve 60 in the first bypass 305 (see, e.g. FIG. 11A). "Downstream"
and "upstream" are used herein in relation to the direction of flow
51 of coolant 50 within the cooling apparatus 1. In other examples,
the heat exchanger 40 can be located in the second bypass 310 or in
the primary cooling loop 300.
[0580] The cooling apparatuses (1, 2) shown in FIGS. 11A-11D,
12A-12Q, 12S, 13, 14A, 16-18, and 68-72 may show heat exchangers 40
that appear to be stand-alone heat exchangers. However, in each of
these examples, the heat exchanger 40 can be connected to an
external heat rejection loop 43 that circulates a flow of external
cooling fluid 42, such as water or a water-glycol mixture, as shown
in FIGS. 75 and 77. The external heat rejection loop 43 can be
fluidly connected to the heat exchanger 40 of the cooling apparatus
(1, 2) and can be configured to transfer heat from the dielectric
coolant 50 and reject the heat to air or an other fluid outside the
room 425 where the cooling system 1 is installed. This allows the
cooling apparatus 1 to avoid rejecting the heat into the room 425
where the cooling apparatus is installed, which would increase the
temperature of the room air and place a higher load on the room air
conditioner. In each example, the external heat rejection loop 43
can be any suitable heat rejection loop 43, such as the heat
rejection loops shown in FIGS. 12R and 75-77. The external heat
rejection loop 43 can include any suitable external heat exchanger
40, such as a liquid-to-liquid heat exchanger 40-2 as shown in FIG.
77 or an air-to-liquid heat exchanger 40-2 as shown in FIG. 75.
Alternately, the heat rejection loop 43 may not include an external
heat exchanger, such as in FIG. 76, where a flow of chilled water
46 from a building is connected directly to the heat exchanger 40
of the cooling apparatus 1.
Flow within Cooling Apparatus
[0581] Flow rates in the cooling apparatus 1 can be adjusted to
ensure stable two-phase flow within the cooling apparatus 1. More
specifically, flow rates within the cooling apparatus 1 can be
adjusted to promote reliable condensing of vapor within a two-phase
flow in the cooling apparatus by mixing the two-phase flow (e.g.
51-2) exiting the one or more heat sink modules 100 with subcooled
liquid flow from the first and/or second bypass (e.g. 51-1, 51-3),
either within the outlet manifold 215, the return line 230, and/or
the reservoir 200. This approach achieves reliable condensing of
vapor upstream of the pump 20 to ensure that only single-phase
liquid coolant is provided to the pump inlet 21 and, therefore, the
pump 20 is only tasked with pumping single-phase liquid coolant,
which can be pumped more efficiently and reliably than two-phase
flow.
[0582] In some examples, the flow rate 51 of coolant 50 provided by
the pump 20 in the cooling apparatus 1 can be selected based, at
least in part, on the number of heat sink modules 100 fluidly
connected to the primary cooling loop 300. In many instances, a
flow rate of about 0.25-5, 0.5-1.5, 0.8-1.2, 0.9-1.1, or about 1
liter per minute through each heat sink module 100 can be
desirable. For a configuration as shown in FIG. 75, where only one
heat sink module 100 is provided, the flow of coolant 51-2 through
the primary cooling loop 300 can be about 1.0 liter per minute in
one specific example. The flow rate 51-3 delivered to the second
bypass 310 can be about equal to the flow rate 51-2 in the primary
cooling loop 300 (i.e. 1.0 liter per minute). The flow rate 51-1 in
the first bypass 305, which is passed through the heat exchanger
40-1, can be about equal to the sum of the flow rate 51-2 in the
primary cooling loop and the flow rate 51-3 in the second bypass
310 (i.e. 51-1=51-2+51-3), or about 2.0 liters per minute.
Consequently, the total flow rate 51 provided by the pump 20-1 can
be about four times the flow rate 51-2 in the primary cooling loop
300 (i.e. 51=4*51-2). Therefore, the total flow rate 51 provided by
the pump 20-1 can be about 4 liters per minute in this specific
example. When higher heat loads are encountered, the total flow
rate 51 can be increased to ensure flow stability within the
cooling apparatus 1.
[0583] FIG. 75 shows a basic cooling apparatus 1 having a primary
cooling loop 300 with a single heat sink module 100. In more
complicated cooling apparatuses 1, such as the cooling apparatus 1
shown in FIG. 78, the flow 51-2 delivered to the primary cooling
loop 300 can be distributed among one or more cooling lines 303
extending between an inlet manifold 210 and an outlet manifold 215.
Consequently, a portion of the primary cooling loop 300 can include
a plurality of cooling lines 303 extending from an inlet manifold
210 to an outlet manifold 215.
[0584] In FIG. 78, the inlet and outlet manifolds (210, 215) are
configured to accommodate up to twelve cooling lines 303, but only
eight cooling lines are shown connected. Consequently, the cooling
apparatus 1 in FIG. 78 can be expanded during operation of the
cooling apparatus 1 to include four additional cooling lines 303 as
additional cooling is required (e.g. as additional servers 400 are
added to a rack 410 of servers). Each cooling line 303 can be
fluidly connected to the inlet and outlet manifolds (210, 215)
using, for example, quick-connect fittings 235. Each cooling line
303 can include one or more heat sink modules 100 arranged on
heat-providing surfaces 12, such as on microprocessors 415 in
servers 400. When a new server 400 is added to the server rack 405,
a new cooling line 303 can be rapidly connected to the inlet and
outlet manifolds (210, 215) using quick-connect fittings 235, and
each heat sink module 100 that is fluidly connected to the cooling
line 303 can be mounted on a heat-providing surface 12 (e.g.
microprocessor, RAM, or power supply) within the new server 400 to
provide efficient, local cooling. This flexible configuration
allows the cooling apparatus 1 to be easily modified to meet the
cooling requirements of a growing collection of servers 400 (e.g.
in a computer room 425) by simply adding additional cooling lines
303 to the existing cooling apparatus 1. The use of quick-connect
fittings 235 can allow additional cooling lines 303 to be added
while the cooling apparatus 1 is operating without risking coolant
leakage or pressure loss. One example of a suitable quick-connect
fitting is a NS4 Series coupling available from Colder Products
Company of St. Paul, Minn. The quick-connect fitting 235 can
include a non-spill shut-off valve 723 and can be made of a
glass-filled polypropylene or medical-grade ABS material. The
non-spill valve 723 can allow the quick-connect fitting 235 to be
disconnected under pressure without spilling any coolant 50. When
Novec 7000 is used as the coolant, the quick-connect fitting 235
can include silicone-based grease in the non-spill shut-off valve
723 to ensure compatibility with the coolant. Likewise, seals (e.g.
o-rings) in the quick-connect fitting 235 can be made of butyl
rubber to ensure compatibility with Novec 7000. Silicon-based
grease and butyl rubber seals are low cost and easy to obtain.
Other compatible materials can also be used.
[0585] The quick-connect fitting 235 can include a coupler body and
a coupler insert. The coupler body can be the female coupler
component, and the coupler insert can be the male coupler
component. The coupler body can receive the coupler insert to form
a fluid-tight seal. The quick-connect fitting 235 can include one
or more seals to provide the fluid-tight seal between the coupler
body and the coupler insert.
[0586] In some examples, the flow rate 51 provided by the pump 20-1
can be selected based, at least in part, on the number of cooling
lines 303 (i.e. maximum number of cooling lines or the actual
number of cooling lines 303) extending between the inlet manifold
210 and the outlet manifold 215. For instance, in FIG. 78, the flow
rate 51 provided by the pump 20-1 can be selected to accommodate
eight cooling lines 303 extending between the inlet manifold 210
and the outlet manifold 215, or the flow rate 51 provided by the
pump 20-1 can be selected to accommodate twelve cooling lines 303
extending between the inlet manifold 210 and the outlet manifold
215. Selecting the flow rate 51 to accommodate the actual number of
cooling lines 303 (i.e. eight) can provide more efficient operation
by reducing the flow rate 51 required from the pump 20-1. Selecting
the flow rate 51 to accommodate the maximum number of cooling lines
303 can ensure adequate flow to allow an operator to connect
additional cooling lines 303 without resulting in unstable
operation of the cooling apparatus 1. The electronic control unit
850 can allow a system operator to input a number of cooling lines
303 through a graphical user interface (GUI). This approach can be
useful for cooling apparatuses 1 that are not equipped with sensors
880.
[0587] In some examples, the electronic control unit 850 can
determine how many cooling lines 303 are connected and
automatically adjust the flow 51 if cooling lines are added or
removed. For cooling apparatuses 1 that are equipped with sensors
that allow the electronic control unit 850 to determine how many
cooling lines 303 are connected between the manifolds, the pump
20-1 speed can be adjusted to provide a flow rate 51 based on the
number of detected cooling lines 303. In some examples, the sensors
can be flow sensors that detect the presence of flow passing
through quick connect fitting 235 connected to the manifold. In
another example, the sensors 880 can be proximity sensors that
detect the presence of quick connect couplers connected to the
manifold and output a signal to the electronic control unit
850.
[0588] In FIG. 79, the flow rate 51 provided by the pump 20-1 can
be selected to accommodate thirty cooling lines 303 extending
between the inlet manifold 210 and the outlet manifold 215. This
configuration can be suitable for cooling thirty servers 400
arranged in close proximity in a server rack 405. A flow rate of
about 1.0 liter per minute can be selected as a suitable flow rate
through each cooling line 303. Since there are thirty cooling lines
303, a total flow rate through the primary cooling loop 300 of
about 30 liters per minute can be provided. A similar flow rate
51-2 of about 30 liters per minute can be delivered through the
second bypass 305, which in the example of FIG. 79 is arranged
between the inlet and outlet manifolds (210, 215). The flow rate
51-1 through the first bypass 305 can be about equal to a sum of
the flow through the primary cooling loop 300 and the flow through
the second bypass 310 (i.e. 51-1=51-2+51-3). Therefore, the flow
rate 51-1 through the first bypass can be about 60 liters per
minute in this example, and the total flow rate 51 provided by the
pump 20-1 can be about 120 liters per minute
(51=51-1+51-2+51-3).
[0589] In the example shown in FIG. 79, a flow of subcooled liquid
coolant 50 can be provided to the inlet manifold 210 by the pump
20-1. In some instances, about half of the flow delivered to the
inlet manifold 210 can be routed through the valve 60 in the second
bypass 310, and the other half of the flow can be routed through
the thirty cooling lines 303. To ensure stable operation of the
cooling apparatus 1, it is preferable to condense the two-phase
bubbly flow in the outlet manifold 215 or return line 230 before it
returns to the reservoir 200. This reduces the chance of vapor
being introduced to the pump 20-1 and causing vapor lock or flow
instabilities. The amount of heat that can be removed by the
cooling apparatus 1 can be defined by the following equation:
Q.sub.sensible={dot over
(m)}.sub.liquid.times.c.sub.p.times..DELTA.T.sub.subcooled
where Q.sub.sensible is the amount of heat in Watts, {dot over
(m)}.sub.liquid is the mass flow rate through the cooling lines 303
and the second bypass 310 (i.e. {dot over
(m)}.sub.liquid=m.sub.coolant.times.(51-2+51-3)), 51-2 is the flow
rate through all cooling lines 303 in the primary cooling loop 300,
51-3 is the flow rate through the second bypass 310, c.sub.p is the
specific heat of the coolant in J/(kg-K), and
.DELTA.T.sub.subcooled is the difference in degrees C. between the
saturation temperature (T.sub.sat) of the coolant in the inlet
manifold 210 and the actual temperature of the coolant in the inlet
manifold (i.e. .DELTA.T.sub.subcooled=T.sub.sat-T.sub.inlet
manifold). In one example of the apparatus 1 shown in FIG. 79,
where the coolant is HFE-7000, the specific heat is about 1300
J/(kg-K) and the mass is about 1.4 kg/liter. Altogether, about 30
liters per minute of coolant 50 can be pumped through the cooling
lines 303, resulting in 51-2 equaling 30 liters per minute. The
flow rate 51-3 being pumped through the second bypass 310 can be
about 30 liters per minute. The total flow rate (51-2+51-3)
delivered to the inlet manifold 210 can be about 60 liters per
minute, which is equal to about 1.4 kg/sec when the coolant is
HFE-7000. The coolant 50 delivered to the inlet manifold 210 can be
subcooled about 10 degrees C. below its saturation temperature at
the inlet manifold pressure. Based on these conditions, the amount
of heat Q that can be removed by the cooling apparatus in FIG. 79
is about 18,200 W. Adding 18,200 watts of heat to the coolant 50
will increase the bulk coolant temperature to its saturation
temperature. It can be desirable not to exceed this amount of heat,
since doing so would not allow for complete condensing of the vapor
in the outlet manifold 215 or return line 230 upstream of the
reservoir 200. Although condensing can also be accomplished in the
reservoir 200, to provide greater stability, it can be desirable to
achieve condensing upstream of the reservoir 200 to reduce the
chance of vapor being drawn from the reservoir into the pump
20-1.
[0590] Within the cooling apparatus 1, heat can be removed from the
plurality of heated surfaces 12 by vaporizing the coolant 50 within
the heat sink modules 100. In the example discussed above relating
to FIG. 79, before vaporization can occur, the subcooled coolant
that is delivered to the cooling lines 303 must first heat to its
saturation temperature via sensible heating. To simplify this
calculation, we assume that all of the flow 51-2 in the cooling
lines 303 is heated to its saturation temperature before any
vaporization occurs. A flow rate of 30 liters per minute
corresponds to a mass flow rate ({dot over (m)}.sub.liquid) of
about 0.7 kg/sec when using HFE-7000 as the coolant 50. Using the
equation above, the heat (Q.sub.sensible) required to sensibly heat
the subcooled liquid to its saturation temperature is about 9,100
W, where {dot over (m)}.sub.liquid is 0.7 kg/sec, .DELTA.T
subcooled is 10 degrees C., and c.sub.p is 1300 J/(kg-K). Since the
total amount of heat that can be removed is 18,200 W, and 9,100 W
is removed through sensible heating, this leaves 9,100 W to be
removed through latent heating. Assuming a heat of vaporization
(.DELTA.h.sub.vaporization) of about 140 kJ/kg for HFE-7000, we can
use the following equation to determine the mass flow rate of vapor
that is generated by absorbing 9,100 W of heat:
Q.sub.latent={dot over
(m)}.sub.vapor.times..DELTA.h.sub.vaporization
Where the heat of vaporization is about 140 kJ/kg, providing 9,100
W of heat to coolant that is already at its saturation temperature
will produce about 0.065 kg/sec of vapor. Where the mass flow rate
of vapor is about 0.065 kg/sec and the mass flow rate of liquid is
about 0.7 kg/sec, an average flow quality (x) of about 9% is
established. This is safe and stable flow quality (x) corresponding
to bubbly flow and is well below the transition to slug flow
described in FIG. 59B.
[0591] In one example, a method of providing stable operation of a
cooling apparatus 1 containing two-phase bubbly flow can include
providing a cooling apparatus having a primary cooling loop 300.
The primary cooling loop 300 can include a pump 20-1 configured to
provide a flow 51 of single-phase liquid coolant 50 at a pump
outlet 22-1, as shown in FIG. 81. The flow 51 of single-phase
liquid coolant can be a dielectric coolant 50 such as, for example,
HFE-7000, HFE-7100, or R-245fa. The dielectric coolant 51 can have
a boiling point of about 15-35 or 30-65 degrees C. at a pressure of
1 atmosphere. The primary cooling loop 300 can include a reservoir
200 fluidly connected to the primary cooling loop 300 and located
upstream of the pump 20-1 and configured to store a supply of
single-phase liquid coolant 50 that can be supplied to an inlet
21-1 of the pump 20-1. The primary cooling loop 300 can include one
or more heat sink modules 100 fluidly connected to the primary
cooling loop. Each heat sink module 100 can be configured to mount
on and remove heat from a heat-providing surface 12, such as a
surface associated with a microprocessor 415 in a personal computer
or server 400.
[0592] The cooling apparatus 1 can include a first bypass 305
having a first end and a second end, as shown in FIG. 81. The first
end of the first bypass 305 can be fluidly connected to the primary
cooling loop 300 downstream of the pump outlet 22-1. The second end
of the first bypass 305 can be fluidly connected to the primary
cooling loop 300 at the reservoir 200. The first bypass 305 can
include a first heat exchanger 40-1 and a first valve 60-1. The
first valve 60-1 can be configured to regulate a first bypass flow
51-1 of the flow 51 of single-phase liquid coolant through the
first heat exchanger 40-1. The first heat exchanger 40-1 can be
configured to subcool the first bypass flow 51-1 of coolant 50
below a saturation temperature of the coolant.
[0593] The cooling apparatus 1 can include a second bypass 310
having a first end and a second end, as shown in FIG. 81. The first
end of the second bypass 310 can be fluidly connected to the
primary cooling loop 300 downstream of the pump outlet 22-1 and
downstream of the first end of the first bypass 305 and upstream of
the one or more heat sink modules 100. The second end of the second
bypass 310 can be fluidly connected to the primary cooling loop 300
downstream of the one or more heat sink modules 100 and upstream of
the reservoir 200. The second bypass 310 can include a second valve
60-2 configured to regulate a second bypass flow 51-3 of the flow
51 of single-phase liquid coolant through the second bypass 310.
The second end of the second bypass 310 can be fluidly connected to
the primary cooling loop 300 upstream of a return line 230 that
transports coolant 50 back to the reservoir 200.
[0594] The method can include setting the first valve 60-1 in the
first bypass 305 to allow about 30-70% of the flow 51 from the pump
outlet 22-1 to be pumped through the first bypass as the first
bypass flow 51-1. The method can include setting the second valve
60-2 in the second bypass 310 to allow 15-50% of the flow 51 from
the pump outlet 22-1 to be pumped through the second bypass 310 as
the second bypass flow 51-3. A remaining portion 51-2 of the flow
51 of single-phase liquid coolant 50 from the pump outlet 22-1 can
be pumped through the one or more heat sink modules 100 and
transformed into two-phase bubbly flow within the one or more heat
sink modules as heat is transferred to the remaining portion 51-2
of the flow from the one or more heat providing surfaces 12. The
method can include mixing the two-phase bubbly flow 51-2 with the
second bypass flow 51-3 upstream of the reservoir 200 to condense
vapor bubbles 275 within the two-phase bubbly flow 51-2.
[0595] Setting the first valve 60-1 in the first bypass 305 to
allow about 30-70% of the flow 51 from the pump outlet 22-1 to be
pumped through the first bypass 305 as the first bypass flow 51-1
can include setting the first valve 60-1 in the first bypass 305 to
allow about 30-40, 35-45, 40-50, 45-55, 50-60, 55-65, or 60-70% of
the flow 51 from the pump outlet 22-1 to be pumped through the
first bypass 305 as the first bypass flow 51-1. Setting the second
valve 60-2 in the second bypass 310 to allow 15-50% of the flow 51
from the pump outlet 22-1 to be pumped through the second bypass
310 as the second bypass flow 51-3 can include setting the second
valve 60-2 in the second bypass 310 to allow 15-25, 20-30, 25-35,
30-40, or 45-50% of the flow 51 from the pump outlet 22-1 to be
pumped through the second bypass 310 as the second bypass flow
51-3.
[0596] The primary cooling loop 300 can include an inlet manifold
210 and an outlet manifold 215 and one or more cooling lines 303
extending between the inlet manifold and the outlet manifold, as
shown in FIGS. 79 and 81. The one or more heat sink modules 100 can
be fluidly connected to the one or more cooling lines 303. Setting
the second valve 60-2 can include setting the second valve 60-2 to
provide a flow rate of about 0.25-1.5, 0.7-1.3, 0.8-1.2, 0.9-1.1,
or 1.0 liters per minute of coolant 50 through each of the one or
more cooling lines 303. Setting the first valve 60-1 can include
establishing a pressure differential of about 5-15 psi between an
inlet and an outlet of the first valve 60-1. Likewise, setting the
second valve 60-2 can include establishing a pressure differential
of about 5-15 psi between an inlet and an outlet of the second
valve 60-2.
[0597] In another example, a method can allow cooling lines 303
extending from an inlet manifold 210 to an outlet manifold 215 of
an operating cooling apparatus 1, as shown in FIG. 78, to be safely
added or removed without causing unstable two-phase flow to develop
within the cooling apparatus 1. The method can include providing a
cooling apparatus 1 with an inlet manifold 210, an outlet manifold
215, a bypass 310 extending from the inlet manifold 210 to the
outlet manifold 215, and M connection ports 235 on each of the
inlet manifold and the outlet manifold to accommodate up to M
cooling lines 303 extending between the inlet manifold and the
outlet manifold, where M is a variable. The bypass 310 can include
a valve 60-2. The method can include providing a flow rate 51 of
single-phase liquid coolant 50 to the inlet manifold 210 and
setting the valve 60-2 in the bypass 310 to provide a flow rate
through the bypass ({dot over (V)}.sub.bypass) 51-3 of about
(M.times.{dot over (V)}.sub.line)+(M-L).times.{dot over
(V)}.sub.line, where {dot over (V)}.sub.line is an average flow
rate through each of the cooling lines, where L is the actual
number of cooling lines 303 installed between the inlet manifold
and the outlet manifold, and L is equal to or less than M. In FIG.
78, M is twelve, and L is eight. In some examples, {dot over
(V)}.sub.line can be about equal to 0.25-1.5, 0.7-1.3, 0.8-1.2,
0.9-1.1, or 1.0 liters per minute of coolant, and M can be 1-10,
5-15, 10-30, 20-40, 30-60, 50-100, 75-150, or 120-240. Where more
than one set of manifolds are used, M can represent the total
number of cooling lines that can be accommodated. For example, in
FIG. 80, M is equal to 60 where two sets of manifolds are used and
each set can accommodate 30 cooling lines 303.
[0598] Providing the flow rate of single-phase liquid coolant 50 to
the inlet manifold 210 can include providing a flow rate of
single-phase, dielectric coolant including HFE-7000, HFE-7100, or
R-245fa. The boiling point of the dielectric coolant can be about
15-35 or 30-65 degrees C. at a pressure of 1 atmosphere. Providing
the flow rate of single-phase liquid coolant to the inlet manifold
210 can include providing a flow of single-phase liquid coolant 50
that is subcooled below a saturation temperature (T.sub.sat) of the
single-phase liquid coolant. Providing the flow rate of
single-phase liquid coolant that is subcooled below a saturation
temperature of the single-phase liquid coolant can include
providing a flow of single-phase liquid coolant 50 that is
subcooled about 2-8, 5-10, or 12-15 degrees C. below the saturation
temperature (T.sub.sat) of the single-phase liquid coolant.
Providing the flow rate of single-phase liquid coolant to the inlet
manifold 210 can include providing a flow rate of single-phase
liquid coolant at a pressure of about 5-20, 15-25, or 20-35
psia.
[0599] In yet another example, a method of selecting flow rates to
provide stable operation within a cooling apparatus 1 in which
two-phase bubbly flow is present can include providing a cooling
apparatus having a primary cooling loop 300. The primary cooling
loop can include a pump 20-1 configured to provide a flow rate 51
of single-phase liquid coolant at a pump outlet. The flow rate of
single-phase liquid coolant at the pump outlet can be a dielectric
coolant such as, for example, HFE-7000, HFE-7100, or R-245fa with a
boiling point of about 15-35 or 30-65 degrees C. at a pressure of 1
atmosphere. The primary cooling loop 300 can include a reservoir
200 fluidly connected to the primary cooling loop 300 and located
upstream of the pump 20 and configured to store a supply of
single-phase liquid coolant 50 for the pump 20. The primary cooling
loop 300 can include one or more cooling lines 303 fluidly
connected to the primary cooling loop 300 and extending between an
inlet manifold 210 and an outlet manifold 215, as shown in FIGS.
75, 79, 80, and 81. Each cooling line 303 can be fluidly connected
to one or more heat sink modules 100, and each heat sink module 100
can be mounted on a heat-providing surface 12, such as a surface
associated with a microprocessor 415, memory module 420, or power
supply of a personal computer or server 12.
[0600] The cooling apparatus 1 can include a first bypass 305
having a first end and a second end. The first end of the first
bypass 305 can be fluidly connected to the primary cooling loop 300
downstream of the pump outlet 22-1. The second end of the first
bypass 305 can be fluidly connected to the primary cooling loop 300
upstream of the reservoir 200 and downstream of the heat sink
modules 100. The first bypass 305 can include a first heat
exchanger 40-1 and a first valve 60-1. The first valve 60-1 can be
configured to regulate a first bypass flow rate 51-1 of the flow
rate 51 of single-phase liquid coolant 50 through the first heat
exchanger 40-1. The first heat exchanger 40-1 can be configured to
subcool the first bypass flow rate 51-1 of coolant 50 below a
saturation temperature of the coolant 50.
[0601] The cooling apparatus 1 can include a second bypass 310
having a first end and a second end. The first end of the second
bypass 310 can be fluidly connected to the primary cooling loop 300
downstream of the pump 20, downstream of the first end of the first
bypass 305, and upstream of the one or more heat sink modules 100.
The second end of the second bypass 310 can be fluidly connected to
the primary cooling loop 300 downstream of the one or more heat
sink modules 100 and upstream of the reservoir 200. The second
bypass 310 can include a second valve 60-2 configured to regulate a
second bypass flow rate 51-3 of the single-phase liquid coolant 50
through the second bypass 310.
[0602] The method can include setting the second valve 60-2 to
provide a flow rate of about through each of the cooling lines 303
and to provide the second bypass flow rate 51-3 about equal to
L.times.{dot over (V)}.sub.line, where L is the number of cooling
lines 303 extending between the inlet manifold 210 and the outlet
manifold 215. The method can include setting the first valve 60-1
to provide the first bypass flow rate 51-1 about equal to
2L.times.{dot over (V)}.sub.line. The average flow rate ({dot over
(V)}.sub.line) of coolant through each cooling line 303 can be
about equal to 0.25-5, 0.25-1.5, 0.7-1.3, 0.8-1.2, 0.9-1.1, or 1.0
liter per minute.
[0603] In one example, a method of condensing vapor present in
two-phase bubbly flow within a cooling apparatus 1 can include
providing a first flow (e.g. 51-2) of coolant including two-phase
bubbly flow. The two-phase bubbly flow can include vapor bubbles
275 dispersed in liquid coolant 50. The first flow of coolant can
have a first flow quality greater than zero. The method can include
providing a second flow (e.g. 51-3) of coolant including
single-phase liquid flow. The second flow of coolant can have a
second flow quality of about zero. The method can include mixing
the first flow of coolant and the second flow of coolant to form a
third flow of coolant, as shown in the return line 230 in FIG. 81.
Mixing the first flow of coolant and the second flow of coolant can
cause heat transfer from the first flow of coolant to the second
flow of coolant and can cause vapor bubbles 275 within first flow
of coolant to condense (e.g. within the return line 230 and/or in
the reservoir 200). The third flow of coolant can have a third flow
quality less than the first flow quality of the first flow of
coolant.
[0604] Providing the first flow (e.g. 51-2) of coolant can include
providing a first predetermined flow rate (e.g. {dot over
(V)}.sub.line) of two-phase bubbly flow. Providing the second flow
(see, e.g. 51-3 and/or 51-1 in FIG. 81) can include providing a
second predetermined flow rate of single-phase liquid flow. The
second predetermined flow rate can be greater than or equal to the
first predetermined flow rate. The second predetermined flow rate
can be at least two times greater than the first predetermined flow
rate. The second predetermined flow rate can be at least four times
greater than the first predetermined flow rate. The first flow
quality can be about 0.05-0.10, 0.07-0.15, 0.10-0.20, 0.15-0.25,
0.2-0.4, or 0.3-0.45. The second flow quality can be about zero.
The third flow quality can be about 0-0.05, 0.04-0.1, 0.08-0.15, or
0.1-0.2. The first predetermined flow rate can be about 0.1-10,
0.2-5, 0.3-2.5, 0.6-1.2, or 0.8-1.1 liters per minute. Providing
the first flow of coolant can include providing the first flow of
coolant from a primary cooling line 303 including a heat sink
module 100 fluidly connected to the primary cooling line 303. The
heat sink module 100 can be configured to mount on a heat-providing
surface 12. Providing the second flow of coolant can include
providing the second flow of coolant from a bypass. The bypass
(e.g. 310) can include a valve 60 configured to control a flow rate
of the second flow of coolant through the bypass.
[0605] In another example, a method of condensing vapor in
two-phase bubbly flow in a cooling apparatus 1 can include
providing a first flow (e.g. 51-2) of coolant including two-phase
bubbly flow, as shown in the section of tubing 225 connected to the
outlet port 110 of the heat sink module 100 in FIG. 81. The
two-phase bubbly flow can include liquid coolant and a plurality of
vapor bubbles 275 of coolant suspended in the liquid coolant. The
first flow can have a first flow quality. The first flow can have a
first predetermined pressure of about 10-20, 15-25, or 20-30 psia
and a first temperature about equal to a saturation temperature of
the first flow of coolant at the first predetermined pressure. The
method can include providing a second flow (e.g. 51-3) of coolant
including single-phase liquid flow having a second flow quality.
The second flow can have a second predetermined pressure of about
10-20, 15-25, or 20-30 psia and a temperature below the saturation
temperature of the second flow of coolant at the second
predetermined pressure. The method can include mixing the first
flow and the second flow to form a third flow of coolant having a
third flow quality. The third flow quality can be less than the
first flow quality of the first flow.
[0606] Providing the first flow (e.g. 51-2) can include providing a
first predetermined flow rate (e.g. {dot over (V)}.sub.line) of
two-phase bubbly flow. Providing the second flow (e.g. 51-3) can
include providing a second predetermined flow rate of single-phase
flow. The second predetermined flow rate can be greater than or
equal to the first predetermined flow rate. The second
predetermined flow rate can be at least two times greater than the
first predetermined flow rate. The second predetermined flow rate
can be at least four times greater than the first predetermined
flow rate. The first flow quality can be about 0.05-0.10,
0.07-0.15, 0.10-0.20, 0.15-0.25, 0.2-0.4, or 0.3-0.45. The second
flow quality can be about zero. The third flow quality can be about
0-1, 0-0.5, 0-0.25, 0-0.2, 0-0.05, 0-0.02, or 0-0.1. The first
predetermined flow rate (e.g. {dot over (V)}.sub.line) can be about
0.1-10, 0.2-5, 0.3-2.5, 0.6-1.2, or 0.8-1.1 liters per minute.
Mixing the first flow with the second flow to form the third flow
can result in condensing of at least a portion of the plurality of
vapor bubbles 275 from the first flow as heat is transferred from
the first flow to the second flow. The first flow can include a
dielectric coolant including R-245fa, HFE-7000, or HFE-7100.
[0607] In yet another example, a method of condensing vapor in
two-phase bubbly flow in a cooling apparatus 1 can include
providing a cooling apparatus having an inlet manifold 210, an
outlet manifold 215, a cooling line 303 extending from the inlet
manifold to the outlet manifold, and a bypass 310 extending from
the inlet manifold to the outlet manifold, as shown in FIG. 79. The
cooling line 303 can be fluidly connected to a heat sink module 100
that is mounted on a heat-providing surface 12. The method can
include providing a flow of single-phase liquid coolant to the
inlet manifold. The method can include flowing a first flow portion
of the flow of single-phase liquid coolant through the cooling line
303 from the inlet manifold 210 to the outlet manifold 215. The
first flow portion can pass through the heat sink module 100 and
can absorb a sufficient amount of heat from the heat-providing
surface 12 to cause a fraction of the first flow portion to change
phase from liquid to a vapor thereby forming a two-phase bubbly
flow of coolant. The method can include flowing a second flow
portion of the flow of single-phase liquid coolant through the
bypass line 310 from the inlet manifold 210 to the outlet manifold
215. The method can include mixing the first flow portion and the
second flow portion in the outlet manifold 215 to form a mixed
flow. Mixing the first and second flow portions can cause heat
transfer from the first flow portion to the second flow portion
thereby condensing at least a portion of the vapor from the first
flow portion. Flowing the first flow portion of the flow of
single-phase liquid coolant through the cooling line 303 can
include flowing a first flow rate of about 0.1-10, 0.2-5, 0.3-2.5,
0.6-1.2, or 0.8-1.1 liters per minute of coolant through the first
cooling line 303. Flowing the second flow portion of the flow of
single-phase liquid coolant through the bypass line 310 can include
flowing a second flow rate through the bypass. The second flow rate
can be greater than or equal to the first flow rate.
[0608] In one example, a method of providing a continuous flow of
single-phase liquid to a pump 20 in a cooling apparatus 1, in which
two-phase flow is present but is condensed upstream of the pump 20
to provide stable pump operation, can include providing a cooling
apparatus 1 having a reservoir 200 fluidly connected to a pump 20.
The reservoir 200 can be configured to store an amount of coolant
50, such as a dielectric coolant. The reservoir 200 can have a
liquid-vapor interface 202 in an upper portion of the reservoir
when partially filled with liquid coolant. The liquid-vapor
interface 202 can be an interface located between an amount of
substantially liquid coolant 50 and an amount of substantially
vapor coolant, as shown in FIGS. 81-83. The method can include
delivering an inlet flow of single-phase liquid coolant to the
reservoir 200. The method can include delivering two-phase bubbly
flow to an upper portion of the reservoir 200 above the
liquid-vapor interface 202. The two-phase bubbly flow of coolant
can include vapor bubbles of coolant dispersed in liquid coolant.
The vapor bubbles 275 can condense upon interacting with and
transferring heat to the amount of liquid coolant 50 in the
reservoir 200. The method can include delivering a continuous
outlet flow of single-phase liquid from a lower portion of the
reservoir 200 to a pump 20 to provide stable pump operation. The
lower portion can be located below a midpoint of the reservoir 200,
and in some cases can be located at a bottom surface of the
reservoir 200 as shown in FIGS. 81-83.
[0609] The inlet flow of single-phase liquid coolant can have a
first flow rate, and the two-phase bubbly flow can have a second
flow rate. The first flow rate can be equal to or greater than the
second flow rate. The amount of liquid coolant in the reservoir 200
can occupy about 50-90, 60-80, or 65-75 percent of an interior
volume of the reservoir. The flow of single-phase liquid coolant to
reservoir can include providing a flow of single-phase liquid
coolant that is subcooled below its saturation temperature.
Providing the flow of single-phase liquid coolant that is subcooled
below its saturation temperature can include providing a flow of
single-phase liquid coolant that is subcooled about 2-8, 5-12, or
10-15 degrees C. below its saturation temperature. Providing the
flow of single-phase liquid coolant to the reservoir can include
providing a flow of single-phase liquid coolant at a pressure of
about 10-20, 15-25, 20-30, or 25-40 psia. Providing the flow of
single-phase liquid coolant to the reservoir can include providing
a flow of single-phase coolant including a dielectric coolant with
a boiling point of about 10-35, 20-45, 30-55, or 40-65 degrees C.,
where the boiling point is determined at a pressure of 1
atmosphere.
[0610] In another example, a method of providing stable operation
of a pump 20 in a two-phase cooling apparatus 1 by condensing a
two-phase flow upstream of the pump 20 and providing substantially
single-phase liquid coolant to the pump 20 to ensure stable pump
operation can include providing a first flow of coolant having a
two-phase bubbly flow of coolant. The two-phase bubbly flow of
coolant can include vapor bubbles 275 of coolant dispersed in
liquid coolant. The first flow of coolant can have a first flow
quality greater than zero. The method can include providing a
second flow of coolant being a single-phase flow of coolant. The
second flow of coolant can have a second flow quality of about
zero. The method can include mixing the first flow of coolant (e.g.
51-2) and the second flow of coolant (e.g. 51-3) to form a return
flow of coolant, as shown in FIGS. 81 and 82. Mixing the first flow
of coolant and the second flow of coolant can cause heat transfer
from the first flow of coolant to the second flow of coolant and
can cause at least a portion of the vapor bubbles 275 of coolant
within first flow of coolant to condense. The return flow of
coolant can have a return flow quality that is less than the first
flow quality of the first flow of coolant. The method can include
delivering the return flow of coolant to a reservoir 200. The
reservoir 200 can contain a supply of subcooled single-phase liquid
coolant. Mixing the return flow with the supply of subcooled
single-phase liquid coolant can cause heat transfer from the return
flow to the supply of subcooled single-phase liquid coolant thereby
condensing any remaining vapor bubbles in the return flow. The
method can include providing an outlet flow of subcooled
single-phase liquid coolant from the reservoir 200 to a pump 20 to
ensure stable pump operation. The method can include delivering a
third flow (e.g. 51-1) of coolant to the reservoir 200, as shown in
FIG. 81. The third flow of coolant (e.g. 51-1) can be a
single-phase flow of coolant. The third flow of coolant can pass
through a heat exchanger (e.g. 40-1) and be subcooled to about
10-15, 12-20, or 15-30 degrees C. below its saturation temperature
before being delivered to the reservoir 200.
[0611] Providing the outlet flow of subcooled single-phase liquid
coolant from the reservoir 200 to the pump 20 can include providing
a flow of single-phase liquid coolant that is subcooled about 2-8,
5-12, or 10-15 degrees C. below its saturation temperature.
Delivering the return flow of coolant to the reservoir 200 can
include delivering the return flow of coolant to an upper portion
of the reservoir 200 above a liquid-vapor interface 202 in the
reservoir. The liquid-vapor interface can separate an amount of
substantially liquid coolant 50 from an amount of substantially
vapor coolant 203. The first flow quality of the first flow of
coolant can be greater than zero and less than about 0.2, 0.25,
0.3, 0.35, 0.4, 0.45, or 0.5. The reservoir 200 can be in thermal
communication with a heat exchanger 40, as shown in FIG. 82. The
heat exchanger 40 can be configured to circulate a chilled fluid
(e.g. a water-glycol mixture) through sealed passageways (e.g.
copper tubing extending into the reservoir or in thermal contact
with a sidewall of the reservoir) that serves to subcool coolant
within the reservoir 200 to about 2-8, 5-12, or 10-15 degrees C.
below its saturation temperature. Delivering the return flow of
coolant to the reservoir can include directing the return flow of
coolant against an inner surface of the reservoir 200 to promote
condensing of the vapor bubbles 275 in the return flow of
coolant.
[0612] In yet another example, a method of providing stable
operation of a pump 20 in a two-phase cooling apparatus 1 by
condensing a two-phase flow upstream of the pump 20 and providing
substantially single-phase liquid coolant to the pump 20 to ensure
stable pump operation can include providing a cooling apparatus 1.
The cooling apparatus 1 can include an inlet manifold 210, an
outlet manifold 215, a cooling line 303 extending from the inlet
manifold to the outlet manifold, and a bypass 310 extending from
the inlet manifold 210 to the outlet manifold 215, as shown in
FIGS. 79 and 81. The cooling line 303 can be fluidly connected to a
heat sink module 100 that is mounted on a heat-providing surface.
The method can include providing a flow of single-phase liquid
coolant to the inlet manifold. The method can include flowing a
first flow portion (e.g. {dot over (V)}.sub.line) of the flow of
single-phase liquid coolant through the cooling line 303 from the
inlet manifold 210 to the outlet manifold 215. The first flow
portion (e.g. {dot over (V)}.sub.line) can pass through the heat
sink module 100 and absorb a sufficient amount of heat from the
heat-providing surface 12 to cause a fraction of the first flow
portion to change phase from a liquid to a vapor thereby forming a
two-phase bubbly flow of coolant. The method can include flowing a
second flow portion (e.g. 51-2) of the flow of single-phase liquid
coolant through the bypass 310 from the inlet manifold 210 to the
outlet manifold 215. The method can include mixing the first flow
portion (e.g. {dot over (V)}.sub.line) and the second flow portion
(e.g. 51-2) in the outlet manifold 210 to form a mixed flow. Mixing
the first and second flow portions can cause heat transfer from the
first flow portion to the second flow portion thereby condensing at
least a portion of the vapor 275 from the first flow portion. The
method can include delivering the mixed flow to a reservoir 200
containing a supply of subcooled liquid coolant 50 where any
remaining vapor 275 from the mixed flow is condensed to liquid. The
method can include providing an outlet flow of substantially liquid
coolant from a lower portion of the reservoir 200 to a pump 20 to
provide stable pump operation.
[0613] Flowing the first flow portion of the flow of single-phase
liquid coolant through the cooling line 303 can include flowing a
first flow rate of about 0.1-10, 0.2-5, 0.3-2.5, 0.6-1.2, or
0.8-1.1 liters per minute of coolant through the cooling line 303.
Flowing the second flow portion of the flow of single-phase liquid
coolant through the bypass 310 can include flowing a second flow
rate through the bypass. The second flow rate can be greater than
or equal to the first flow rate. Providing the flow of single-phase
liquid coolant to the inlet manifold 210 can include providing a
flow of single-phase liquid coolant that is subcooled about 2-8,
5-10, or 12-15 degrees C. below its saturation temperature.
Providing the flow of single-phase liquid coolant to the inlet
manifold can include providing a flow of single-phase liquid
coolant at a pressure of about 10-20, 15-25, 20-30, or 25-45 psia.
Providing the flow of single-phase liquid coolant to the inlet
manifold 210 can include providing a flow of single-phase
dielectric coolant, such as HFE-7000, HFE-7100, or R-245fa. The
method can include routing a third flow portion (e.g. 51-1) of the
flow of single-phase liquid coolant from the reservoir 200 through
a heat exchanger 40-1 and back to the reservoir 200 to provide a
flow of subcooled single-phase liquid coolant to the reservoir, as
shown in FIGS. 79 and 81. The third flow portion can be subcooled
about 10-15, 12-20, or 15-30 degrees C. below its saturation
temperature upon exiting the heat exchanger and returning to the
reservoir.
Cooling Apparatus with Dry Cooler
[0614] FIG. 12P shows a schematic of a cooling apparatus 1 having a
primary cooling loop 300, a first bypass 305, and a second bypass
310, where the first bypass 305 is connected to a heat exchanger 40
that can be a rooftop dry cooler. The cooling apparatus 1 can
include an electronic control system 850 having a microcontroller
that receives inputs from sensors regarding flow rate, pressure,
and temperature and determines heat removed (W), rate of heat
removed (kW-h over time), and pump 20 power consumption. The
cooling apparatus 1 can include two pumps 20 arranged in a parallel
configuration for redundancy. Shut-off valves 250 can be provided
near each pump inlet 21 and outlet 22, thereby allowing for
hot-swapping of a failed pump 20. The shut-off valves 250 can be
electronically controlled by the electronic control system 850 or
manually controlled, depending on the complexity of the cooling
apparatus 1. Where the shut-off valves 250 are electronically
controlled, a motor fail-safe 855 (see, e.g. FIG. 12P) can be
provided to monitor the status of the pumps 20, and in case of pump
failure, can deactivate the failed pump and activate the non-failed
pump to ensure continued flow of coolant through the primary
cooling loop 300 to the surface to be cooled 12. In some examples,
the cooling apparatus 1 can include a strainer 260 downstream of
the pumps 20 and a filter 260 upstream of the pumps 20. In some
examples, the valve 60 located between the heat exchanger 40 and
the reservoir 200 can be a back-pressure valve, such as a liquid
relief valve manufactured by Kunkle Valve and available from
Pentair, Ltd. of Minneapolis, Minn. In some examples, the valve 60
positioned in the first bypass 305 can be a back pressure valve,
such as a liquid relief valve manufactured by Cash Valve, also
available from Pentair, Ltd.
Electronic Control Unit
[0615] The cooling apparatus 1 can include an electronic control
unit 850, as shown in FIGS. 12Q, 74, 83, and 115. The electronic
control unit 850 can monitor and enable remote monitoring of
cooling system performance when electrically or wirelessly
connected to a network 960. In FIGS. 12Q, 74, 83, and 115, dashed
lines connecting the electronic control unit 850 to other
components (e.g. sensors 880) indicate electrical or wireless
connections.
[0616] In some examples, the electronic control unit 850 can
dynamically adjust cooling system parameter based on inputs from
one or more sensors 880 to improve system performance and stability
and/or reduce power consumption of the cooling apparatus 1. In some
examples, the electronic control unit 850 can include a
microcontroller. The microcontroller can be electrically or
wirelessly connected to one or more system components, such as a
heat exchanger fan 26 (where a liquid-to-gas heat exchanger 40 is
used), a valve 60, a shut-off valve, or a pump 20. The
microcontroller can be configured to dynamically adjust settings
(e.g. pump speed, valve angle, fan speed) of the one or more
components within the cooling apparatus 1 during operation of the
cooing apparatus to enhance performance and/or reduce overall power
consumption. In one example, the microcontroller can be
electrically connected to a variable speed drive (VSD) 80 of the
pump 20. A variable speed drive 80 can be used to control pump
speed. Pump speed can be selected from predetermined speeds or can
be infinitely adjustable within an operating range to optimize
system performance and/or efficiency. The variable speed drive 80
can be mechanical, electromechanical, hydraulic, or electric.
[0617] FIG. 115 shows a cooling apparatus 1 having a primary
cooling loop 300 with a first pump 20-1 and a heat rejection loop
43 with a second pump 20-2. The first pump 20-1 can be connected to
a first variable speed drive 80-1 capable of varying the speed of
the first pump 20-1, and the second pump 20-2 can be connected to a
second variable speed drive 80-2 capable of varying the speed of
the second pump 20-2. The first and second variable speed drives
(80-1, 80-2) can be electrically connected to the microcontroller
of the electronic control unit 850. Based on inputs from one or
more sensors 880 (e.g. temperature, pressure, flow quality, or flow
rate), the microcontroller can instruct the variable speed drive 80
to decrease pump speed to reduce power consumption when the thermal
load from the heat-providing surfaces 12 is low and/or decreasing
or when the flow quality (x) of the two-phase flow in the return
line 230 is less than about 0.4, 0.3, 0.2, or 0.1. By reducing pump
speed, the operating pressure at the pump outlet 22 is decreased,
thereby decreasing the flow rate through the cooling apparatus 1
and the heat sink modules 100, which can promote boiling in the
modules leading to more vapor bubble generation and higher flow
quality (x). The ability to operate the variable speed drive 80 at
a lower speed conserves energy, and is therefore desirable. Where
the cooling apparatus 1 includes independent redundant cooling
loops, the electronic control system 850 can be configured to
operate a first cooling loop while a second cooling loop remains on
standby. In some examples, the electronic control system 850 can be
configured to activate the second cooling loop only if the first
cooling loop experiences a malfunction or is otherwise unable to
effectively cool the surface to be cooled 12. In this way, the
redundant cooling apparatus 1 can reduce power consumption by about
50% compared to a redundant cooling apparatus where both cooling
loops operate continuously.
[0618] When a redundant cooling apparatus is provided, the
apparatus may run for long periods of time (e.g. years) without
experiencing any malfunctions or component failures. During these
long periods of time, only one cooling loop is needed and the other
cooling loop will remain on standby. To ensure that each cooling
loop remains functional and ready to operate when needed, the
electronic control system 850 can alternate between operating the
first cooling loop and the second cooling loop when only one
cooling loop is needed. For instance, the control system can be
configured to activate the first cooling loop for a certain period
of time (e.g. a number of hours or days) while the second cooling
loop remains on standby. Once the certain period of time has
passed, the electronic control system 850 can then activate the
second cooling loop, and once the second cooling loop is operating
as desired, can place the first cooling loop on standby. Cycling
between operating the first cooling loop and operating the second
cooling loop can extend the life of certain system components
within each loop (e.g. pump seals) and can increase the likelihood
that the standby loop is ready for operation if the other cooling
loop experiences a malfunction. Cycling between the first and
second cooling loops can also ensure that operating time is equally
distributed between the two cooling loops, thereby potentially
increasing the overall useful life of the redundant cooling
apparatus 1.
[0619] The cooling apparatus 1 can include one or more sensors 880
(see, e.g., FIGS. 12Q, 115, and 140) that deliver information to
the electronic control system 850 to allow a malfunction or
condition within the cooling apparatus 1 to be detected and
communicated to a memory device and/or facility operator. The
cooling apparatus 1 can include one or more sensors 880, such as
temperature sensors, pressure sensors, visual flow sensors, flow
quality (x) sensors, vibration sensors, smoke detectors, flow rate
sensors, fluorocarbon detectors, or leak detectors that provide
data to the electronic control system 850. The number of sensors
can vary depending on the level of precision desired in controlling
and monitoring the cooling system 1. In some examples, the cooling
system 1 may have a single sensor (e.g. T, P, or x) on a return
line 230. In other examples, the cooling system 1 may have a
plurality of sensors. Sensors can be located on an inlet and outlet
of each component as well as within certain components, such as
within the reservoir 200 and manifolds (210, 215) to monitor
dynamic conditions and provide signals to the electronic control
system 850 that allow the cooling apparatus to improve its
performance, stability, and/or efficiency. Increasing the number of
sensors 880 can allow the operation of the cooling system to be
controlled within a tighter operating range, which can improve
performance, stability, and/or efficiency. Decreasing the number of
sensors 880 can reduce cost and complexity of the cooling
system.
[0620] Each sensor 880 can be electrically connected or wirelessly
connected to the electronic control system 850, as shown in FIGS.
12Q, 74, 83, and 115. Upon detection or indication of a malfunction
within the cooling apparatus 1, the electronic control system 850
can be configured to notify a system operator, for example, with a
visual or audible alarm. The electronic control system 850 can be
configured to communicate with a network 960 and send an electronic
message (e.g. an email or text message) to a system operator to
alert the operator of the malfunction. The electronic message can
include specific details associated with the malfunction, including
information recorded from the one or more sensors 880 connected to
the electronic control system 850. The electronic message can also
include a part number associated with the component that has likely
failed to permit the operator to immediately determine if the part
exists in local inventory, and if not, to order a replacement part
from a vendor as soon as possible. The electronic message, and any
data relating to the malfunction, can be stored in a computer
readable medium (e.g. memory 854) and/or transmitted to the system
manufacturer for quality control, warranty, and/or recall
purposes.
[0621] The electronic control unit 850 can include processing
circuitry 851 that receives measurement signals from one or more
sensors 880 via cables 852. The processing circuitry can include
one or more microcontrollers, microprocessors, digital signal
processors (DSPs), field programmable gate arrays (FPGAs),
programmable logic devices (PLDs), application specific integrated
circuits (ASICs), or the like. In some cases, the functions of
processing circuit 851 may be also be performed by discrete digital
components and/or discrete analog components. Cables 852 may
include any type of wire, electrical conductor, conductive
material, fiber optics, and/or another medium for communicating
information between the sensors 880 and processing circuitry. In
some cases, one or more of sensors 880 may communicate with the
processing circuitry wirelessly.
[0622] The sensors 880 may provide measurement signals or data to
the processing circuitry 851 in raw or unconditioned form. The
sensors 880 may also provide measurement signals or data to the
processing circuitry in conditioned form. For example, measurement
signals or data may be conditioned, filtered, normalized, averaged,
and/or scaled by a sensor 880 prior to transmission to the
processing circuitry over the cable 852. In addition, one or more
of the sensors 852 may provide a digital or digitized signal to the
processing circuitry. Consequently, an analog-to-digital converter
(ADC) may be included in the sensor 880 or processing circuitry
851. It is understood by those of skill in the art that processing
circuitry 851 and/or sensors 880 may include various other
electrical components, including integrated circuits (ICs) and/or
discrete components.
[0623] While sensors 880 are illustrated as being interconnected to
processing circuitry 851 with individual cables 852 in a hub and
spoke configuration, it should be understood that other
configurations are possible. For example, sensors 880 may be
connected to processing circuitry in a serially connected or daisy
chain configuration.
[0624] Processing circuitry 851 may be implemented on a single
printed circuit board (PCB), multiple PCBs, a flex circuit, and/or
multiple flex circuits. Distributing processing circuitry may be
advantageous to place certain components in a better position for
communications with external devices, to facilitate ease of
replacing damaged or outdated sections, and/or to better protect
certain elements of the processing circuitry from damage. The
processing circuitry may be encased in a housing or sealed by other
means to protect it from moisture, dirt, dust, impact, shock,
and/or other environmental hazards. In some cases, the processing
circuitry may include a housing or other protective element that
blocks radiation at certain frequencies or frequency ranges. For
example, the processing circuitry may be hardened against
electromagnetic pulse, atomic radioactive radiation, cosmic rays,
heat, and/or the like.
[0625] One or more of the sensors 880 may communicate with the
processing circuitry 851 through wireless communication. Wireless
communication may take place using one or more wireless
communication protocols such as Bluetooth, Bluetooth Low Energy,
ZigBee, and/or WiFi. Alternatively, wireless communication may be
implemented using known methods of optical or infrared
communication.
[0626] As shown in FIG. 140, the processing circuitry 851 of the
electronic control unit 850 can include other components, modules,
or subsystems, such as processors 853, memory 854, and
communication circuitry 855. Processors 853 may include one or more
microcontrollers, microprocessors, digital signal processors
(DSPs), field programmable gate arrays (FPGAs), programmable logic
devices (PLDs), application specific integrated circuits (ASICs),
and/or the like. Memory 854 may include one or more memory devices
for storing computer instructions and/or data. Memory 854 may
include random access memory (RAM), dynamic RAM (DRAM), flash
memory, electrically programmable read only memory (EPROM),
erasable EPROM (EEPROM), a hard drive, a memory card, a tape drive,
micro electro mechanical (MEMs) storage devices, and/or a
combination thereof. Memory 854 may be contained in a single device
or distributed among a plurality of devices. In addition, some or
all of memory 854 may be contained in the processors 853 or in
another device in the system. The memory device 854 may store
non-transitory computer-readable instructions for execution by the
processor 853. The memory 854 may also store data received from
other sources such as directly from the sensors 880 and/or or from
external devices or systems, such the network 960, for temporary or
long-term storage.
[0627] An antenna 857 is any device for facilitating wireless
communication between the communication circuitry 855 and an
external device. The antenna 857 may be integrated into a printed
circuit board associated with the processing circuitry 851, may be
attached to some element of the processing circuitry, or may be
separate from processing circuitry. The antenna 857 may be a single
antenna or may include an array of antennas. The antenna 857 may
include a wire antenna, a dipole antenna, a monopole antenna, a
travelling wave antenna, a reflector antenna, a microstrip antenna,
an aperture antenna, a log-periodic antenna, and/or another type of
antenna. The communication circuitry 851 and the antenna 857 may
support unidirectional communication or bidirectional
communication.
[0628] The processing circuitry 851 can include communication
circuitry 855, as shown in FIG. 140. The communication circuitry
855 may include various digital components, analog components,
radio frequency (RF) components, and/or ICs configured to provide
communication capabilities between elements of the cooling
apparatus 1 and a facility network 960. The provided communication
capabilities may include wired, wireless, and/or optical
communication.
[0629] The communication circuitry 851 may include elements for
performing communications in more than one protocol, format, or
standard. For example, the communication circuitry can include a
Bluetooth Low Energy (BLE) module, WiFi module, general packet
radio service (GPRS) module, Global System for Mobile
Communications (GSM) module, ZigBee module, and/or WiMax module.
The communication circuitry 851 can include any combination or
subset of these elements including configuration that includes
modules for other communication protocols such as LTE, LTE-A,
HSDPA, or the like. In some cases, any of the sensors 880 may
interface directly with and communicate directly through the
communication circuitry or may communicate through the processing
circuitry.
Portable Cooling Device
[0630] FIG. 74 shows a portable cooling device 750 that includes a
plurality of heat sink modules 100 mounted on a portable layer 755.
In some examples, the portable layer 755 can be a rigid material,
such as metal, carbon fiber composite, or plastic. In other
examples, the portable layer 755 can be a conformable material,
such as fabric, foam, or an insulating blanket. The portable layer
755 can be contoured to correspond to any heated surface 12. The
plurality of heat sink modules (100, 700) can be attached to the
portable layer 755 by any suitable method of adhesion. The heat
sink modules (100, 700) can be fluidly connected in series and/or
parallel configurations. The portable cooling device 750 can
include one or more inlet connections 236 and one or more outlet
connections 237 that can be connected to a cooling apparatus 1 that
delivers a flow of pressurized coolant 50 to the portable cooling
device 750 to permit cooling of the heated surface 12 through
sensible and latent heating of the coolant within the plurality of
heat sink modules. In some examples, each heat sink module can be
mounted on a thermally conductive base member 430. Where the
portable layer 755 is made from an insulated blanket or other
insulating member, the portable cooling device 750 can be wrapped
around a vessel to cool the vessel and its contents. In this
example, the portable layer 755 can include suitable fastening
devices (e.g. snaps, ties, zippers, Velcro, or magnets) to allow
the portable cooling device to be removably attachable to the
vessel.
Heat Pipe
[0631] A heat pipe can be used as the thermally conductive base
member 430. The heat pipe can include a sealed casing and a wick, a
vapor cavity, and a working fluid within the sealed casing. In some
examples, the working fluid can be R134a. During a thermal cycle of
the heat pipe, the working fluid evaporates to vapor as it absorbs
thermal energy (e.g. from a microprocessor 415 in a server 400).
The vapor then migrates along the vapor cavity from a first end of
the heat pipe toward a second end of the heat pipe, where the
second end is at a lower temperature than the first end. As the
vapor migrates toward the second end of the heat pipe, it cools and
condenses back to fluid, which is absorbed by the wick. The fluid
in the wick then flows back to the first end of the heat pipe due
to gravity or capillary action. The thermal cycle then repeats
itself.
[0632] In some cooling applications, size, shape, or environmental
constraints may prevent a heat sink module 100 from being placed
directly on a component or device that requires cooling. In these
examples, a heat pipe can be used to transfer heat from the
component or device to the heat sink module 100 located at a
distance from the component or device. For instance, a first
portion of the heat pipe can be placed in thermal communication
with a heat-providing surface, and the heat sink module 100 can be
placed in thermal communication with a second portion of the heat
pipe, where the second portion is a distance from the first
portion. This approach can allow the heat sink module 100 to
efficiently absorb heat from the heat-providing surface without
being in direct contact or near the heat-providing surface.
[0633] By using one or more heat pipes, a single heat sink module
(100, 700) can be used to cool two or more heat sources. In one
example, a server 400 can have two microprocessors 415. A first
heat pipe can have a first end in thermal communication with a
first microprocessor 415 and a second end in thermal communication
with a copper base plate 430. A second heat pipe can have a first
end in thermal communication with a second microprocessor 415 and a
second end in thermal communication with the same copper base plate
430. A heat sink module (100, 700) can be mounted on a surface to
be cooled 12 of the copper base plate 430. By circulating a flow of
coolant 50 through the heat sink module, and causing jet streams 16
of coolant to impinge the surface to be cooled of the copper base
plate 430, the coolant 50 can effectively absorb heat originating
from the microprocessors 415 that was transferred through the heat
pipes to the thermally conductive base member 430. The heat pipe
can be any suitable heat pipe, such as a heat pipe available from
Advanced Cooling Technologies, Inc. located in Lancaster, Pa.
Fire Suppression System
[0634] The cooling system 1 can be equipped with a fire suppression
system configured to protect valuable electronic devices (e.g.
servers, network switches) and the cooling system itself from
suffering damage in the event of a facility fire. The dielectric
coolant in the cooling apparatus 1 (e.g. Novec 7000) can serve as a
suitable fire suppressant. The cooling system 1 can include a fire
sprinkler 95 mounted to a server rack 410 and fluidly connected to
the cooling apparatus. The cooling system 1 can also include a
sensor 880 capable of detecting a facility fire. The sensor can be,
for example, an opacity sensor, thermocouple, or infrared sensor.
In one example, the sensor can be a glass bulb, containing liquid
alcohol, that shatters when the liquid alcohol reaches a
predetermined temperature. The sensor 880 can be connected to the
electronic control unit 850 as shown in FIG. 140B. When a signal
from the sensor 880, received at the electronic control unit 850,
exceeds a predetermined threshold, the electronic control unit 850
can instruct the fire sprinkler to open (e.g. by actuating a
solenoid valve in the fire sprinkler). In one example, the fire
sprinkler 95 can be mounted proximate a top side of the server rack
410, and opening the fire sprinkler can result in coolant showering
down on an upper server and cascading downward over the lower
servers. In another example, the fire sprinkler 95 can be threaded
into an upper opening (661, 676) in the manifold assembly 680 and
can be condo shower coolant over the servers arranged in the rack
410. In this example, the fire sprinkler 95 can be a
VK104--Micromatic Standard Response Horizontal Sidewall Sprinkler
from Viking Corporation of Hastings, Mich. The fire sprinkler 95
can remain open until the coolant 50 is fully depleted from the
cooling system 1 or, to avoid damaging pump 20 components by
operating with low coolant levels, the fire sprinkler can remain
open until the coolant level is depleted to a minimum allowable
level. In some examples, the coolant can be released from the fire
sprinkler 95 in a continuous manner. In other examples, the
electronic control unit 850 can instruct the fire sprinkler 95 to
release coolant intermittently, which can prolong the duration of
coolant delivery, which may be desirable in some fire scenarios.
During the release of coolant, the electronic control unit 850 can
continue to receive signals from fire indicating sensor(s) (e.g.
opacity, thermocouple, and/or infrared sensors) and can modify
coolant delivery based on the received signals. For instance, if
sensor signals indicate that the fire is intensifying, the
electronic control unit 850 can instruct the fire sprinkler valve
to remain open. Conversely, if sensor signals indicate the fire is
decreasing in intensity or has been extinguished, the electronic
control unit 850 can close the fire sprinkler valve. In addition
to, or instead of, receiving signals from fire-indicating sensors
880, the electronic control unit 850 may receive facility signals
from the facility network 960. In this scenario, the network 960
may be configured to activate fire sprinklers 95 only on server
racks 410 located along a perimeter where the fire is threatening
to enter the data center 425. This approach can create a
coolant-based firewall or fire barrier that can slow or prevent the
fire from spreading through the data center 425 and can provide
first responders time to extinguish the fire without requiring
unnecessary depletion of coolant from cooling systems located away
from the fire. Although only one fire sprinkler 95 is described
above, this is not limiting. The cooling system 1 can have one or
more fire sprinklers arranged on one or more server racks 410. For
example, in a cooling apparatus connected to twenty server racks
410, and each server rack can have one or more fire sprinklers 95
mounted thereon or mounted nearby (e.g. from a ceiling fixture) and
directed at servers 400 mounted in the rack.
Examples of Heat Sinks
[0635] In one example, a heat sink module 100 for cooling a heat
providing surface 12 can include an inlet chamber formed 145 within
the heat sink module and an outlet chamber 150 formed within the
heat sink module. The outlet chamber 150 can have an open portion,
such as an open surface. The open portion can be enclosed by the
heat providing surface 12 to form a sealed chamber when the heat
sink module 100 is installed on the heat providing surface 12, as
shown in FIG. 26. The heat sink module 100 can include a dividing
member 195 disposed between the inlet chamber 145 and the outlet
chamber 150. The dividing member 195 can include a first plurality
of orifices 155 formed in the dividing member. The first plurality
of orifices 155 can extend from a top surface of the dividing
member 195 to a bottom surface of the dividing member 195. The
first plurality of orifices 155 can be configured to deliver a
plurality of jet streams 16 of coolant 50 into the outlet chamber
150 and against the heat-providing surface 12 when the heat sink
module 100 is installed on the heat providing surface 12 and when
pressurized coolant 50 is delivered to the inlet chamber 145.
[0636] A distance between the bottom surface of the dividing member
195 and the heat providing surface 12 can define a jet height 18 of
the plurality of orifices 155 when the heat sink module 100 is
installed on the heat providing surface 12. The jet height 18 can
be about 0.01-0.75, 0.05-0.5, 0.05-0.25, 0.020-0.25, 0.03-0.125, or
0.04-0.08 in.
[0637] The first plurality of orifices 155 can have an average
diameter of about 0.001-0.020, 0.001-0.2, 0.001-0.150, 0.001-0.120,
0.001-0.005, or 0.030-0.050 in. The first plurality of orifices 155
can have an average diameter of D and an average length of L, and L
divided by D can be greater than or equal to one or about 1-10,
1-8, 1-6, 1-4, or 1-3.
[0638] The dividing member can have a thickness of about
0.005-0.25, 0.020-0.1, 0.025-0.08, 0.025-0.075, 0.040-0.070,
0.1-0.25, or 0.040-0.070 in. Each orifice of the first plurality of
orifices 155 can have a central axis, and the central axes of the
first plurality of orifices 155 can be arranged at an angle of
about 20-80, 30-60, 40-50, or 45 degrees with respect to the
surface to be cooled 12.
[0639] The first plurality of orifices 155 can be arranged in an
array 76, and the array can be organized into staggered columns 77
and staggered rows 78, as shown in FIG. 31, such that a given
orifice 155 in a given column 77 and a given row 78 does not have a
corresponding orifice 155 in a neighboring row 78 in the given
column 77 or a corresponding orifice in a neighboring column 77 in
the given row 78.
[0640] The heat sink module 100 can include a second plurality of
orifices 156 extending from the inlet chamber 145 to a rear wall of
the outlet chamber 150, as shown in FIG. 38. The second plurality
of orifices 156 can be configured to deliver a plurality of
anti-pooling jet streams of coolant 16 to a rear portion of the
outlet chamber 150 when pressurized coolant is provided to the
inlet chamber 145. Each orifice of the second plurality of orifices
can have a central axis, where the central axes of the second
plurality of orifices are arranged at an angle of about 40-80,
50-70, or 60 degrees with respect to the surface to be cooled. The
second plurality of orifices 156 can be arranged in a column along
the rear wall of the outlet chamber 150.
[0641] The heat sink module 100 can include one or more
boiling-inducing members 196 extending from the bottom side of the
dividing member 195 toward the heat providing surface, wherein the
one or more boiling-inducing members 196 are slender members
extending from the bottom surface of the dividing member 195. In
one example, the one or more boiling-inducing members 196 can be
configured to contact the heat providing surface 12. In another
example, the one or more boiling-inducing members 196 can be
configured to extend toward the heat providing surface 12, but not
contact the heat providing surface 12. Instead, a clearance
distance can be provided between the ends of the one or more
boiling-inducing members 196 and heat providing surface. The
clearance distance can be about 0.001-0.0125, 0.001-0.05,
0.001-0.02, 0.001-0.01, or 0.005-0.010 in.
[0642] The inlet chamber 145 of the heat sink module 100 can
decrease in cross-sectional area in a direction from a front
surface 175 of the heat sink module toward a rear surface 180 of
the heat sink module, as shown in FIG. 26. The outlet chamber 150
of the heat sink module 100 can increase in cross-sectional area in
a direction from a front surface 170 of the heat sink module toward
a rear surface 180 of the heat sink module.
[0643] The heat sink module 100 can include an inlet port 105 and
an inlet passage 165 fluidly connecting the inlet port 105 to the
inlet chamber 145. The heat sink module 100 can include an outlet
port 110 an outlet passage 166 fluidly connecting the outlet
chamber 150 to the outlet port 110. The heat sink module 100 can
include a bottom surface 135 and a bottom plane 19 associated with
the bottom surface, as shown in FIG. 26. The inlet port 105 can
have a central axis 23 that defines an angle (.alpha.) of about
10-80, 20-70, 30-60, or 40-50 degrees with respect to the bottom
plane 19 of the heat sink module 100. Similarly, the outlet port
110 can have a central axis that defines an angle of about 10-80,
20-70, 30-60, or 40-50 degrees with respect to the bottom plane of
the heat sink module.
[0644] An additive manufacturing process, such as
stereolithography, can be used to manufacture the heat sink module
100. The stereolithography process can include forming layers of
material curable in response to synergistic stimulation adjacent to
previously formed layers of material and successively curing the
layers of material by exposing the layers of material to a pattern
of synergistic stimulation corresponding to successive
cross-sections of the heat sink module. The material curable in
response to synergistic stimulation can be a liquid
photopolymer.
[0645] In one example, a heat sink can be configured to receive and
discharge a flow of pumped coolant, such as pumped coolant 50
circulating through a cooling system. The heat sink can include a
thermally conductive base member 430 configured to mount on, or be
placed in thermal communication with, a heat source. The thermally
conductive base member 430 can have a thermal conductivity greater
than 100, 150, or 200 Btu/(hr-ft-F). The heat sink can include a
heat sink module 100 having a bottom surface 135 that is mounted on
a top surface of the thermally conductive base member, as shown in
FIG. 38. The heat sink module 100 can include an inlet chamber 145,
an outlet chamber 150, and a dividing member 195. The inlet chamber
145 can be formed within the heat sink module 100. The outlet
chamber 150 can be formed at least partially within the heat sink
module 100. The outlet chamber 150 can include an open portion
enclosed by the top surface 12 of the thermally conductive base
member 430 when the heat sink module is mounted on the top surface
12 of the thermally conductive base member 430. The dividing member
195 can be located between the inlet chamber 145 and the outlet
chamber 150. The dividing member 195 can include a first plurality
of orifices 155 formed in the dividing member 195 and passing from
a top side of the dividing member to a bottom side of the dividing
member. The first plurality of orifices 155 can be configured to
deliver a plurality of jet streams 16 of coolant 50 into the outlet
chamber 150 and against the top surface 12 of the thermally
conductive base member 430 when pumped coolant 50 is provided to
the inlet chamber 145 of the heat sink module 100, as shown in FIG.
38.
[0646] The first plurality of orifices 155 can have an average
diameter of about 0.001-0.020, 0.001-0.2, 0.001-0.150, 0.001-0.120,
0.001-0.005, or 0.030-0.050 in. The first plurality of orifices 155
can have an average length of about 0.005-0.25, 0.020-0.1,
0.025-0.08, 0.025-0.075, 0.040-0.070, 0.1-0.25, or 0.040-0.070 in.
Each orifice 155 of the first plurality of orifices can have a
central axis 17 that is arranged at an angle of about 30-60, 40-50,
or 45 degrees with respect to the top surface 12 of the thermally
conductive base member 430. The first plurality of orifices 155 can
be arranged in an array 76 organized into staggered columns 77 and
staggered rows 78, as shown in FIG. 31, such that a given orifice
155 in a given column and a given row does not have a corresponding
orifice in a neighboring row in the given column or a corresponding
orifice in a neighboring column in the given row. An average jet
height can be about 0.01-0.75, 0.05-0.5, 0.05-0.25, 0.020-0.25,
0.03-0.125, or 0.04-0.08, where the average jet height is an
average of jet heights 18 measured between the surface 12 of the
thermally conductive member 430 and each orifice outlet of each of
the plurality of orifices (see, e.g. FIG. 26).
[0647] In another example, a heat sink for cooling a heat source
can include a thermally conductive base member 430 configured to
mount on, or be placed in thermal communication with, a heat
source. The heat sink can include a heat sink module 100 having a
bottom surface 135 configured to mount on a surface 12 of the
thermally conductive base member 430. The heat sink module 100 can
include an inlet chamber 145 formed within the heat sink module
100. The heat sink module 100 can include an outlet chamber 150
formed at least partially in the heat sink module and bounded by
the surface 12 of the thermally conductive base member 430 when the
heat sink module is mounted on the thermally conductive base
member, as shown in FIG. 26. The heat sink module 100 can include a
first plurality of orifices 155 extending from the inlet chamber
145 to the outlet chamber 150. The first plurality of orifices 155
can be configured to deliver a plurality of jet streams 16 of
coolant into the outlet chamber 150 and against the surface 12 of
the thermally conductive base member 430 when a flow 51 of pumped
coolant 50 is provided to the inlet chamber 145.
[0648] The inlet chamber 145 can have a volume of about 0.01-0.02,
0.01-0.05, 0.04-0.08, 0.07-0.15, 0.1-0.2, 0.15-0.25, 0.2-0.4, or
0.3-0.5 in.sup.3. The outlet chamber 150 can have a volume of about
0.02-0.05, 0.04-0.08, 0.07-0.15, 0.1-0.2, 0.15-0.25, 0.2-0.4,
0.3-0.5, or 0.4-0.75 in.sup.3. The inlet chamber 145 can decrease
in cross-sectional area in a direction aligned with the direction
of coolant flow 51, as shown in FIG. 26. Conversely, the outlet
chamber 150 can increase in cross-sectional area in a direction
aligned with the direction of coolant flow 51, as shown in FIG. 38.
The heat sink module 100 can include an inlet passage 165 fluidly
connecting an inlet port 105 to the inlet chamber 145, as shown in
FIG. 26. Likewise, the heat sink module 100 can include an outlet
passage 166 fluidly connecting the outlet chamber 150 to an outlet
port 110, as shown in FIG. 38. The inlet port 105 and outlet port
110 can each include threads 170 to facilitate connecting sections
of flexible tubing 225 to the inlet and outlet ports of the module
100. The inlet port 105 can include a central axis 23 defining an
angle of about 10-80, 20-70, 30-60, or 40-50 degrees with respect
to a bottom plane associated with the bottom surface 135 of the
heat sink module 100, as shown in FIG. 26. The outlet port 110 can
include a central axis 24 defining an angle of about 10-80, 20-70,
30-60, or 40-50 degrees with respect to a bottom plane associated
with the bottom surface 135 of the heat sink module 100, as shown
in FIG. 38.
[0649] In yet another example, a heat sink can be configured to
cool a microprocessor 415, as shown in FIGS. 28 and 84-89, by
transferring heat from the microprocessor 415 to a flow 51 of
pumped coolant 50 passing through the heat sink. The heat sink can
include a thermally conductive base member 430 configured to mount
on a surface of a microprocessor 415, a heat sink module 100
mounted on a surface 12 of the thermally conductive base member
430, and a sealing member 125 located between the heat sink module
100 and the surface 12 of the thermally conductive base member 430.
The sealing member 125 can be configured to provide a liquid-tight
seal between the heat sink module 430 and the surface 12 of the
thermally conductive base member 430 to form an outlet chamber 150.
The heat sink module 100 can include a plurality of orifices 155
configured to deliver a plurality of jet streams 16 of coolant 50
into the outlet chamber 150 and against the surface 12 of the
thermally conductive base member 430 when pumped coolant is
provided to inlets of the plurality of orifices 155.
[0650] The sealing member 125 can be disposed in a continuous
channel 140 formed in a bottom surface 135 of the heat sink module
100. The continuous channel 140 can circumscribe the outlet chamber
150. The sealing member 125 can be at least partially compressed
between the continuous channel 140 and the surface 12 of the
thermally conductive base member 430 to provide the liquid-tight
seal. The heat sink can include one or more fasteners 115 securing
the heat sink module 100 against the surface of the thermally
conductive base member 430. The one or more fasteners 115 can
provide a compressive force that compresses the sealing member 125
between the continuous channel 140 and the surface 12 of the
thermally conductive base member 430.
[0651] The heat sink module 100 can include a plurality of
anti-pooling orifices 156 arranged in or proximate a rear wall of
the outlet chamber 150, as shown in FIGS. 24, 34, and 35. The
plurality of anti-pooling orifices 156 can have an average diameter
of about 0.001-0.020, 0.001-0.2, 0.001-0.150, 0.001-0.120,
0.001-0.005, or 0.030-0.050 in. The plurality of anti-pooling
orifices 156 can be configured to deliver a plurality of
anti-pooling jet streams 16 of coolant 50 against the surface of
the thermally conductive base member 430 when pumped coolant is
provided to inlets of the plurality of anti-pooling orifices 156,
as shown in FIG. 38. Each of the plurality of anti-pooling orifices
156 can include a central axis 75 (see, e.g. FIG. 35) arranged at
an angle of about 40-80, 50-70, or 60 degrees with respect to the
surface of the thermally conductive base member 430. The heat sink
module 100 can include one or more boiling-inducing members 196
extending from an inner surface of the outlet chamber 150 toward
the surface 12 of the thermally conductive base member 430, as
shown in FIG. 47. A flow clearance 197 (see, e.g. FIG. 48) can be
provided between ends of the one or more boiling-inducing members
196 and the surface 12 of the thermally conductive base member 430.
The flow clearance 197 can be about 0.001-0.0125, 0.001-0.05,
0.001-0.02, 0.001-0.01, or 0.005-0.010 in.
Examples of Redundant Heat Sink Modules
[0652] In one example, a redundant heat sink module 700 can be
configured to transfer heat away from a surface to be cooled 12.
The redundant heat sink module 700 can include a first independent
coolant pathway 701 and a second independent coolant pathway 701.
The first independent coolant pathway 701 can be formed within the
redundant heat sink module 700 and can include a first inlet
chamber 145-1, a first outlet chamber 150-1, and a first plurality
of orifices 155-1 extending from the first inlet chamber 145-1 to
the first outlet chamber 150-1. The first plurality of orifices
155-1 can be configured to provide a first plurality of impinging
jet streams 16 of coolant 50 against a first region of a surface to
be cooled 12 when the redundant heat sink module 700 is mounted on
the surface to be cooled 12 and when pressurized coolant is
provided to the first inlet chamber 145-1. The second independent
coolant pathway 702 can be formed within the redundant heat sink
module 700 and can include a second inlet chamber 145-2, a second
outlet chamber 150-2, and a second plurality of orifices 155-2
extending from the second inlet chamber 145-2 to the second outlet
chamber 150-2. The second plurality of orifices 155-2 can be
configured to provide a second plurality of impinging jet streams
16 of coolant against a second region of the surface to be cooled
12 when the redundant heat sink module 700 is mounted on the
surface to be cooled 12 and when pressurized coolant is provided to
the second inlet chamber 145-2.
[0653] The first plurality of orifices 155-1 can have an average
jet height 18 of about 0.01-0.75, 0.05-0.5, 0.05-0.25, 0.020-0.25,
0.03-0.125, or 0.04-0.08 in. The first plurality of orifices 155-1
can have an average diameter of D and an average length of L, and L
divided by D can be greater than or equal to one or about 1-10,
1-8, 1-6, 1-4, or 1-3. The first plurality of orifices 155-1 have
an average diameter of about 0.001-0.020, 0.001-0.2, 0.001-0.150,
0.001-0.120, 0.001-0.005, 0.020-0.045, 0.030-0.050 in, or 0.040
in.
[0654] The first inlet chamber 145-1 can decrease in
cross-sectional area in a direction of flow 90, and the first
outlet chamber 150-1 can increase in cross-sectional area in the
direction of flow 90. The second outlet chamber 150-2 can
circumscribe or be adjacent to the first outlet chamber 150-1. The
first independent coolant pathway 701 can include a hydrofoil 705
located upstream of the first inlet chamber 145-1. The hydrofoil
705 can have a curved surface 706 that interacts with the flow of
coolant to assist in providing an even distribution of coolant to
the first plurality of orifices, as shown in FIG. 51N. The
redundant heat sink module 700 can include a flow-guiding lip 162
proximate an exit of the first outlet chamber, as shown in FIG.
51K. A surface of the flow-guiding lip 162 can have an angle of
less than about 45 degrees with respect to a bottom plane of the
redundant heat sink module 700.
[0655] In another example, a redundant apparatus for cooling a heat
source (e.g. a microprocessor 415) can include a thermally
conductive base member 430, a redundant heat sink module 700
mounted on the thermally conductive base member 430, and one or
more sealing members (125-1, 125-2) disposed between the redundant
heat sink module 700 and the thermally conductive base member 430.
The thermally conductive base member 430 can be placed in thermal
communication with a heat source, such as a microprocessor 415 or a
power electronic device. The thermally conductive base member 430
can include a surface to be cooled 12. The redundant heat sink
module 700 can include a first independent coolant pathway 701
formed within the redundant heat sink module 700. The first
independent coolant pathway 701 can include a first inlet chamber
145-1, a first outlet chamber 150-1, and a first plurality of
orifices 155-1 configured to provide a first plurality of impinging
jet streams 16 of coolant 50 against a first region of the surface
to be cooled 12 when pressurized coolant is provided to the first
inlet chamber 145-1. The redundant heat sink module 700 can include
a second independent coolant pathway 702 formed within the
redundant heat sink module 700. The second independent coolant
pathway 702 can include a second inlet chamber 145-2, a second
outlet chamber 150-2, and a second plurality of orifices 155-2
configured to provide a second plurality of impinging jet streams
16 of coolant against a second region of the surface to be cooled
12 when pressurized coolant is provided to the second outlet
chamber 150-2. The one or more sealing members (125-1, 125-5) can
be disposed between a bottom surface 135 of the redundant heat sink
module 700 and a surface of the thermally conductive base member
430 to provide a first liquid-tight seal around a perimeter of the
first outlet chamber 150-1 and a second liquid-tight seal around a
perimeter of the second outlet chamber 150-2.
[0656] The second region of the surface to be cooled 12 can
circumscribe the first region of the surface to be cooled 12. The
thermally conductive base member 430 can be a metallic base plate.
The thermally conductive base member 430 can be a heat pipe having
a sealed vapor cavity.
[0657] In yet another example, a redundant heat sink module 700 for
cooling a heat providing surface can include a first independent
coolant pathway 701 and a second independent coolant pathway 702.
The first independent coolant pathway 701 can include a first inlet
chamber 145-1 formed within the redundant heat sink module 700 and
a first outlet chamber 150-1 formed within the redundant heat sink
module 700. The first outlet chamber 150-1 can have a first open
portion configured to be enclosed by the heat providing surface 12
when the redundant heat sink module 700 is sealed against the heat
providing surface 12. The first independent coolant pathway 702 can
include a first plurality of orifices 155-1 extending from the
first inlet chamber 145-1 to the first outlet chamber 150-1. The
second independent coolant pathway 702 can include a second inlet
chamber 145-2 formed within the redundant heat sink module 700 and
a second outlet chamber 150-2 formed within the redundant heat sink
module 700. The second outlet chamber 150-2 can have a second open
portion configured to be enclosed by the heat providing surface 12
when the redundant heat sink module 700 is sealed against the heat
providing surface 12. The second independent coolant pathway 702
can also include a second plurality of orifices 155-2 extending
from the second inlet chamber 145-2 to the second outlet chamber
150-2.
[0658] The first plurality of orifices 155-1 can be arranged at an
angle of about 20-80, 30-60, 40-50, or 45 degrees with respect to a
bottom plane 19 of the redundant heat sink module 700. The first
plurality of orifices 155-1 can be arranged in an array 76
organized into staggered columns 77 and staggered rows 78 such that
a given orifice in a given column and a given row does not have a
corresponding orifice in a neighboring row in the given column or a
corresponding orifice in a neighboring column in the given row.
[0659] The redundant heat sink module 700 can include a plurality
of anti-pooling orifices 156-1 extending from the first inlet
chamber 145-1 to a rear wall of the first outlet chamber 150-1. The
plurality of anti-pooling orifices 156-1 can be configured to
deliver a plurality of anti-pooling jet streams 16 of coolant 50 to
a rear portion of the first outlet chamber 150-1 when pressurized
coolant 50 is provided to the first inlet chamber 145-1. The first
inlet chamber 145-1 can have a volume of about 0.01-0.02,
0.01-0.05, 0.04-0.08, 0.07-0.15, 0.1-0.2, 0.15-0.25, 0.2-0.4,
0.3-0.5 in.sup.3.
[0660] The redundant heat sink module 700 can include one or more
boiling-inducing members 196 extending into the first outlet
chamber 150-1 toward the heat providing surface 12. A flow
clearance 197 can be provided between end portions of the
boiling-inducing members 196 and a bottom plane 19 of the redundant
heat sink module 700, as shown in FIG. 48. The flow clearance 197
can be about 0.001-0.0125, 0.001-0.05, 0.001-0.02, 0.001-0.01, or
0.005-0.010 in.
[0661] The first independent coolant pathway 701 can include an
upwardly angled inlet port 105-1 fluidly connected to the first
inlet chamber 145-1. The upwardly angled inlet port 145-1 can have
a central axis 24 that defines an angle of about 10-80, 20-70,
30-60, or 40-50 degrees with respect to a bottom plane 19 of the
redundant heat sink module 700. The redundant heat sink module 700
can include additional upwardly angled ports (105-2, 110-1, 110-2),
as shown in FIG. 51A.
[0662] An additive manufacturing process, such as
stereolithography, can be used to manufacture the heat sink module
700. The stereolithography process can include forming layers of
material curable in response to synergistic stimulation adjacent to
previously formed layers of material and successively curing the
layers of material by exposing the layers of material to a pattern
of synergistic stimulation corresponding to successive
cross-sections of the heat sink module. The material curable in
response to synergistic stimulation can be a liquid
photopolymer.
Examples of Methods
[0663] In one example, a method of cooling two heat-providing
surfaces (12-1, 12-2) within a server 400 using a cooling apparatus
1 having two series-connected heat sink modules (100-1, 100-2) can
include providing a flow 51 of single-phase liquid coolant 50 to an
inlet port 105-1 of a first heat sink module 100-1 mounted on a
first heat-providing surface 12-1 within a server 400. A first
amount of heat can be transferred from the first heat-providing
surface 12-1 to the single-phase liquid coolant 50 resulting in
vaporization of a portion of the single phase liquid coolant 50
thereby changing the flow 51 of single-phase liquid coolant 50 to
two-phase bubbly flow containing liquid coolant 50 with vapor
coolant dispersed as bubbles 275 in the liquid coolant 50. The
two-phase bubbly flow can have a first quality (x.sub.1). The
method can include transporting the two-phase bubbly flow from an
outlet port 110-1 of the first heat sink module 100-1 to an inlet
port 105-1 of a second heat sink module 100-2. The second heat sink
module 100-2 can be mounted on a second heat-providing surface 12-2
within the server 400. A second amount of heat can be transferred
from the second heat-providing surface 12-2 to the two-phase bubbly
flow resulting in vaporization of a portion of the liquid coolant
50 within the two-phase bubbly flow thereby resulting in a change
from the first quality (x.sub.1) to a second quality (x.sub.2). The
second quality can be higher than the first quality
(x.sub.2>x.sub.1). The energy from the first amount of heat and
the second amount of heat can be stored, at least in part, as
latent heat in the two-phase bubbly flow and transported out of the
server 400 through the cooling apparatus 1. The amount of heat
transferred out of the server 400 can be a function of the amount
of vapor formed within the two-phase bubbly flow and the heat of
vaporization of the coolant.
[0664] Providing the flow 51 of single-phase liquid coolant 50 to
the inlet port 105-1 of the first heat sink module 100-1 can
include providing a flow rate of about 0.1-10, 0.2-5, 0.25-1.5,
0.3-2.5, 0.6-1.2, or 0.8-1.1 liters per minute of single-phase
liquid coolant 50 to the first inlet 105-1 of the first heat sink
module 100-1. The flow 51 of single-phase liquid coolant 50 can be
a dielectric coolant such as, for example, HFE-7000, R-245fa,
HFE-7100 or a combination thereof.
[0665] Providing the flow 51 of single-phase liquid coolant 50 to
the first heat sink module 100-1 can include providing the flow 51
of single-phase liquid coolant 50 at a predetermined temperature
and a predetermined pressure, where the predetermined temperature
is slightly below the saturation temperature (T.sub.sat) of the
single-phase liquid coolant 50 at the predetermined pressure. The
predetermined temperature can be about 0.5-20, 0.5-15, 0.5-10,
0.5-7, 0.5-5, 0.5-3, 0.5-1, 1-20, 1-15, 1-10, 1-7, 1-5, 1-3, 3-20,
3-15, 3-10, 3-7, 3-5, 5-20, 5-15, 5-10, 5-7, 7-20, 7-15, 7-10,
10-20, 10-15, or 15-20 degrees C. below the saturation temperature
of the single-phase liquid coolant 50 at the predetermined
pressure.
[0666] A pressure differential of about 0.5-5.0, 0.5-3, or 1-3 psi
can be maintained between the inlet port 105-1 of the first heat
sink module 100-1 and the outlet port 110-1 of the first heat sink
module 100-1. The pressure differential can be suitable to promote
the flow 51 to advance from the inlet port 105-1 of the first heat
sink module 100-1 to the outlet port 110-1 of the first heat sink
module 100-1.
[0667] A saturation temperature (T.sub.sat, x.sub.2) and pressure
of the two-phase bubbly flow having a second quality (x.sub.2) can
be less than a saturation temperature (T.sub.sat, x.sub.1) and
pressure of the two-phase flow having a first quality (x.sub.1) (as
shown in FIG. 14B), thereby allowing the second heat-providing
surface 12-2 to be maintained at a lower temperature than the first
heat-providing surface 12-1 when a first heat flux from the first
heat-providing surface is approximately equal to a second heat flux
from the second heat-providing surface.
[0668] The first quality (x.sub.1) can be about 0-0.1, 0.05-0.15,
0.1-0.2, 0.15-0.25, 0.2-0.3, 0.25-0.35, 0.3-0.4, 0.35-0.45,
0.4-0.5, 0.45-0.55, and the second quality (x.sub.2) can be greater
than the first quality, such as, for example, 0-0.1, 0.05-0.15,
0.1-0.2, 0.15-0.25, 0.2-0.3, 0.25-0.35, 0.3-0.4, or 0.4-0.45
greater than the first quality.
[0669] The liquid component 50 of the two-phase bubbly flow that is
transported between the first heat sink module 100-1 and the second
heat sink module 100-2 can have a temperature slightly below its
saturation temperature. The pressure of the two-phase bubbly flow
can be about 0.5-5.0, 0.5-3, or 1-3 psi less than the predetermined
pressure of the flow 51 of single-phase liquid coolant 50 provided
to the inlet port 105-1 of the first heat sink module 100-1.
[0670] The first heat-providing surface 12-1 can be a surface of a
microprocessor 415 within the server 400. The first heat-providing
surface 12-1 can be a surface of a thermally conductive base member
430 in thermal communication with a microprocessor 415 within the
server 400. The thermally conductive base member 430 can be a
metallic base plate mounted on the microprocessor 415 using a
thermal interface material.
[0671] In another example, a method of cooling two or more
heat-providing surfaces (12-1, 12-2) using a cooling apparatus 1
having two or more fluidly connected heat sink modules (e.g. 100-1,
100-2) arranged in a series configuration can include providing a
flow 51 of single-phase liquid coolant 50 to a first inlet port
105-1 of a first heat sink module 100-1 mounted on a first surface
to be cooled 12-1. The flow 51 of single-phase liquid coolant 50
can have a predetermined pressure and a predetermined temperature
at the first inlet port 105-1 of the first heat sink module 100-1.
The predetermined temperature can be slightly below a saturation
temperature of the coolant at the predetermined pressure. The
method can include projecting the flow 51 of single-phase liquid
coolant 50 against the first heat-providing surface 12-1 within the
first heat sink module 100-1, where a first amount of heat is
transferred from the first heat-providing surface 12-1 to the flow
51 of single-phase liquid coolant 50 thereby inducing phase change
in a portion of the single-phase liquid coolant 50 and thereby
changing the flow 51 of single-phase liquid coolant to two-phase
bubbly flow containing a liquid coolant 50 and a plurality of vapor
bubbles 275 dispersed within the liquid coolant 50. The plurality
of vapor bubbles 275 can have a first number density.
[0672] The method can include providing a second heat sink module
100-2 mounted on a second heat-providing surface 12-2. The second
heat sink module 100-2 can include a second inlet port 105-2 and a
second outlet port 110-2. The method can include providing a first
section of tubing 225 having a first end connected to the first
outlet port 110-1 of the first heat sink module 100-1 and a second
end connected to the second inlet port 105-2 of the second heat
sink module 100-2. The first section of tubing 225 can transport
the two-phase bubbly flow having the first number density of vapor
bubbles from the first outlet port 110-1 of the first heat sink
module 100-1 to the second inlet port 105-2 of the second heat sink
module 100-2. The method can include projecting the two-phase
bubbly flow having the first number density against the second
heat-providing surface 12-2 within the second heat sink module
100-2, where a second amount of heat is transferred from the second
heat-providing surface 12-2 to the two-phase bubbly flow having a
first number density and thereby changing two-phase bubbly flow
having a first number density to a two-phase bubbly flow having a
second number density greater than the first number density.
[0673] A saturation temperature and pressure of the two-phase flow
having a second number density can be less than a saturation
temperature and pressure of the two-phase flow having a first
number density, thereby allowing the second heat-providing surface
12-2 to be maintained at a lower temperature than the first
heat-providing surface 12-1 when a first heat flux from the first
heat-providing surface is approximately equal to a second heat flux
from the second heat-providing surface.
[0674] The predetermined temperature of the flow 51 of single-phase
liquid coolant 50 at the first inlet port 105-1 of the first heat
sink module 100-1 can be about 0.5-20, 0.5-15, 0.5-10, 0.5-7,
0.5-5, 0.5-3, 0.5-1, 1-20, 1-15, 1-10, 1-7, 1-5, 1-3, 3-20, 3-15,
3-10, 3-7, 3-5, 5-20, 5-15, 5-10, 5-7, 7-20, 7-15, 7-10, 10-20,
10-15, or 15-20 degrees C. below the saturation temperature of the
flow 51 of single-phase liquid coolant 50 at the predetermined
pressure of the flow 51 of single-phase liquid coolant at the first
inlet of the first heat sink module.
[0675] Providing the flow 51 of single-phase liquid coolant 50 to
the inlet port 105-1 of the first heat sink module 100-1 can
include providing a flow rate of about 0.1-10, 0.2-5, 0.3-2.5,
0.6-1.2, or 0.8-1.1 liters per minute of single-phase liquid
coolant 50 to the first inlet port 100-1 of the first heat sink
module 100-1.
[0676] The liquid in the two-phase bubbly flow being transported
between the first heat sink module 100-1 and the second heat sink
module 100-2 can have a temperature at or slightly below its
saturation temperature, where a pressure of the two-phase bubbly
flow having a first number density is about 0.5-5.0, 0.5-3, or 1-3
psi less than the predetermined pressure of the flow 51 of
single-phase liquid coolant 50 provided to the first heat sink
module 100-1.
[0677] The first heat sink module 100-1 can include an inlet
chamber 145 formed within the first heat sink module and an outlet
chamber 150 formed within the first heat sink module. The outlet
chamber 150 can have an open portion enclosed by the first surface
to be cooled 12-1 when the first heat sink module 100-1 is mounted
on the first surface to be cooled 12-1. The first heat sink module
100-1 can include a plurality of orifices 155 extending from the
inlet chamber 145 to the outlet chamber 150. Projecting the flow 51
of single-phase liquid coolant 50 against the first heat-providing
surface 12-1 can include projecting a plurality of jet streams 16
of single-phase liquid coolant 50 through the plurality of orifices
155 into the outlet chamber 150 and against the first surface to be
cooled 12-1 when the flow 51 of single-phase liquid coolant 50 is
provided to the inlet chamber 145 from the first inlet port 105-1
of the first heat sink module 100-1. The first plurality of
orifices 155 can have an average diameter of about 0.001-0.020,
0.001-0.2, 0.001-0.150, 0.001-0.120, 0.001-0.005, or 0.030-0.050
inches. Outlets of the plurality of orifices 155 can be arranged at
a jet height 18 from the first surface to be cooled 12-1. The jet
height 18 can be about 0.01-0.75, 0.05-0.5, 0.05-0.25, 0.020-0.25,
0.03-0.125, or 0.04-0.08 inches. At least one of the orifices 155
can have a central axis 74 arranged at an angle of about 30-60,
40-50, or 45 degrees with respect to the first surface to be cooled
12-1.
[0678] In another example, a method of cooling two microprocessors
415 on a motherboard 405 using a two-phase cooling apparatus 1
having two series-connected heat sink modules (100-1, 100-2) can
include providing a flow 51 of single-phase liquid coolant 50 to an
inlet port 105 of a first heat sink module 100-1 mounted on a first
thermally conductive base member 430. The first thermally
conductive base member 430 can be mounted on a first microprocessor
415 mounted on a motherboard 405, where heat is transferred from
the first microprocessor 415 through the first thermally conductive
base member 430 and to the flow 51 of single-phase liquid coolant
50 resulting in boiling of a first portion of the single-phase
liquid coolant 50, thereby changing the flow 51 of single-phase
liquid coolant 50 to two-phase bubbly flow having a first quality
(x.sub.1). The method can include transporting the two-phase bubbly
flow from an outlet port 110 of the first heat sink module 100-1 to
an inlet port 105 of a second heat sink module 100-2 through
flexible tubing 225. The second heat sink module 100-2 can be
mounted on a second thermally conductive base member 430 that is
mounted on a second microprocessor 415 mounted on the motherboard
405. Heat can be transferred from the second microprocessor 415
through the second thermally conductive base member 430 and to the
two-phase bubbly flow resulting in vaporization of a portion of
liquid coolant 50 within the two-phase bubbly flow thereby
resulting in a change from the first quality (x.sub.1) to a second
quality (x.sub.1), the second quality being higher than the first
quality (i.e. x.sub.2>x.sub.1).
Examples of Cooling Apparatuses
[0679] In one example, a flexible two-phase cooling apparatus 1 for
cooling microprocessors 415 in servers 400 can include a primary
cooling loop 300, a first bypass 305, and a second bypass 310. The
primary cooling loop 300 can be configured to circulate a
dielectric coolant 50. The primary cooling loop 300 can include a
reservoir 200, a pump 20 downstream of the reservoir 200, an inlet
manifold 210 downstream of the pump 20, an outlet manifold 215
downstream of the inlet manifold 210, and two or more flexible
cooling lines 303 extending from the inlet manifold 210 to the
outlet manifold 215, as shown in FIG. 79. The two or more flexible
cooling lines 303 can each be routable within a server housing 400,
as shown in FIG. 84, and can each be fluidly connected to two or
more series-connected heat sink modules. The two or more flexible
cooling lines can be configured to transport low-pressure,
two-phase dielectric coolant 50. Each heat sink module 100 can
include a thermally conductive base member 430 sized to cover a top
surface of a microprocessor 415, as shown in FIG. 28. A thermal
interface material 435 can be provided between the thermally
conductive base member 430 and the microprocessor 415. The cooling
apparatus 1 can include a first bypass 305 having a first end and a
second end. The first end of the first bypass 305 being can be
connected to the primary cooling loop 300 downstream of the pump 20
and upstream of the inlet manifold 210, as shown in FIG. 79. The
second end of the first bypass 305 can be connected at or upstream
of the reservoir 200. The first bypass 305 can include a first
valve 60-1 configured to regulate a first bypass flow 51-1 of
coolant through the first bypass 305. The cooling apparatus 1 can
include a second bypass 310 having a first end and a second end.
The first end of the second bypass 310 can be connected to the
inlet manifold 210, and the second end of the second bypass 310 can
be connected to the outlet manifold 215, as shown in FIG. 79. The
second bypass 310 can include a second valve 60-2 configured to
regulate a second bypass flow 51-3 of coolant through the second
bypass 310.
[0680] Each of the two or more flexible cooling lines 303 can have
a minimum bend radius R of less than 3, 2.5, or 2 inches to permit
routing within a server housing 400, as shown in FIG. 84. Each of
the two or more flexible cooling lines 303 can have an inner
diameter of about 0.125-0.250 or 0.165-0.185 inches and an outer
diameter of about 0.2-0.4 inches. The primary cooling loop 300 can
be configured to circulate a dielectric coolant 50 having a boiling
point of about 15-35, 20-45, 30-55, or 40-65 degrees C. determined
at a pressure of 1 atm. Each of the two or more flexible cooling
lines 303 can be low pressure cooling lines with a maximum
operating pressure of less than about 35, 50, 75, 100, or 200 psi.
Although the actual operating pressure of the cooling apparatus 1
can be well below 75 or 100 psi, flexible tubing 225 with a higher
pressure rating (e.g. a pressure rating of 100 or 200 psi) may be
selected to provide a suitable factor of safety (e.g. a factor of
safety of 1.5-2.5). The first bypass 305 can include a heat
exchanger 40-1 downstream of the first valve 60-1, as shown in FIG.
79. The heat exchanger 40-1 can be a liquid-to-liquid heat
exchanger configured to fluidly connect to an external heat
rejection loop 43.
[0681] The first valve 60-1 can be configured to provide a pressure
differential of about 5-20 psi between an inlet and an outlet of
the first valve 60-1. Likewise, the second valve 60-2 can be
configured to provide a pressure differential of about 5-20 psi
between an inlet and an outlet of the second valve 60-2. The
cooling apparatus 1 can be configured to hold a predetermined
amount of coolant 50. The reservoir 200 can have an inner volume
configured to hold at least 15% of the predetermined amount of
coolant in the cooling apparatus 1.
[0682] In another example, a flexible two-phase cooling apparatus 1
for cooling one or more heat-generating devices can include a
primary cooling loop 300, a first bypass 305, and a second bypass
310, as shown in FIG. 81. The primary cooling loop 300 can include
a pump 20 configured to provide a flow 51 of pressurized liquid
coolant though the primary cooling loop 300. The primary cooling
loop 300 can include a heat sink module 100 fluidly connected to
the primary cooling loop 300. The heat sink module 100 can be
configured to mount on and remove heat from a surface 12 of a
heat-generating device. The primary cooling loop can include a
reservoir 200 fluidly connected to the primary cooling loop 300
upstream of the pump 20. The first bypass 305 can have a first end
and a second end. The first end of the first bypass 305 can be
fluidly connected to the primary cooling loop 300 downstream of the
pump 20. The second end of the first bypass 305 can be fluidly
connected to the primary cooling loop 300 upstream of the pump 20.
The first bypass can include a first heat exchanger 40-1 and a
first valve 60-1. The first valve 60-1 can be configured to adjust
a first bypass flow 51-1 through the first heat exchanger 40-1. The
first heat exchanger 40-1 can be configured to subcool the first
bypass flow 51-1 of pressurized coolant below a saturation
temperature (T.sub.sat) of the pressurized coolant. A second bypass
310 can have a first end and a second end. The first end of the
second bypass 310 can be fluidly connected to the primary cooling
loop 300 downstream of the pump and upstream of the one or more
heat sink modules 100. The second end of the second bypass 310 can
be fluidly connected to the primary cooling loop 300 downstream of
the one or more heat sink modules 100 and upstream of the reservoir
200. The second bypass 310 can include a second valve 60-2
configured to adjust a second bypass flow 51-3 of pressurized
coolant through the second bypass 310.
[0683] The pump 20 can be configured to provide the flow of
pressurized coolant at a pressure of about 5-20, 15-25, 20-35, or
25-45 psia, where the pressure is measured at the pump outlet 22.
At least a portion of the primary cooling loop 300 can include a
section of flexible tubing 225 fluidly connected to the heat sink
module 100. The section of flexible tubing 225 can have a minimum
bend radius of less than about 3, 2.5, or 2 inches. The section of
flexible tubing 225 can have a maximum operating pressure of less
than 35, 50, 75, 100, or 200 psi.
[0684] The heat sink module 100 can include an inlet chamber 145,
an outlet chamber 150, and a dividing member 195, as shown in FIG.
26. The inlet chamber 145 can be formed within the heat sink module
100. The outlet chamber 150 can be formed within the heat sink
module 100. The outlet chamber 150 can have an open portion along a
bottom surface 135 of the heat sink module 100. The open portion
152 (see, e.g. FIG. 25) can be enclosed by and sealed against a
thermally conductive base member 430, as shown in FIG. 26. A
sealing member 125 can be provided between the heat sink module 100
and the thermally conductive base member 430 to facilitate sealing.
The thermally conductive base member 430 can be configured to mount
on a heat-generating device (e.g. a microprocessor 415), as shown
in FIG. 28, using a thermal interface material 435. The dividing
member 195 can be disposed between the inlet chamber 145 and the
outlet chamber 150. The dividing member 195 can include a first
plurality of orifices 155 formed in the dividing member 195. The
first plurality of orifices 155 can extend from a top surface of
the dividing member 195 to a bottom surface of the dividing member
195. The first plurality of orifices 155 can be configured to
deliver a plurality of jet streams 16 of coolant 50 into the outlet
chamber 150 and against a surface of the thermally conductive base
member 430 when the heat sink module 100 is installed on the
heat-generating device and when pressurized coolant is provided to
the inlet chamber 145, as shown in FIG. 26. The first plurality of
orifices 155 can have an average diameter of about 0.001-0.020,
0.001-0.2, 0.001-0.150, 0.001-0.120, 0.001-0.005, or 0.030-0.050
in. The first plurality of orifices 155 can have an average
diameter of D and an average length of L, and L divided by D can be
greater than or equal to one or about 1-10, 1-8, 1-6, 1-4, or
1-3.
[0685] In yet another example, a flexible two-phase cooling
apparatus 1 for cooling a microprocessor 415 can include a primary
cooling loop 300 and a bypass 310, as shown in FIG. 82. The primary
cooling loop 300 can include a pump 200 configured to provide a
flow 51 of pressurized coolant through the primary cooling loop
300. The primary cooling loop 300 can include a first heat sink
module 100 fluidly sealed against a thermally conductive base
member 430. The heat sink module 100 can be configured to mount on
a surface of a microprocessor 415 such that the thermally
conductive base member 430 is in thermal communication with the
microprocessor 415. The first heat sink module 100 can include a
plurality of internal orifices 155 that are configured to transform
at least a portion of the flow 51 of pressurized coolant into a
plurality of jet streams 16 of coolant 50 directed at a surface of
the thermally conductive base member 430, as shown in FIG. 26. The
plurality of jet streams 16 of coolant 50 can be configured to
remove heat from the thermally conductive base member 430 by way of
latent heat transfer as a fraction of the coolant from the
plurality of jet streams 16 changes phase to vapor bubbles 275 as a
result of absorbing heat from the thermally conductive base member
430, the heat originating from the microprocessor 415. The bypass
310 can have a first end and a second end. The first end of the
bypass 310 can be fluidly connected to the primary cooling loop 300
upstream of the heat sink module 100. The second end of the bypass
310 can be fluidly connected to the primary cooling loop 300
downstream of the heat sink module 100. The bypass 310 can include
a valve 60-2 configured to allow a pressure differential to be
established between an inlet 105 of the heat sink module 100 and an
outlet 110 of the heat sink module 100 to control a flow rate ({dot
over (V)}.sub.line) of pressurized coolant through the heat sink
module. The valve 60-2 can be configured to allow a pressure
differential of about 0.5-3, 1-5, 5-25, 5-20, 10-15, or about 12
psi to be established between an inlet 105 of the heat sink module
and an outlet 110 of the heat sink module.
[0686] The primary cooling loop 300 can include a second heat sink
module 100 fluidly connected in series with the first heat sink
module, as shown in FIG. 84. The outlet port 110 of the first heat
sink module 100 can be fluidly connected to an inlet port 105 of
the second heat sink module 100 by a section of flexible tubing 225
having a minimum bend radius of less than about 3, 2.5, or 2
inches. The section of flexible tubing 225 can be low-pressure
tubing having a maximum operating pressure of less than 35, 50, 75,
or 100 psi. The flow rate ({dot over (V)}.sub.line) of pressurized
coolant through the first and second series-connected heat sink
modules 100 can be about 0.25-5, 0.5-3, 0.5-2, or 0.8-1.2 liters
per minute.
[0687] The cooling apparatus 1 can include a second bypass 305
having a first end and a second end, as shown in FIG. 82. The first
end of the second bypass 305 can be fluidly connected to the
primary cooling loop 300 downstream of the pump and upstream of the
heat sink module 100. The second end of the second bypass 305 can
be fluidly connected to the primary cooling loop 300 downstream of
the one or more heat sink modules 100 and upstream of a reservoir
200. The second bypass 305 can include a second valve 60-1
configured to adjust a second bypass flow 51-1 of pressurized
coolant through the second bypass. The second bypass can include a
heat exchanger configured to provide subcooling of the second
bypass flow 51-1 of pressurized coolant.
[0688] The coolant 50 can be a dielectric coolant with a boiling
point of about 15-35, 20-45, 30-55, or 40-70 degrees C. determined
at a pressure of 1 atm. The dielectric coolant 50 can be
homogeneous or, in some examples, can be a mixture of R-245fa and
HFE 7000, such as about 5-50, 10-35, or 15-25% R-245fa by
volume.
[0689] The elements and method steps described herein can be used
in any combination whether explicitly described or not. All
combinations of method steps as described herein can be performed
in any order, unless otherwise specified or clearly implied to the
contrary by the context in which the referenced combination is
made.
[0690] As used herein, the singular forms "a," "an," and "the"
include plural referents unless the content clearly dictates
otherwise.
[0691] Numerical ranges as used herein are intended to include
every number and subset of numbers contained within that range,
whether specifically disclosed or not. Further, these numerical
ranges should be construed as providing support for a claim
directed to any number or subset of numbers in that range. For
example, a disclosure of from 1 to 10 should be construed as
supporting a range of from 2 to 8, from 3 to 7, from 5 to 6, from 1
to 9, from 3.6 to 4.6, from 3.5 to 9.9, and so forth.
[0692] All patents, patent publications, and peer-reviewed
publications (i.e., "references") cited herein are expressly
incorporated by reference to the same extent as if each individual
reference were specifically and individually indicated as being
incorporated by reference. In case of conflict between the present
disclosure and the incorporated references, the present disclosure
controls.
[0693] The methods and compositions of the present invention can
comprise, consist of, or consist essentially of the essential
elements and limitations described herein, as well as any
additional or optional steps, components, or limitations described
herein or otherwise useful in the art.
[0694] It is understood that the invention is not confined to the
particular construction and arrangement of parts herein illustrated
and described, but embraces such modified forms thereof as come
within the scope of the claims.
[0695] Several impingement technologies exist, but few have shown
commercial promise and none have gained wide-scale commercial
acceptance to date due to instability issues, relatively high flow
rate requirements, limitations on scalability, and other
shortcomings.
[0696] Improved heat sink modules (100, 700) with one or more
arrays 96 of impinging jet streams 16 have been developed and are
described herein. The heat sink modules can be connected in series
and/or parallel configurations to cool a plurality of heat sources
12 simultaneously, thereby providing a scalable jet impingement
technology. Importantly, the heat sink modules described herein are
compact and easy to package within new and existing server and
personal computer housings. The heat sink modules can also be
easily packaged in a wide variety of other electrical and
mechanical devices that require a highly efficient and scalable
cooling apparatus 1.
[0697] The foregoing description has been presented for purposes of
illustration and description. It is not intended to be exhaustive
or to limit the claims to the embodiments disclosed. Other
modifications and variations may be possible in view of the above
teachings. The embodiments were chosen and described to explain the
principles of the invention and its practical application to enable
others skilled in the art to best utilize the invention in various
embodiments and various modifications as are suited to the
particular use contemplated. It is intended that the claims be
construed to include other alternative embodiments of the invention
except insofar as limited by the prior art.
* * * * *