SYSTEMS AND METHODS FOR TWO-PHASE COLD PLATE COOLING

A cold plate can include a first end, a second end opposite the first end, and a plurality of channels therein. A first plurality of channels can run from the first end to the second end. A second plurality of channels can run from the second end to the first end. The first and second pluralities of channels can be interleaved. The cold plate can include first and second outlet ports of greater height and width than first and second inlet ports, and a third outlet port of greater height and width than a third inlet port. A third channel can be disposed at least partially between first and second channels.

Not applicable.

REFERENCE TO APPENDIX

Not applicable.

BACKGROUND OF THE INVENTION

Field of the Invention

The present disclosure relates generally to cooling systems, such as for use with computer processors, and more specifically relates to refrigerant based cooling systems utilizing cold plates.

DESCRIPTION OF THE RELATED ART

Many industries use various types of electronic devices, such as computer servers and other electronic devices having electronic processors and sensors that generate heat during use. The electronic devices are frequently attached to racks capable of supporting the electronic devices and require the continuous removal of heat for proper operation. With the ongoing shrinkage of electronic devices, the use of air as a cooling medium has reached a limitation on how much heat can be reasonably removed with a reasonably attainable air stream. Accordingly, an improved cooling method employs direct conduction cooling from a cooling fluid, or refrigerant, flowing within one or more heat sinks used in this field, generally known as “cold plates,” that contact either the components themselves or the heat rejection plate of a secondary cooling loop in contact with the components.

The cold plates require a sufficient flow of cooling fluid, or refrigerant, that can be significantly lower than flow rates previously encountered in air heat exchanger applications and even in other fluid-cooled applications. However, large pressure drops (such as can occur due to a change of phase from higher density liquid to lower density vapor) across such cold plates can require increased system pressures and temperatures, thereby decreasing overall system efficiency.

BRIEF SUMMARY OF THE INVENTION

Applicants have created new and useful devices, systems and methods for refrigerant-based cooling systems utilizing cold plates. In at least one embodiment, a cooling system can utilize a cold plate to cool a computer processor, or other heat source, and a compressor and/or pump (and/or heat exchanger) to pump a refrigerant through the cold plate, where the refrigerant changes from liquid to vapor, absorbing heat from the processor. In at least one embodiment, the cold plate can have a top, a bottom, a first end, a second end opposite the first end, and a plurality of channels therein. In at least one embodiment, the cold plate can include first and second inlet ports positioned along the first end. In at least one embodiment, the cold plate can include a third inlet port positioned along the second end. The inlet ports can be adjacent to the bottom of the cold plate.

In at least one embodiment, the cold plate can include first and second outlet ports positioned along the second end. In at least one embodiment, the cold plate can include a third outlet port positioned along the first end. The outlet ports can be adjacent to the top of the cold plate. The outlet ports can be of greater height and width than the inlet ports.

The cold plate can further include a plurality of channels running between respective ones of the inlet and outlet ports. For example, cold plate can include a first channel running between the first inlet port and the first outlet port, a second channel running between the second inlet port and the second outlet port, and a third channel running between the third inlet port and the third outlet port. In at least one embodiment, the third channel can be located at least partially between the first and second channels. In at least one embodiment, the first and second channels can be identical and parallel. In at least one embodiment, the third channel can be identical but oppositely oriented to the first and/or second channels.

In at least one embodiment, the cold plate can be configured to receive refrigerant, in a liquid phase, into both first and second ends and transmit the refrigerant, in a vapor phase, from both first and second ends. For example, the first and second inlet ports can be fluidically coupled by a first manifold, such as adjacent to the bottom of the first end of the cold plate, and the first and second outlet ports can be fluidically coupled by a second manifold, such as adjacent to the top of the second end of the cold plate. Similarly, the third inlet port can be fluidically coupled to a third manifold, such as adjacent to the bottom of the second end of the cold plate below the second manifold, and the third outlet port can be fluidically coupled to a fourth manifold, such adjacent to the top of the first end of the cold plate above the first manifold.

Thus, in at least one embodiment, the cold plate can have some channels flowing refrigerant from the first end to the second end and other channels flowing refrigerant from the second end to the first end. Such a configuration may maximize thermal transfer by providing a more uniform thermal transfer.

In at least one embodiment, the cold plate can have a different number of channels flowing refrigerant from the first end to the second end as compared to the number of channels flowing refrigerant from the second end to the first end. In at least one embodiment, the cold plate can have the same number of channels flowing refrigerant from the first end to the second end and as channels flowing refrigerant from the second end to the first end. For example, the cold plate can include a fourth inlet port positioned along the second end adjacent to the bottom, a fourth outlet port positioned along the first end adjacent to the top, and a fourth channel running between the fourth inlet port and the fourth outlet port. The fourth channel can be identical and/or parallel to the third channel. The fourth channel can be located adjacent to the first or second channel.

In at least one embodiment, one or more channels can be configured to minimize pressure drop of a refrigerant as the refrigerant changes phase from liquid to vapor flowing from the inlet ports to the outlet ports. In at least one embodiment, one or more channels can have an internal cross-sectional area or flow area larger than that of one or more inlet ports and/or outlet ports.

In at least one embodiment, one cold plate of one cooling system can be coupled with another cold plate of another cooling system, such as to provide at least some cooling even if one cooling system malfunctions, or is shut down (such as when maximum cooling is not required). For example, the inlet ports of one cold plate can be connected to the outlet ports of another cold plate.

In at least one embodiment, the cooling fluid provided to the inlet manifolds on both ends of the cold plate can come from the same cooling circuit and/or the fluid leaving the outlet manifolds on both ends can return to the same cooling circuit. In at least one embodiment, the cooling fluid provided to the inlet manifold on the first end of the cold plate can come from a first cooling circuit, with the cooling fluid from the outlet ports on the second end of the cold plate returning to the first cooling circuit, and/or the cooling fluid into the inlet manifold on the second end of the cold plate can come from a second cooling circuit, with the cooling fluid from the outlet ports on the first end of the cold plate returning to the second cooling circuit. In this manner, these and other embodiments can be adapted for providing redundancy at one or more cold plates, e.g., if one or more heat exchange circuits are not functioning normally or are offline for one reason or another.

In at least one embodiment, two or more channels can be substantially uniform and/or parallel. In at least one embodiment, two or more channels can be non-uniform and/or not parallel. In at least one embodiment, each channel can be designed and arranged for directing refrigerant flow in order to manage hot spots or otherwise optimize cooling in accordance with an implementation of the disclosure, which can include optimizing cooling for uniquely or irregularly shaped heat sources. For example, one or more cold plates can be designed and arranged to optimize cooling for a specific processor or arrangement of processor(s) (or other heat source(s), as the case may be), and each channel can be designed and arranged for directing or routing refrigerant flow to best manage heat exchange for one or more implementation-specific hot spots, such as one or more hot spots or other areas in need of cooling identified by way of a heat map, thermal CAD analysis, or other assessment for mapping heat transfer needs in accordance with one or more heat sources at hand.

In at least one embodiment, a cold plate according to the disclosure can have a top, a bottom, a first end, a second end opposite the first end, and a plurality of channels therein. In at least one embodiment, the cold plate can include first and second inlet ports positioned along the first end, a third inlet port positioned along the second end, first and second outlet ports positioned along the second end, a third outlet port positioned along the first end, a first channel running between the first inlet port and the first outlet port; a second channel running between the second inlet port and the second outlet port, a third channel running between the third inlet port and the third outlet port, the third channel located between the first and second channels, or any combination thereof. In at least one embodiment, any or all of the outlet ports can have a greater cross sectional area than any or all of the inlet ports. In at least one embodiment, a first channel wall, between the first channel and the third channel, can be thicker than a second channel wall, between the second channel and the third channel.

In at least one embodiment, the cold plate can include a fourth channel running between a fourth inlet port, positioned along the second end, and a fourth outlet port, positioned along the first end. In at least one embodiment, the fourth channel can be located adjacent the second channel. In at least one embodiment, a third channel wall, between the second channel and the fourth channel can be thicker than the second channel wall. In at least one embodiment, the third channel wall, between the second channel and the fourth channel can be thinner than the second channel wall.

In at least one embodiment, the first and second channels can be identical and/or parallel. In at least one embodiment, the third channel can be identical, but oppositely oriented, to the first channel and/or the second channel. In at least one embodiment, the cold plate can receive refrigerant, in a liquid phase, into both the first and second ends and can transmit the refrigerant, in a vapor phase, from both the first and second ends.

In at least one embodiment, the first and second inlet ports can be fluidically coupled by a first manifold adjacent to the first end of the cold plate and/or the first and second outlet ports can be fluidically coupled by a second manifold adjacent to the second end of the cold plate. In at least one embodiment, the third inlet port can be fluidically coupled to a third manifold adjacent to the second end of the cold plate, meshed with the second manifold, and/or the third outlet port can be fluidically coupled to a fourth manifold adjacent to the first end of the cold plate, meshed with the first manifold.

DETAILED DESCRIPTION OF THE INVENTION

The use of a singular term, such as, but not limited to, “a,” is not intended as limiting of the number of items. Also, the use of relational terms, such as, but not limited to, “top,” “bottom,” “left,” “right,” “upper,” “lower,” “down,” “up,” “side,” and the like are used in the written description for clarity in specific reference to the Figures and are not intended to limit the scope of the inventions or the appended claims. The terms “including” and “such as” are illustrative and not limitative. The terms “couple,” “coupled,” “coupling,” “coupler,” and like terms are used broadly herein and can include any method or device for securing, binding, bonding, fastening, attaching, joining, inserting therein, forming thereon or therein, communicating, or otherwise associating, for example, mechanically, magnetically, electrically, chemically, operably, directly or indirectly with intermediate elements, one or more pieces of members together and can further include without limitation integrally forming one functional member with another in a unity fashion. The coupling can occur in any direction, including rotationally. Further, all parts and components of the disclosure that are capable of being physically embodied inherently include imaginary and real characteristics regardless of whether such characteristics are expressly described herein, including but not limited to characteristics such as axes, ends, inner and outer surfaces, interior spaces, tops, bottoms, sides, boundaries, dimensions (e.g., height, length, width, thickness), mass, weight, volume and density, among others.

Process flowcharts discussed herein illustrate the operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the blocks might occur out of the order depicted in the figures. For example, blocks shown in succession may, in fact, be executed substantially concurrently. It will also be noted that each block of a flowchart illustration can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.

Applicants have created new and useful devices, systems and methods for refrigerant based cooling systems utilizing cold plates. Embodiments of the disclosure can help maximize thermal transfer by providing a more uniform thermal transfer versus conventional devices. Embodiments of the disclosure can help minimize pressure drop of a refrigerant as the refrigerant changes phase from liquid to vapor flowing from the inlet ports to the outlet ports. In at least one embodiment, a cold plate can include first and second inlet ports positioned along a first end and a plurality of channels. The cold plate can include a third inlet port positioned along a second end and first and second outlet ports positioned along the second end. A third outlet port can be positioned along the first end. The outlet ports can be of greater height and width than the inlet ports. The plurality of channels can run between respective ones of the inlet and outlet ports. For example, a first channel can run between the first inlet port and the first outlet port, a second channel can run between the second inlet port and the second outlet port, and a third channel can run between the third inlet port and the third outlet port. In at least one embodiment, the third channel can be located at least partially between the first and second channels. In at least one embodiment, the first and second channels can be identical and parallel to one another. In at least one embodiment, the third channel can be identical but oppositely oriented to the first and/or second channels. In at least one embodiment, the channels can each have an internal cross-sectional area or flow area larger than that of the inlet ports and/or the outlet ports.

FIG.1is a schematic diagram of one of many embodiments of a cooling system according to the disclosure.FIG.2is a cross sectional elevation view of one of many embodiments of a cold plate, showing a channel flowing right to left according to the disclosure.FIG.3is a cross sectional elevation view of one of many embodiments of a cold plate, showing a channel flowing left to right according to the disclosure.FIG.4is an end elevation view of one of many embodiments of a cold plate according to the disclosure.FIG.5is a cross sectional plan view of one of many embodiments of a cold plate, showing multiple channels flowing right to left and left to right according to the disclosure.FIG.6is a cross sectional plan view of another one of many embodiments of a cold plate, showing multiple channels flowing right to left and left to right according to the disclosure.FIG.7is a cross sectional plan view of the cold plate ofFIG.6, showing inlet and outlet manifolds.FIG.8is a perspective view of the cold plate ofFIG.6.FIG.9is an end elevation view of the cold plate ofFIG.6, showing a heat load contour.FIG.10is a side elevation view of the cold plate ofFIG.6.FIG.11is cross sectional elevation view of one of many embodiments of an outlet manifold for a cold plate according to the disclosure.FIG.12is cross sectional elevation view of one of many embodiments of an inlet manifold for a cold plate according to the disclosure.FIG.13is cross sectional elevation view of one of many embodiments of inlet and outlet manifolds, shown meshed for use with a cold plate according to the disclosure.FIGS.1-13are described in conjunction with one another.

In at least one embodiment, a cooling system100can utilize a cold plate110to cool a computer processor120, or other heat source, and a compressor and/or pump130(and/or heat exchanger) to pump a refrigerant through the cold plate110, where the refrigerant changes from liquid to vapor, absorbing heat from the processor120. In at least one embodiment, the refrigerant flows to the cold plate110in liquid form through inlet lines150. In at least one embodiment, the refrigerant flows from the cold plate110in vapor form through outlet lines170.

In at least one embodiment, the cold plate110can have a top, a bottom, a first end112, a second end114opposite the first end112, and a plurality of channels180therein. In at least one embodiment, the cold plate110can include a plurality of inlet ports144positioned along the first end112and a plurality of outlet ports164positioned along the second end114. In at least one embodiment, the inlet ports144can be adjacent to the bottom of the cold plate110and/or the outlet ports164can be adjacent to the top of the cold plate110, but other configurations are envisioned. In at least one embodiment, the outlet ports164can be of greater height and width, and therefore have a greater cross-sectional area, than the inlet ports144.

In at least one embodiment, the cold plate110can include first and second inlet ports144a,144bpositioned along the first end112. In at least one embodiment, the cold plate110can include first and second outlet ports164a,164bpositioned along the second end114. In at least one embodiment, the cold plate110can include a third inlet port144cpositioned along the second end114. In at least one embodiment, the cold plate110can include a third outlet port164cpositioned along the first end112.

The cold plate110can further include a plurality of channels180running between respective ones of the inlet and outlet ports144,164. For example, cold plate110can include a first channel180arunning between the first inlet port144aand the first outlet port164a, a second channel180bbetween the second inlet port144band the second outlet port164b, and a third channel180crunning between the third inlet port144cand the third outlet port164c. In at least one embodiment, the third channel180ccan be located at least partially between the first and second channels180a,180b. In at least one embodiment, the first and second channels180a,180bcan be identical and parallel. In at least one embodiment, the third channel180ccan be identical but oppositely oriented to the first and/or second channels180a,180b.

In at least one embodiment, the cold plate110can be configured to receive refrigerant, in a liquid phase, into both first and second ends112,114and transmit the refrigerant, in a vapor phase, from both first and second ends112,114. For example, the first and second inlet ports144a,144bcan be fluidically coupled by a first inlet manifold140a, such as adjacent to the bottom of the first end112of the cold plate110. Similarly, the first and second outlet ports164a,164bcan be fluidically coupled by a first outlet manifold160a, such as adjacent to the top of the second end114of the cold plate110. In at least one embodiment, the third inlet port144ccan be fluidically coupled to a second inlet manifold140b, such as adjacent to the bottom of the second end112the cold plate110below the second manifold first outlet manifold160a, and the third outlet port164ccan be fluidically coupled to a second outlet manifold160b, such adjacent to the top of the first end112of the cold plate110above the first inlet manifold140a.

Thus, in at least one embodiment, the cold plate110can have some channels180flowing refrigerant from the first end112to the second end114and other channels180flowing refrigerant from the second end114to the first end112. Such a configuration may maximize thermal transfer by providing a more uniform thermal transfer. For example, it can be seen that refrigerant enters the cold plate, in liquid form, at both the first end112and the second end114. As the refrigerant absorbs heat from the heat source120, the refrigerant at least partially changes phase to vapor, or gas, and exits both the first end112and the second end114of the cold plate110.

In at least one embodiment, the cold plate110have a different number of channels180flowing refrigerant from the first end112to the second end114and as compared to the number of channels180flowing refrigerant from the second end114the first end112. In at least one embodiment, the cold plate110can have the same number of channels180flowing refrigerant from the first end112to the second end114as channels180flowing refrigerant from the second end114to the first end112. For example, the cold plate110can include a fourth inlet port144dpositioned along the second end114adjacent to the bottom; a fourth outlet port164dpositioned along the first end112adjacent to the top; and a fourth channel180drunning between the fourth inlet port144dand the fourth outlet port164d. In at least one embodiment, the fourth channel180dbe identical and/or parallel to the third channel180c. In at least one embodiment, the fourth channel180dcan be located adjacent to the first or second channel180a,180b.

In at least one embodiment, the channels180can be configured to minimize pressure drop of a refrigerant as the refrigerant changes phase from liquid to vapor flowing from the inlet ports144to the outlet ports164, which can be larger than the inlet ports144. Minimizing pressure drop can also minimize the overall system temperature approach and result in more efficient cooling. In at least one embodiment, the channels180can each have an internal expansion chamber. For example, the channels180can each have an internal cross-sectional area184larger than the inlet ports144and/or the outlet ports164.

As shown inFIG.3, which presents one of many possible embodiments, refrigerant enters the first inlet port144aat the first end112of the cold plate110, in liquid form. As the refrigerant moves from left to right in the first channel180ait at least partially changes from liquid to vapor phase, absorbing heat from the heat source120. The refrigerant then exits the cold plate through the outlet port164a. It can be seen that the outlet port164ais larger than the inlet port144a, which allows the refrigerant to change phase, while minimizing the pressure drop across the cold plate110. It can also be seen that the internal expansion chamber, within the first channel180a, can be larger than the outlet port164a. In at least one embodiment, as shown in the depicted embodiment, the adjacent channel180c, with its inlet port144cand outlet port164c, can occupy part of the same cross-section of the cold plate110. For example, the third inlet port144ccan encroach upon the cross-section of the first outlet port164a, causing the first outlet port164ato be smaller in cross-sectional area than the internal expansion chamber of the first channel180a. This can be used to, for example, help control the flow of refrigerant through the cold plate110, such as to optimize heat absorption.

Similarly, as shown inFIG.2, which presents one of many possible embodiments, refrigerant enters the third inlet port144cat the second end114of the cold plate110, in liquid form. As the refrigerant moves from right to left in the third channel180cit at least partially changes from liquid to vapor phase, absorbing heat from the heat source120. The refrigerant then exits the cold plate through the outlet port164c. It can be seen that the outlet port164cis larger than the inlet port144c, which allows the refrigerant to change phase, while minimizing the pressure drop across the cold plate110. It can also be seen that the internal expansion chamber, within the third channel180c, can be larger than the outlet port164c. In at least one embodiment, as shown in the depicted embodiment, the adjacent channel180b, with its inlet port144band outlet port164b, can occupy part of the same cross-section of the cold plate110. For example, the second inlet port144bcan encroach upon the cross-section of the third outlet port164c, causing the third outlet port164cto be smaller in cross-sectional area than the internal expansion chamber of the third channel180c. This can be used to, for example, help control the flow of refrigerant through the cold plate110, such as to optimize heat absorption.

In both the embodiments pictured inFIGS.2and3, the internal expansion chamber of the channels180a,180ccan have a cross-sectional area184larger than the respective outlet ports164a,164c. In at least one embodiment, the shape of the channels180maximizes liquid refrigerant contact at the bottom thereof, while allowing more space for the vapor refrigerant to escape from the outlet ports164. In at least one embodiment, with additive manufacturing for example, the shapes of the channels (and/or their walls) can be non-uniform and/or non-linear in any direction. In at least one embodiment, the channels180a,180ccan be designed to maximize heat transfer while minimizing pressure drop in the direction of flow due to the lower density vapor as the refrigerant changes phase.

As shown inFIG.4, which presents one of many possible embodiments, refrigerant enters the inlet ports144at one end of the cold plate110, adjacent to the bottom thereby ensuring good heat absorption from the heat source120, and exits the cold plate110through the outlet ports164, adjacent to the top of the cold plate110. In one embodiment, the channels180can be interleaved with alternating (or adjacent) ones of the channels flowing in opposite directions, which can provide improved distribution of two-phase cooling while minimizing refrigerant pressure, pressure drop, velocity, or any combination thereof.

The cold plate110can be manufactured in a number of ways that can remove or minimize design constraints in shaping the channels180and/or portions thereof, such as the internal expansion chambers. In one embodiment, the cold plate110can be manufactured using three-dimensional printing, such as three-dimensional metal printing. In one embodiment, the cold plate110can be manufactured using laminated thin sheet stacking. In any case, the cold plate110can be manufactured such that the size, shape, dimensions, or any combination thereof, of the channels180can be varied in the direction of flow. For example, the cold plate110can be manufactured such that the size, shape, dimensions, or any combination thereof, of the channels180can be expanded in the direction of flow. In at least one embodiment, the cold plate110can be manufactured such that any of the dimensions of the channels180can diverge, or grow, in the direction of flow. In at least one embodiment, the cold plate110can be manufactured such that the velocity of the refrigerant is minimized through the cold plate110, such as by minimizing the pressure drop across the cold plate110, thereby minimizing the overall system temperature approach and maximizing cooling efficiency.

In at least one embodiment, one cold plate110of one cooling system100can be coupled with another cold plate110of another cooling system100, such as to provide at least some cooling even if one cooling system100malfunctions, or is shut down (such as when maximum cooling is not required). For example, the inlet ports144of one cold plate110can be connected to the outlet ports of another cold plate110.

In at least one embodiment, the cooling fluid provided to the inlet manifolds140a,140bon both ends of the cold plate110can come from the same cooling circuit and/or the fluid leaving the outlet manifolds160a,160bon both ends can return to the same cooling circuit. In at least one embodiment, the cooling fluid provided to the inlet manifold140aon the first end112of the cold plate110can come from a first cooling circuit, with the cooling fluid from the outlet manifold160aon the second end114of the cold plate110returning to the first cooling circuit, and/or the cooling fluid into the inlet manifold140bon the second end114of the cold plate110can come from a second cooling circuit, with the cooling fluid from the outlet manifold160bon the first end112of the cold plate110returning to the second cooling circuit. These and other embodiments can provide redundancy at the one or more cold plates.

In at least one embodiment, the channels180can be substantially uniform and/or parallel. In at least one embodiment, the channels180can be non-uniform and/or not parallel. In at least one embodiment, each channel180can be designed to direct refrigerant flow to manage hots spots. For example, a cold plate110can be designed for a specific processor, or other heat source, and one or more channels180can be designed and arranged for directing refrigerant flow to one or more individual hots spots or other heat source areas, such as one or more heat-producing areas identified in a heat map, thermal model or similar thermal analysis.

As best shown inFIGS.6-13, which presents one of many possible embodiments, the channels180of the cold plate110can be aligned next to each other and/or have the same height and/or elevation. In at least one embodiment, the inlet ports144can be aligned next to the outlet ports164and/or have the same height and/or elevation. In at least one embodiment, the inlet manifolds140and the outlet manifolds160can mesh together, with one or more portions of the inlet manifolds140meshing with one or more portions of the outlet manifolds160. In at least one embodiment, one or more portions of the inlet manifolds140can extend below one or more portions of the outlet manifolds160. In at least one embodiment, one or more portions of the inlet manifolds140can extend above one or more portions of the outlet manifolds160.

In at least one embodiment, the inlet manifold140adjacent the first end112of the cold plate110can be identical to the inlet manifold140adjacent the second end114of the cold plate110and/or the outlet manifold160adjacent the first end112of the cold plate110can be identical to the outlet manifold160adjacent the second end114of the cold plate110. In at least one embodiment, the inlet manifold140adjacent the first end112of the cold plate110can be different than the inlet manifold140adjacent the second end114of the cold plate110and/or the outlet manifold160adjacent the first end112of the cold plate110can be different than the outlet manifold160adjacent the second end114of the cold plate110. For example, the inlet manifold140adjacent the first end112of the cold plate110can be designed to mesh with the outlet manifold160adjacent the first end112of the cold plate110but not the outlet manifold160adjacent the second end114of the cold plate110and/or the inlet manifold140adjacent the second end114of the cold plate110can be designed to mesh with the outlet manifold160adjacent the second end114of the cold plate110but not the outlet manifold160adjacent the first end112of the cold plate110.

In at least one embodiment, one or more channel walls190between the channels180can be substantially uniform along their length and/or with respect to each other. In at least one embodiment, one or more channel walls190between the channels180can be non-uniform along their length and/or with respect to each other. In at least one embodiment, one or more channel walls190can be thicker adjacent the first end112of the cold plate110than the second end114. In at least one embodiment, one or more channel walls190can be thinner adjacent the first end112of the cold plate110than the second end114. In at least one embodiment, one or more channel walls190can be thicker than an adjacent channel wall190. In at least one embodiment, one or more channel walls190can be thinner near a center of the cold plate110, such as to provide more cooling near the center of the cold plate110, than the channel walls190nearer to the sides of the cold plate110. In at least one embodiment, one or more channel walls190can be thinner near one side of the cold plate110, such as to provide more cooling near that side of the cold plate110, than the channel walls190nearer to the opposite side of the cold plate110.

In at least one embodiment, a cold plate110according to the disclosure can have a top, a bottom, a first end112, a second end114opposite the first end114, and a plurality of channels180therein. In at least one embodiment, the cold plate110can include first and second inlet ports144positioned along the first end112, a third inlet port144positioned along the second end114, first and second outlet ports164positioned along the second end114, a third outlet port164positioned along the first end112, a first channel180running between the first inlet port144and the first outlet port164; a second channel180running between the second inlet port144and the second outlet port164, a third channel180running between the third inlet port144and the third outlet port164, the third channel180located between the first and second channels180, or any combination thereof. In at least one embodiment, any or all of the outlet ports164can have a greater cross sectional area than any or all of the inlet ports144. In at least one embodiment, a first channel wall190, between the first and third channels180, can be thicker than a second channel wall190, between the second and third channels180.

In at least one embodiment, the cold plate110can include a fourth channel180running between a fourth inlet port144, positioned along the second end114, and a fourth outlet port164, positioned along the first end112. In at least one embodiment, the fourth channel180can be located adjacent the second channel180. In at least one embodiment, a third channel wall190, between the second and fourth channels180can be thicker than the second channel wall190. In at least one embodiment, the third channel wall190, between the second and fourth channels180can be thinner than the second channel wall190.

In at least one embodiment, the first and second channels180can be identical and/or parallel. In at least one embodiment, the third channel180can be identical, but oppositely oriented, to the first and/or second channel(s)180. In at least one embodiment, the cold plate110can receive refrigerant, in a liquid phase, into both the first and second ends112,114and can transmit the refrigerant, in a vapor phase, from both the first and second ends112,114.

In at least one embodiment, the first and second inlet ports144can be fluidically coupled by a first manifold140adjacent to the first end112of the cold plate110and/or the first and second outlet ports164can be fluidically coupled by a second manifold160adjacent to the second end144of the cold plate110. In at least one embodiment, the third inlet port144can be fluidically coupled to a third manifold140adjacent to the second end114of the cold plate110, meshed with the second manifold160, and/or the third outlet port164can be fluidically coupled to a fourth manifold160adjacent to the first end112of the cold plate110, meshed with the first manifold140.

In at least one embodiment, a cooling system can utilize a cold plate to cool a computer processor, or other heat source, and a compressor and/or pump (and/or heat exchanger) to pump a refrigerant through the cold plate, where the refrigerant changes from liquid to vapor, absorbing heat from the processor. In at least one embodiment, the cold plate can have a top, a bottom, a first end, a second end opposite the first end, and a plurality of channels therein. In at least one embodiment, the cold plate can include first and second inlet ports positioned along the first end. In at least one embodiment, the cold plate can include a third inlet port positioned along the second end. The inlet ports can be adjacent to the bottom of the cold plate.

In at least one embodiment, the cold plate can include first and second outlet ports positioned along the second end. In at least one embodiment, the cold plate can include a third outlet port positioned along the first end. The outlet ports can be adjacent to the top of the cold plate. The outlet ports can be of greater height and width than the inlet ports.

The cold plate can further include a plurality of channels running between respective ones of the inlet and outlet ports. For example, cold plate can include a first channel running between the first inlet port and the first outlet port, a second channel running between the second inlet port and the second outlet port, and a third channel running between the third inlet port and the third outlet port. In at least one embodiment, the third channel can be located at least partially between the first and second channels. In at least one embodiment, the first and second channels can be identical and parallel. In at least one embodiment, the third channel can be identical but oppositely oriented to the first and/or second channels.

In at least one embodiment, the cold plate can be configured to receive refrigerant, in a liquid phase, into both first and second ends and transmit the refrigerant, in a vapor phase, from both first and second ends. For example, the first and second inlet ports can be fluidically coupled by a first manifold, such as adjacent to the bottom of the first end of the cold plate, and the first and second outlet ports can be fluidically coupled by a second manifold, such as adjacent to the top of the second end of the cold plate. Similarly, the third inlet port can be fluidically coupled to a third manifold, such as adjacent to the bottom of the second end of the cold plate below the second manifold, and the third outlet port can be fluidically coupled to a fourth manifold, such adjacent to the top of the first end of the cold plate above the first manifold.

Thus, in at least one embodiment, the cold plate can have some channels flowing refrigerant from the first end to the second end and other channels flowing refrigerant from the second end to the first end. Such a configuration may maximize thermal transfer by providing a more uniform thermal transfer.

In at least one embodiment, the cold plate can have a different number of channels flowing refrigerant from the first end to the second end and as compared to the number of channels flowing refrigerant from the second end to the first end. In at least one embodiment, the cold plate can have the same number of channels flowing refrigerant from the first end to the second end and as channels flowing refrigerant from the second end to the first end. For example, the cold plate can include a fourth inlet port positioned along the second end adjacent to the bottom; a fourth outlet port positioned along the first end adjacent to the top; and a fourth channel running between the fourth inlet port and the fourth outlet port. The fourth channel can be identical and/or parallel to the third channel. The fourth channel can be located adjacent to the first or second channel.

In at least one embodiment, the channels can be configured to minimize pressure drop of a refrigerant as the refrigerant changes phase from liquid to vapor flowing from the inlet ports to the outlet ports. In at least one embodiment, the channels can each have an internal cross-sectional area larger than the inlet ports and/or the outlet ports.

In at least one embodiment, one cold plate of one cooling system can be coupled with another cold plate of another cooling system, such as to provide at least some cooling even if one cooling system malfunctions, or is shut down (such as when maximum cooling is not required). For example, the inlet ports of one cold plate can be connected to the outlet ports of another cold plate.

In at least one embodiment, the cooling fluid provided to the inlet manifolds on both ends of the cold plate can come from the same cooling circuit and/or the fluid leaving the outlet manifolds on both ends can return to the same cooling circuit. In at least one embodiment, the cooling fluid provided to the inlet manifold on the first end of the cold plate can come from a first cooling circuit, with the cooling fluid from the outlet ports on the second end of the cold plate returning to the first cooling circuit, and/or the cooling fluid into the inlet manifold on the second end of the cold plate can come from a second cooling circuit, with the cooling fluid from the outlet ports on the first end of the cold plate returning to the second cooling circuit. These, and other, embodiment(s) provide redundancy at the one or more cold plates.

In at least one embodiment, the channels can be substantially uniform and/or parallel. In at least one embodiment, the channels can be non-uniform and/or not parallel. In at least one embodiment, each channel can be designed to direct refrigerant flow to manage hots spots. For example, a cold plate can be designed for a specific processor, or other heat source, with each channel designed direct refrigerant flow to individual hots spots, which can be identified in a heat map or similar analysis.

In at least one embodiment, a cold plate according to the disclosure can have a top, a bottom, a first end, a second end opposite the first end, and a plurality of channels therein. In at least one embodiment, the cold plate can include first and second inlet ports positioned along the first end, a third inlet port positioned along the second end, first and second outlet ports positioned along the second end, a third outlet port positioned along the first end, a first channel running between the first inlet port and the first outlet port; a second channel running between the second inlet port and the second outlet port, a third channel running between the third inlet port and the third outlet port, the third channel located between the first and second channels, or any combination thereof. In at least one embodiment, any or all of the outlet ports can have a greater cross sectional area than any or all of the inlet ports. In at least one embodiment, a first channel wall, between the first channel and the third channel, can be thicker than a second channel wall, between the second channel and the third channel.

In at least one embodiment, the cold plate can include a fourth channel running between a fourth inlet port, positioned along the second end, and a fourth outlet port, positioned along the first end. In at least one embodiment, the fourth channel can be located adjacent the second channel. In at least one embodiment, a third channel wall, between the second channel and the fourth channel can be thicker than the second channel wall. In at least one embodiment, the third channel wall, between the second channel and the fourth channel can be thinner than the second channel wall.

In at least one embodiment, the first and second channels can be identical and/or parallel. In at least one embodiment, the third channel can be identical, but oppositely oriented, to the first channel and/or the second channel. In at least one embodiment, the cold plate can receive refrigerant, in a liquid phase, into both the first and second ends and can transmit the refrigerant, in a vapor phase, from both the first and second ends.

In at least one embodiment, the first and second inlet ports can be fluidically coupled by a first manifold adjacent to the first end of the cold plate and/or the first and second outlet ports can be fluidically coupled by a second manifold adjacent to the second end of the cold plate. In at least one embodiment, the third inlet port can be fluidically coupled to a third manifold adjacent to the second end of the cold plate, meshed with the second manifold, and/or the third outlet port can be fluidically coupled to a fourth manifold adjacent to the first end of the cold plate, meshed with the first manifold.

Other and further embodiments utilizing one or more aspects of the disclosure can be devised without departing from the spirit of Applicants' disclosure. For example, the devices, systems and methods can be implemented for numerous different types and sizes in numerous different industries. Further, the various methods and embodiments of the devices, systems and methods can be included in combination with each other to produce variations of the disclosed methods and embodiments. Discussion of singular elements can include plural elements and vice versa. The order of steps can occur in a variety of sequences unless otherwise specifically limited. The various steps described herein can be combined with other steps, interlineated with the stated steps, and/or split into multiple steps. Similarly, elements have been described functionally and can be embodied as separate components or can be combined into components having multiple functions.