Device and method for providing immersion cooling in a compact-format circuit card environment

An apparatus for providing immersion cooling in a compact-format circuit card environment comprises a plurality of circuit cards. A plurality of thermal energy transfer devices is provided, each thermal energy transfer device at least partially inducing a respective one of first and second operating temperatures to a corresponding circuit card subassembly. At least one first temperature cooling manifold is in selective fluid communication with at least one first operating temperature thermal energy transfer device. At least one second temperature cooling manifold is in selective fluid communication with at least one second operating temperature thermal energy transfer device. A plurality of manifold interfaces is provided, each manifold interface being in fluid communication with a corresponding thermal energy transfer device. A housing includes first and second operating fluid inlets in fluid communication with first and second operating fluid outlets, respectively.

TECHNICAL FIELD

This disclosure relates to a temperature control method, system, and apparatus and, more particularly, to an apparatus, system, and method for providing immersion cooling in a compact-format circuit card environment.

BACKGROUND

A circuit card is the current state of the art for building assemblies of electronic devices including a plurality of integrated circuits (“chips”). These assemblies can be separated into multiple types: organic multilayer laminated printed wire board (PWB), low temperature co-fired ceramic (LTCC), and high temperature co-fired ceramic (HTCC). Using each of these technologies, circuit card assemblies have been fabricated.

In a superconducting supercomputer, many of the operating processing integrated circuits (“chips”) are cooled to about 4K, but certain of the memory chips instead have a much warmer operating temperature of about 77K. Providing cooling at 4K is a costly activity, so every effort is made in superconducting supercomputer design to reduce the thermal parasitic load. This includes placing the assembly in vacuum (no convection), use of coatings and multilayer insulation to reduce radiation, and limiting the conductive thermal load between the “hot side” and “cool side” of the entire assembly.

For large scale applications, the state of the art currently solves the problem of achieving the desired operating temperatures for a superconducting supercomputer while avoiding thermal parasitic load by using dewars for each of the cryogenic temperatures. A 4K dewar is maintained with liquid helium and a 77K dewar uses liquid nitrogen. Signals between the two temperature sides are completed by cabling. This solution requires cables that are long from a digital perspective, which results in significant latency between the 4K and 77K regions and would require more parts in the 4K stage, such as, but not limited to, amplifiers to compensate for the loss in the longer signal path. These additional parts consume significant power and make certain designs of superconducting supercomputers infeasible.

In small scale applications, a cryocooler can be used for both temperatures. The intermediate stage of the cryocooler provides a 77K platform while the final stage of the cryocooler provides a 4K stage. Connections between the two zones are completed by cabling. While this brings the two temperatures sides closer together, this approach is not scalable to large applications.

Additionally, neither of the above strategies is particularly suited to a compact-format use environment, such as providing computing resources on an aircraft, due to the significant space and equipment needed.

SUMMARY

In an aspect, an apparatus for providing immersion cooling in a compact-format circuit card environment is provided. The apparatus comprises a plurality of circuit cards. Each circuit card includes first and second longitudinally spaced circuit card subassemblies, connected together into a single circuit card oriented substantially in a lateral-longitudinal plane. The first and second circuit card subassemblies are connected together by a longitudinally extending card connector. The first and second circuit card subassemblies have first and second operating temperatures, respectively. The first and second operating temperatures are different from one another. A plurality of thermal energy transfer devices is provided, with each thermal energy transfer device being operatively connected to an area of a corresponding circuit card correlated with a selected one of the first and second circuit card subassemblies. Each thermal energy transfer device at least partially induces the respective one of the first and second operating temperatures to a corresponding circuit card subassembly. Each thermal energy transfer device transversely overlies at least a supermajority of the corresponding circuit card subassembly and is longitudinally spaced from an other circuit card subassembly of the corresponding circuit card. At least one first temperature cooling manifold is in selective fluid communication with at least one thermal energy transfer device at least partially induce the first operating temperature. The first temperature cooling manifold selectively introduces a first cooling fluid into, and selectively removes the first cooling fluid from, the thermal energy transfer device at least partially inducing the first operating temperature. At least one second temperature cooling manifold is in selective fluid communication with at least one thermal energy transfer device at least partially inducing the second operating temperature. The second temperature cooling manifold selectively introduces a second cooling fluid into, and selectively removes the second cooling fluid from, the thermal energy transfer device at least partially inducing the second operating temperature. A plurality of manifold interfaces is provided. Each manifold interface is in fluid communication with a corresponding thermal energy transfer device. Each manifold interface is provided for selective fluid communication with a corresponding cooling manifold. A housing includes a first operating fluid inlet in fluid communication via the first temperature cooling manifold with a first operating fluid outlet and a second operating fluid inlet in fluid communication via the second temperature cooling manifold with a second operating fluid outlet. The housing supports and at least partially surrounds the plurality of circuit cards, the plurality of thermal energy transfer devices, the plurality of manifold interfaces, and the first and second temperature cooling manifolds.

In an embodiment, a method of providing immersion cooling in a compact-format circuit card environment is provided. The method comprises providing an apparatus including a plurality of circuit cards. Each circuit card includes first and second circuit card subassemblies. A plurality of thermal energy transfer devices is provided. Each thermal energy transfer device is associated with a corresponding circuit card subassembly. The first circuit card subassembly is configured for operation at a first operating temperature, and the second circuit card subassembly being configured for operation at a second operating temperature which is different from the first operating temperature. At least one first temperature cooling manifold and at least one second temperature cooling manifold are provided. Each thermal energy transfer device is operatively connected to an associated different one of the first and second circuit card subassemblies. The first circuit card subassemblies are at least partially exposed to the first operating temperature via placing at least one first temperature cooling manifold in selective fluid communication with a plurality of thermal energy transfer devices corresponding to the first circuit card subassemblies. A first cooling fluid is selectively introduced into, and selectively removed from, the thermal energy transfer devices which are operatively connected to the first circuit card subassemblies. The second circuit card subassemblies are at least partially exposed to the second operating temperature via placing at least one second temperature cooling manifold in selective fluid communication with a plurality of thermal energy transfer devices corresponding to the second circuit card subassemblies. A second cooling fluid is selectively introduced into, and selectively removed from, the thermal energy transfer devices which are operatively connected to the second circuit card subassemblies.

In an aspect, a system for providing immersion cooling in a compact-format circuit card environment is provided. The system comprises an apparatus comprising a plurality of circuit cards. Each circuit card includes first and second longitudinally spaced circuit card subassemblies, connected together into a single circuit card oriented substantially in a lateral-longitudinal plane. The first and second circuit card subassemblies are connected together by a longitudinally extending card connector. The first and second circuit card subassemblies have first and second operating temperatures, respectively. The first and second operating temperatures are different from one another. A plurality of thermal energy transfer devices is provided. Each thermal energy transfer device is operatively connected to an area of a corresponding circuit card correlated with a selected one of the first and second circuit card subassemblies. Each thermal energy transfer device at least partially induces the respective one of the first and second operating temperatures to a corresponding circuit card subassembly. Each thermal energy transfer device transversely over lies at least a supermajority of the corresponding circuit card subassembly and is longitudinally spaced from an other circuit card subassembly of the corresponding circuit card. At least one first temperature cooling manifold is in selective fluid communication with at least one thermal energy transfer device at least partially inducing the first operating temperature. The first temperature cooling manifold selectively introduces a first cooling fluid into, and selectively removes the first cooling fluid from, the thermal energy transfer device at least partially inducing the first operating temperature. At least one second temperature cooling manifold is in selective fluid communication with at least one thermal energy transfer device at least partially inducing the second operating temperature. The second temperature cooling manifold selectively introduces a second cooling fluid into, and selectively removes the second cooling fluid from, the thermal energy transfer device at least partially inducing the second operating temperature. A plurality of manifold interfaces is provided. Each manifold interface is in fluid communication with a corresponding thermal energy transfer device. Each manifold interface is configured for selective fluid communication with a corresponding cooling manifold. A housing includes a first operating fluid inlet in fluid communication via the first temperature cooling manifold with a first operating fluid outlet and a second operating fluid inlet in fluid communication via the second temperature cooling manifold with a second operating fluid outlet. The housing supports and at least partially surrounds the plurality of circuit cards, the plurality of thermal energy transfer devices, the plurality of manifold interfaces, and the first and second temperature cooling manifolds. A first cooling fluid source is in fluid supplying communication with the first temperature cooling manifold via the first operating fluid inlet. A second cooling fluid source is in fluid supplying communication with the second temperature cooling manifold via the second operating fluid inlet. A first cooling fluid destination is in fluid removing communication with the first temperature cooling manifold via the first operating fluid outlet. A second cooling fluid destination is in fluid removing communication with the second temperature cooling manifold via the second operating fluid outlet. A cabinet supports and at least partially encloses the apparatus, the first and second cooling fluid sources, and the first and second cooling fluid destinations.

Description of Aspects of the Disclosure

This technology comprises, consists of, or consists essentially of the following features, in any combination.

With reference toFIGS. 1-2, a cryogenic supercomputer (shown generally as “CS”) may be desirably carried within an aircraft use environment (represented by a partial fuselage A inFIG. 1). For example, a cryogenic supercomputer CS could provide more than one hundred teraflops of computing capacity onboard an aircraft while consuming about fifty watts of electricity. This is significantly higher performance, with less power draw, than non-cryogenic computing systems currently available in aircraft applications. However, the cryogenic support systems needed to maintain appropriate operating temperatures (e.g., 4 K for RQL processors and 77 K for memory) require scarce space aboard the aircraft. Often, the low-temperature components of the cryogenic supercomputer are cooled with immersion cooling techniques. Accordingly, a system100can be configured for providing immersion cooling in a compact-format circuit card environment. The compact-format environment will be shown and described herein as an aircraft use environment, but one of ordinary skill in the art will understand that the system100could be used in any desired use environment, such as, but not limited to, one in which transportation and/or operating space is at a premium (e.g., submarine, spacecraft, remote scientific station, or the like).

The system100includes at least one apparatus102for providing immersion cooling in a compact-format circuit card environment. The apparatus102includes a plurality of circuit cards104, two example configurations of which are shown in partial phantom view inFIGS. 7A-7B. Each circuit card104includes first and second longitudinally spaced circuit card subassemblies706and708, respectively, connected together into a single circuit card104oriented substantially in a lateral-longitudinal plane. The “longitudinal” direction is substantially parallel to arrow “Lo”, and the “lateral” direction is substantially parallel to arrow “La:” inFIGS. 7A-7B, thus making the lateral-longitudinal plane substantially coincident with the plane of the page in those Figures. The first and second circuit card subassemblies706and708are connected together by a laterally extending card connector710. The first and second circuit card subassemblies706and708could comprise, as in the example shown inFIG. 7A, two longitudinally spaced groups of IC chips712mounted on a single backing substrate714—here, the backing substrate714serves also as a card connector710. Thus, as shown inFIG. 9, the first and second circuit card subassemblies706and708are simply spaced-apart areas, each comprising a plurality of IC chips712mounted on, and extending transversely from, the single backing substrate714. (The “transverse” direction is substantially perpendicular to both the longitudinal and lateral directions, and is into and out of the plane of the page inFIGS. 7A-7B, though is shown as arrow “T” inFIG. 11.)

Additionally or alternatively, one or both of the first and second circuit card subassemblies706and708could comprise a plurality of IC chips712mounted on, and extending transversely from, a subassembly substrate716, with two subassembly substrates716shown inFIGS. 7B and 11. The subassembly substrates716(before or after the IC chips712are mounted thereon) for a single circuit card104of the type shown inFIGS. 7B and 11may then be, in turn, attached via one or more flexible card connectors710to achieve the desired longitudinal spacing for the first and second circuit card subassemblies706and708. As shown inFIGS. 7B and 11, each card connector710comprises at least one longitudinally extending flexible interconnect718. This “modular” construction (using subassembly substrates716) is shown in at leastFIGS. 7B and 11.

Stated differently, two longitudinally adjacent first and second circuit card subassemblies706and708can be maintained (via their inclusion in the apparatus102) in close spatial proximity to each other, each at a different temperature, with low thermal parasitic heat transfer between first and second circuit card subassemblies706and708due to at least one of the cooling structures described herein and/or the presence of at least a portion of the card connector710(regardless of type) longitudinally between the first and second circuit card subassemblies706and708.

One example of a suitable circuit card104is provided in U.S. Pat. No. 9,648,749, issued 9 May 2017 and entitled “CIRCUIT CARD ASSEMBLY AND METHOD OF PROVIDING SAME”, incorporated herein by reference in its entirety. The presence of the circuit card104, or portions thereof, may help to restrict at least one of magnetic, thermal, and radiation transmission longitudinally between the IC chips712of the first and second circuit card subassemblies706and708. For example, the card connector710could act in a heat shielding and electro-magnetic interference (“EMI”) shielding capacity.

In other words, the first and second circuit card subassemblies706and708may be connected together by a longitudinally extending card connector710(shown and described herein as either a portion of the backing substrate714—FIG. 7A—or the flexible interconnect718ofFIG. 7B), oriented in a parallel lateral-longitudinal plane to the first and second circuit card subassemblies706and708. (It should be noted that, as in the case of the single backing substrate714, the first and second circuit card subassemblies706and708can be considered to be oriented in the same lateral-longitudinal plane as the card connector710.) As in the arrangement ofFIGS. 7B and 11, each circuit card subassembly706and708may include a plurality of IC chips712extending transversely from a subassembly substrate716. Each subassembly substrate716in the arrangement ofFIGS. 7B and 11may be connected to another subassembly substrate716by a flexible interconnect718.

However, in all of the depicted circuit cards104, the first and second circuit card subassemblies706and708may be spaced longitudinally apart, with a longitudinally intervening portion of the card connector710. The card connector710may be less thermally conductive than either of the first and second circuit card subassemblies706and708, which may assist in preventing parasitic heat transfer between the first and second circuit card subassemblies706and708in some use environments.

The IC chips712of a single circuit card104may have different temperature requirements. For example, the longitudinally rightmost (in the orientation ofFIGS. 7A-7B) array of IC chips712(e.g., those on the first circuit card subassembly706) could have a desired operating temperature in the range of about 2-6K, such as about 4K. Similarly, the longitudinally leftmost (in the orientationFIGS. 7A-7B) array of IC chips712(e.g., those on the second circuit card subassembly708) could have a desired operating temperature in the range of about 75-79K, such as about 77K. As described below, the apparatus102can help provide a desired temperature-differential environment for the first and second circuit card subassemblies706and708, and the card connector710(regardless of type) can assist with thermal efficiency by blocking, among other energies, thermal energy transfer longitudinally between the first and second circuit card subassemblies706and708. Having greater physical separation between the first and second first and second circuit card subassemblies706and708increases the thermal isolation; however, it also increases the signal loss and latency. A balance should be struck, by one of ordinary skill in the art, between acceptable signal loss/latency and thermal isolation to determine the optimal separation for a particular use environment.

The first and second circuit card subassemblies706and708, as previously mentioned, may have first and second operating temperatures, respectively. The first and second operating temperatures are different from one another. A plurality of thermal energy transfer devices720, which will be discussed at length below, are provided, with each thermal energy transfer device720being operatively connected to an area of the circuit card104correlated with a selected one of the first and second circuit card subassemblies706and708. Each thermal energy transfer device720at least partially induces the respective, or appropriate, one of the first and second operating temperatures to the selected circuit card subassembly706and708with which that thermal energy transfer device720is associated. The thermal energy transfer device720transversely overlies at least a supermajority of the selected circuit card subassembly706and708and is laterally spaced from the other circuit card subassembly706and708, as depicted in the Figures. There may be one or more thermal energy transfer devices720provided to each apparatus100, as desired.

The thermal energy transfer devices720may be in direct thermally conductive contact with at least a portion of the selected circuit card subassembly706and708as shown inFIGS. 7A-7B, in order to assist with heat transfer between these two structures. In some use environments, the thermal energy transfer devices720may be a circulating-coolant heat sink; this is the arrangement shown and described herein. The thermal energy transfer devices720could, for some use environments of the system100, be similar to those disclosed in U.S. patent application Ser. No. 15/916,019, filed 8 Mar. 2018 and entitled “IMMERSION COOLING TEMPERATURE CONTROL METHOD, SYSTEM AND APPARATUS”, incorporated herein by reference in its entirety.

FIGS. 7A-7Bshow two example configurations of circuit card units722. The first and second thermal energy transfer devices720aand720bhave been placed into thermally significant proximity with their respective first and second circuit card subassemblies706and708. “Thermally significant proximity” is used herein to indicate a degree of physical closeness between the “proximate” structures which facilitates a desired direction, type, and amount of heat transfer. For example, “thermally significant proximity” includes, but is not limited to, one or more of direct contact for thermal conduction and a spaced relationship for thermal convection and/or radiation. The thermal energy transfer device(s)720can have any desired form factor or configuration. For example, when the first and second circuit card subassemblies706and708and/or the backing substrate714are planar, the thermal energy transfer device(s)720may have a substantially planar or flat surface (e.g., an “underside”) which is placed into thermally significant proximity to those structures.

The relationship between the first and second thermal energy transfer devices720aand720band their respective first and second circuit card subassemblies706and708(as well as the other components of the same circuit card unit722, some of which will be described below) may be established and maintained in any desired manner and with any suitable assistance including, but not limited to, one or more of frictional fit, adhesives, mechanical fastener(s) or other attachment structures, gravity, magnetics, soldering/welding, or the like. As with all aspects of the described system100, one of ordinary skill in the art will be able to produce a suitable circuit card unit722according to aspects of the present invention for a particular use environment based upon the current description and depictions.

With reference toFIGS. 7A-7B and 8, each circuit card unit722could include any number of desired input and/or output connectors for electrically interconnecting the circuit card104, or components thereof, with other circuit cards104, an outside computer, a power source, or any other desired connection devices. For example, as shown inFIG. 8, a clock input824and/or an optical I/O826could be provided in any desired manner. Similarly, as shown inFIGS. 7A-7B and 11, a network interface board connector728could be provided to the circuit card104. It is contemplated that, for most use environments, the network interface board connector728will be connected to the first and second circuit card subassemblies706and708analogously to the way that the first and second circuit card subassemblies706and708are connected to each other via a card connector710. That is, when the card connector710is a portion of the backing substrate714as inFIG. 7A, the network interface board connector728will be connected to the first and second circuit card subassemblies706and708via connection to a portion of the backing substrate714.

Conversely, when the card connector710is a flexible interconnect718, the network interface board connector728will also be connected to the first and second circuit card subassemblies706and708via a flexible interconnect718as shown inFIGS. 7B and 11. As shown in those Figures, at least one spring730(two shown) may be used to help dampen or cushion motion of the network interface board connector728relative to the first and/or second circuit card subassembly706or708, as desired.

ThoughFIGS. 7A-7Bdepict examples of circuit card units722with differing substrate714,716and card connector710configurations, the system100is agnostic as to which of these types of configurations, or any other configurations (whether or not shown and described herein) which could be used. Accordingly, the below description of the system100, and components/features thereof, should be considered to apply equally to either of the circuit card unit722configurations ofFIGS. 7A-7B, or to any other desired circuit card unit configuration.

As shown inFIGS. 4-6, each apparatus100may include at least one first temperature cooling manifold432in selective fluid communication with at least one thermal energy transfer device720afor at least partially inducing the first operating temperature. The first temperature cooling manifold432selectively introduces a first cooling fluid into, and selectively removes the first cooling fluid from, the thermal energy transfer device720awhich is at least partially inducing the first operating temperature. Each circuit card unit722may also include at least one second temperature cooling manifold434in selective fluid communication with at least one thermal energy transfer device720bfor at least partially inducing the second operating temperature. The second temperature cooling manifold434selectively introduces a second cooling fluid into, and selectively removes the second cooling fluid from, the thermal energy transfer device720bat least partially inducing the second operating temperature.

As shown inFIGS. 7A-7B and 11, the apparatus102may include a plurality of manifold interfaces736, with each manifold interface736being in fluid communication with a corresponding thermal energy transfer device720. By way of example, manifold interface736ais in fluid communication with thermal energy transfer device720a, and manifold interface736bis in fluid communication with thermal energy transfer device720b. Stated differently, each manifold interface736is in bidirectional fluid communication with a corresponding thermal energy transfer device720via an interface connector738, as shown inFIG. 10.

The interface connector738is shown as a “gooseneck” type, with a curved center section to allow for stress relief under thermal expansion and/or relative movement (e.g., “swinging” due to aircraft motion) of the manifold interface736and the corresponding thermal energy transfer device720. As will be described below, in certain use environments of the system100, liquid-phase coolant is routed downward (in the orientation ofFIG. 10) from the manifold interface736into the thermal energy transfer device720through the interface connector738sequentially and/or concurrently with “bubbles” of vapor-phase coolant rising upward (in the orientation ofFIG. 10) from the thermal energy transfer device720through the interface connector738toward the manifold interface736. As a result, liquid-phase coolant can be provided from a cooling manifold432or434, through the manifold interface736and the interface connector738, and then directed (e.g., pumped) into the thermal energy transfer device720to “wash” across at least a portion of a circuit card subassembly706and/or708. As the liquid coolant circulates (e.g., via convection) within the thermal energy transfer device720, it is at least partially sublimated into vapor coolant due to the heat absorbed into the coolant from the IC chips712. The vapor coolant then will naturally rise through the interface connector738(which could occur concurrently with flow of liquid coolant in the opposite direction through the same interface connector738) for removal from the thermal energy transfer device720through the manifold interface736. It is contemplated that at least a portion of the coolant could remain liquid during this cycle through the thermal energy transfer device720and the interface connector738, particularly if the liquid coolant is being pumped into the thermal energy transfer device720under pressure which would naturally force a portion of the existing liquid coolant out of the thermal energy transfer device720along with the vapor coolant. It is also contemplated that expansion of the liquid coolant into vapor coolant may naturally urge some of the liquid and/or vapor coolant out of the thermal energy transfer device720through the interface connector738.

Each manifold interface736is also configured for selective fluid communication with a corresponding cooling manifold432,434, as shown in more detail in at leastFIGS. 3-6. As shown particularly inFIGS. 5-6, each cooling manifold432,434serves a plurality of circuit card units722by supplying cooling fluid to, and removing cooling fluid from, the manifold interfaces736using manifold ports740. Each manifold port740of each manifold interface736is in fluid communication with a corresponding cooling manifold432,434, depending upon which of the first and second operating temperatures is intended to be induced by the respective connected thermal energy transfer device720. If one or more circuit card units722are not desired to be cooled for some reason, the manifold port740can be blocked to prevent cooling fluid being supplied thereto.

The cooling fluid(s) can be supplied to, and removed from, the apparatus102in any desired manner. With specific reference toFIGS. 2-3, a first cooling fluid source242(e.g., a “cool side” Dewar of liquid helium, at about 4 K) is in fluid supplying communication with the first temperature cooling manifold432via a first operating fluid inlet344. A second cooling fluid source246(e.g., a “hot side” Dewar of liquid nitrogen, at about 77 K) is in fluid supplying communication with the second temperature cooling manifold434via a second operating fluid inlet348. Though the cryogenic fluids described herein could be compressed on board an airplane, it is contemplated that, for most use environments of the system100, compressed cryogenic liquids could be provided, for example, using the infrastructure accommodations for gas liquefaction which are commonly available at aircraft facilities. As a result of use of the system100and the first and second cooling fluid sources242and246, weight and power consumption on board the aircraft can be reduced from that which otherwise would be needed to initially produce/compress cryogenic liquids on board. It is believed that first and second cooling fluid sources242and246having capacities and form factors well within the capabilities of current aircraft accommodations could support cryogenic cooling for supercomputer usage of even extremely lengthy airplane flights (e.g., a 12-hour flight using commercial Dewars, a 24-hour flight using Dewars which are custom-shaped for the cabinet162, or any other desired flight time via provision of appropriate amounts and types of cooling fluid(s)), through use of the system100.

Once the cooling fluid(s) have been passed through the apparatus102as described, they will normally be in a largely vapor phase and could be considered “waste” products. Therefore, the system100may include a first cooling fluid destination (shown schematically at250) in fluid removing communication with the first temperature cooling manifold432via a first operating fluid outlet352. For example, when the first cooling fluid is liquid and/or vapor helium, the helium may be re-compressed as desired and stored as a compressed gas at ambient temperature. If it is not stored, the helium gas could be vented outside the aircraft, but helium gas has some value and would likely be recaptured. A second cooling fluid destination (shown schematically at254) is in fluid removing communication with the second temperature cooling manifold434via a second operating fluid outlet356. For example, when the second cooling fluid is liquid and/or vapor nitrogen, this fluid has little value, and with the most likely be vented outside the aircraft, unless there was a reason for the nitrogen to be re-compressed as desired and stored in much the same way as mentioned above for helium. Because of uncertainty as to the ultimate desired nature of the first and second cooling fluid destinations250and254, it is presumed that whatever component within the system100is connected to the first and second operating fluid outlet352and356, respectively, is considered as a first or second cooling fluid destination250and254, even if the “waste” or “spent” cooling fluid is ultimately routed outside the system100for further processing and/or to be employed in other cooling applications aboard the aircraft, for maximum utility. One of ordinary skill in the cryogenics arts will be able to provide suitable cooling fluid flow paths, supplies, and piping for a particular use environment of aspects of the present invention.

As shown inFIGS. 3-6, the apparatus102includes a plurality of circuit card units722aggregated inside a housing358, as will be described in detail below. The housing358includes the first operating fluid inlet344in fluid communication via the first temperature cooling manifold432with the first operating fluid outlet352, as well as the second operating fluid inlet348in fluid communication via the second temperature cooling manifold434with the second operating fluid outlet356. In other words, the housing358includes the necessary connections to route cooling fluid in a “loop” or “cycle” type manner past the circuit cards104, as described above with reference to at leastFIGS. 7A-11. The housing358supports and at least partially surrounds at least the plurality of circuit cards104, the plurality of thermal energy transfer devices720, the plurality of manifold interfaces736, and the first and second temperature cooling manifolds432and434. The housing358may be contained in a vacuum ambient environment, such as within vacuum cabinet260shown inFIG. 2. The housing358helps to assist the apparatus102to be transported and handled as a one-piece unit.

As shown inFIGS. 1-2, a cabinet162may support and at least partially enclose at least one apparatus102, the first and second cooling fluid sources242and246, and the first and second cooling fluid destinations250and254(with the understanding that the first and second cooling fluids may eventually be passed to an ultimate destination outside the cabinet162, as desired). It is contemplated that the cabinet162is configured and/or selected based upon its ability to physically enter and fit into a particular aircraft use environment, optionally with minimal wasted space. For example, the components of the system100could be configured to fit within a cabinet162having standardized dimensions for a certain make and model of aircraft, as desired.

Turning now toFIG. 12, an exploded view of the apparatus102is shown. Here, the housing358a,358bis a two-piece “nesting” construct which supports and encloses the other components of the apparatus102a variety of electrical cables and connections1264are shown schematically at the left side ofFIG. 12, but could attach to any desired portion of the apparatus102or components thereof. In the configuration shown inFIG. 12, the second temperature cooling manifold434is shown as being integrated into one of the pieces of the housing358a. The first temperature cooling manifold432then slips into that piece of the housing358a. A plurality of circuit card units are in the innermost portion of the housing358, and (if desired) an insulating blanket1266may surround at least a portion of the apparatus102components within the housing358. A network interface board assembly1268is placed into electrical content with the plurality of network interface board connector728of the circuit card units.

It should be noted that at least one suspension joint1270may be provided to one or more of the circuit card units722. When present, at least one of the plurality of circuit cards104may be supported by the housing358via a corresponding suspension joint1270to allow relative transverse movement (i.e., substantially into and out of the plane of the page, in the orientation ofFIG. 12) between the housing358and the corresponding circuit card104. For example, the suspension joint1270may pivotally attach the corresponding circuit card104to the housing358for relative pivotal movement between the housing358and the corresponding circuit card104. Relative motion between a circuit card104, or circuit card units722, in the housing358may occur due to motion of the aircraft and/or cabinet162, such as during installation of the cabinet162and/or turbulent flight of the aircraft. Potentially with the assistance of the flexible features of the interface connectors738and the suspension joints1270, desired mechanical and electrical contact can be maintained between portions of the apparatus102, and incidental motion can be “damped” or absorbed in a way that allows the apparatus102to continue operation and avoid damage, even during relatively significant motion, including severe air turbulence.

One of ordinary skill in the art can provide an apparatus102and system100suitable for a desired use environment, based upon the teachings of the present application. However, one example sequence of assembly of the apparatus102shown inFIG. 12is depicted schematically inFIGS. 13A-13I.

InFIG. 13A, the network interface board assembly1268and first temperature cooling manifold432have already been assembled together. A circuit card unit722is shown as being inserted longitudinally into a “backplane” comprising the first temperature cooling manifold432and associated structures, and the network interface board assembly1268. InFIG. 13B, the inserted circuit card unit722is fastened into place in any desired manner, to bring the first temperature cooling manifold432into fluid connection with the manifold interface736a. The sequence ofFIGS. 13A-13Bis repeated as many times as desired, once for each circuit card unit722(24shown) included in the apparatus102—the configuration ofFIG. 13Cis then achieved. Effectively, in forming the construct shown inFIG. 13C, each of the plurality of circuit cards104becomes transversely positioned with respect to an adjacent circuit card104, with at least one thermal energy transfer device720interposed transversely between each transversely adjoining pair of circuit cards104.

InFIG. 13D, one piece of the housing3508A, with the second temperature cooling manifold434integrated therein, is slid around the subassembly shown inFIG. 13C. This will bring the manifold interfaces736binto fluid contact with the second temperature cooling manifold434, and these two structures are placed into fluid connection and fastened as desired inFIG. 13E. As shown inFIG. 13F, at least a portion of the insulating blanket1266is inserted into the first piece of the housing358a, which may help in thermally insulating the first temperature cooling manifold432and second temperature cooling manifold434from each other. The insulating blanket1266, when present, may also or instead insulate components of the apparatus102from ambient space or from each other, as desired.

In the sequence ofFIGS. 13G-13H, the second piece of the housing358bis slid into the first piece358a, to create an assembled apparatus102. InFIG. 13I, any desired electrical cables or connections1264can be put in place in order to facilitate usage of the apparatus102. Since the housing358exposes the first and second cooling fluid inlets344and348, as well is the first and second cooling fluid outlets352and356, the apparatus102formed inFIGS. 13A-13Ican be fluidly connected to other components of the system100to form a complete cryogenically cooled compact-format circuit card104environment, either immediately or after the passage of a predetermined period of time.

FIG. 14is a flowchart summarizing an example method of providing immersion cooling in a compact-format circuit card104environment using an apparatus102and/or a system100as previously discussed. In first action block1372, an apparatus102as previously described is provided. At least one apparatus102, the first and second cooling fluid sources242and246, and the first and second cooling fluid destinations250and254could be at least partially enclosed within a cabinet162, and the cabinet162mounted within an aircraft, at any desired time relative to performance of the first action block1472. As previously shown and described, providing the apparatus102as in the first action block1372could include placing each manifold interface736in bidirectional fluid communication with a corresponding thermal energy transfer device720via an interface connector738. Similarly, during the performance of the first action block1372, each of the plurality of circuit cards104could be transversely positioned with respect to an adjacent circuit card104, with at least one thermal energy transfer device720being interposed transversely between each transversely adjoining pair of circuit cards104. It should also be noted that at least one of the plurality of circuit cards104may be supported by the housing358via a corresponding suspension joint1268, such that some degree of relative transverse movement is allowed between the housing358and the corresponding circuit card104.

Regardless of the exact way in which the apparatus102is provided in assembled, control moves from first action block1372to second action block1374, wherein each thermal energy transfer device720is operatively connected to an associated different one of the first and second circuit card subassemblies706and708.

In the third action block1376the first circuit card subassemblies706are at least partially exposed to the first operating temperature via placing at least one first temperature cooling manifold432in selective fluid communication with a plurality of thermal energy transfer devices720acorresponding to the first circuit card subassemblies706. A first cooling fluid is selectively introduced into, and selectively removed from, the thermal energy transfer devices720which are operatively connected to the first circuit card subassemblies706in fourth action block1378.

Similarly, in the fifth action block1380, the second circuit card subassemblies708are at least partially exposed to the second operating temperature via placing at least one second temperature cooling manifold434in selective fluid communication with a plurality of thermal energy transfer devices720corresponding to the second circuit card subassemblies708. Finally, in sixth action block1382, a second cooling fluid is selectively introduced into, and selectively removed from, the thermal energy transfer devices720which are operatively connected to the second circuit card subassemblies708.

Steps of the method ofFIG. 14can be carried out before, during, or after assembly of the apparatus102into a system100and/or use of a system100in an aircraft or other compact-format use environment, as previously described. The method ofFIG. 14can also or instead be carried out similarly with a plurality of apparatuses102or portions thereof, sequentially or concurrently. One of ordinary skill in the art will be able to configure and operate a system100as shown and described herein for a desired use environment.

Spatially relative terms, such as “under,” “below,” “lower,” “over,” “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms can encompass different orientations of a device in use or operation, in addition to the orientation depicted in the figures. For example, if a device in the figures is inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features.

While aspects of this disclosure have been particularly shown and described with reference to the example embodiments above, it will be understood by those of ordinary skill in the art that various additional embodiments may be contemplated. For example, the specific methods described above for using the apparatus are merely illustrative; one of ordinary skill in the art could readily determine any number of tools, sequences of steps, or other means/options for placing the above-described apparatus, or components thereof, into positions substantively similar to those shown and described herein. Though cooling is used herein as a temperature control example, one of ordinary skill in the art could providing heating using the apparatus102and/or system100, or substantially similar constructs thereto. Any of the described structures and components could be integrally formed as a single unitary or monolithic piece or made up of separate sub-components, with either of these formations involving any suitable stock or bespoke components and/or any suitable material or combinations of materials. Any of the described structures and components could be disposable or reusable as desired for a particular use environment. Any component could be provided with a user-perceptible marking to indicate a material, configuration, at least one dimension, or the like pertaining to that component, the user-perceptible marking aiding a user in selecting one component from an array of similar components for a particular use environment. A “predetermined” status may be determined at any time before the structures being manipulated actually reach that status, the “predetermination” being made as late as immediately before the structure achieves the predetermined status. Though certain components described herein are shown as having specific geometric shapes, all structures of this disclosure may have any suitable shapes, sizes, configurations, relative relationships, cross-sectional areas, or any other physical characteristics as desirable for a particular application. Any structures or features described with reference to one embodiment or configuration could be provided, singly or in combination with other structures or features, to any other embodiment or configuration, as it would be impractical to describe each of the embodiments and configurations discussed herein as having all of the options discussed with respect to all of the other embodiments and configurations. A device or method incorporating any of these features should be understood to fall under the scope of this disclosure as determined based upon the claims below and any equivalents thereof.

Other aspects, objects, and advantages can be obtained from a study of the drawings, the disclosure, and the appended claims.