Decoupled spring-loaded mounting apparatus and method of manufacturing thereof

A spring loaded mounting assembly secures a heat exchanger coupled to a heat source. The mounting assembly includes at least one support bracket positioned at one or more fixed locations with respect to the heat source, and a clip coupled to the support bracket and configured to maintain the heat exchanger in contact with the heat source. The mounting assembly also includes at least one bracket for securing a pump and heat rejector thereupon, wherein the heat exchanger and the pump are independently moveable with respect to one another. The heat rejector is preferably positioned above and alternatively positioned adjacent to the heat exchanger. The clip applies a downward force to the heat exchanger and consistently urges the heat exchanger in contact with the heat source irrespective of movements.

FIELD OF THE INVENTION

The invention relates to an apparatus for securing components of a cooling system in general, and specifically, to a decoupled spring-loaded mounting apparatus and method of manufacturing thereof.

BACKGROUND OF THE INVENTION

Closed fluid loops are used in cooling electronic devices, such as microprocessors in a computer. The fluid loop includes a heat exchanger which is placed in contact with the microprocessor as well as a heat rejector and pump coupled to the heat exchanger by one or more fluid tubes.FIG. 1illustrates an existing fluid loop assembly10. As shown inFIG. 1, the assembly10includes the heat exchanger12having a protruding tongue14and a pair of attach legs20extending from the body of the heat exchanger12. In addition, the assembly10includes a substantially larger heat rejector16that is coupled to the heat exchanger12by three fluid tubes18, whereby the heat rejector16includes a pair of attach legs24extending therefrom. The components in the assembly10are rigidly connected to one another to form one rigid assembly10. As shown inFIG. 1, the microprocessor26is attached to a printed circuit board22by conventional means. The heat exchanger12of the assembly10is placed in contact with the microprocessor26and secured thereto by inserting the tongue14under a retaining member28and screwing the attach legs20into the printed circuit board22using screws99. In addition, the attach legs24of the heat rejector16are also screwed into the printed circuit board22using screws99. The system10is thereby rigidly attached to the printed circuit board22at several locations24,28with very stiff mounting elements.

Closed loop cooling systems are required to retain fluid and vapor during extended operation. Ordinary flexible tubing made from rubber, silicone, plastics, or other highly-flexible materials are incapable of retaining fluids and vapors for extended periods. To overcome this deficiency, the materials of the tubing and fluidic connections includes metals, ceramics, glasses, and other impermeable materials and structures. Such materials and designs of the tubing and fluidic connections share the characteristic in that they are very stiff and cannot be flexed without cracking the cooling system or damaging the electronic system.

In the event of sudden deceleration, shock or bending force applied to the system or the circuit board22, the stiff, fixed mounts are subjected to very large concentrated stresses which may crack the circuit board22or damage the cooling system. During the assembly process, it is common for the fasteners between the system and the printed circuit board to be applied sequentially. As a result, the cooling system will shift and/or tilt some amount of distance at various moments during the assembly process, thereby causing the gap between the microprocessor and the heat exchanger to increase momentarily. Additionally, during the process of attaching the cooling system10to the circuit board22, dimensional tolerances in the components may lead to slightly bent or misaligned components along the circuit board22. In this case, the stiff mounting structures will lead to very large concentrated stresses between the components that might damage the mounting point, crack the circuit board, or damage the cooling system. These stresses can lead to torque on the heat exchanger element12and slight gaps forming between the heat exchanger12and the microprocessor26. The fluid tubes18which connect the heat exchanger12to the heat rejector16are rigid and cannot move independently of one another with respect to the circuit board. In other words, the components of the assembly10do not incorporate any tolerance and are not flexible to respond to sudden movements. The stiffness and rigidity of the assembly10inFIG. 1thus makes the assembly10susceptible to cracking or breaking whenever the printed circuit board22or entire packaging undergoes sudden movements or is dropped. In addition, the inability of the individual components in the assembly10to independently move or tolerate movement often causes the heat exchanger12to come out of or lose contact with the microprocessor26when subjected to sudden movements. Additionally, sudden movements experienced by the assembly10may cause the heat grease or thermal interface material between the heat exchanger12and microprocessor26to move, thereby making the heat exchanger12less effective in removing heat from the microprocessor26. Any of the above scenarios can be detrimental to the electronic device packaging utilizing the closed fluid loop within.

What is needed is an assembly for coupling a closed loop fluid system to a mounting surface in which the individual components are decoupled and able to move independently with respect to one another. What is also needed is an assembly which secures and maintains all necessary interface contacts to retain the integrity of the cooling system. What is also needed is an assembly configured to apply force which is approximately constant and maintains the heat exchanger in consistent contact with the electronic device irrespective of sudden movements are shocks applied to the system.

SUMMARY OF THE INVENTION

One aspect of the invention includes a mounting assembly which secures a heat exchanger that is coupled to a heat source. The mounting assembly comprises at least one support bracket which is positioned at one or more fixed locations with respect to the heat source. The mounting assembly also comprises a clip which is coupled to the support bracket and is configured to resiliently urge the heat exchanger in contact with the heat source. The mounting assembly further comprises at least one bracket which secures the heat rejector and/or pump thereupon, wherein the heat exchanger and heat rejector are independently moveable with respect to one another. In one embodiment, the heat rejector is positioned substantially above the heat exchanger, and in another embodiment, the heat rejector is positioned adjacent to the heat exchanger.

Another aspect of the invention includes a package which has a closed-loop fluid system within. The package comprises a heat exchanger which is coupled to an electronic device at an interface. The package also includes a heat rejector that is coupled to the heat exchanger via at least one fluid tube. A first mount secures the heat exchanger to the electronic device at the interface. A second mount secures the heat rejector thereupon, wherein the first mount and the second mount are independently moveable with respect to each other.

Another aspect of the invention includes a closed loop fluid system which controls a temperature of an electronic device. The system comprises a heat exchanger which is coupled to the electronic device at an interface as well as a heat rejector which is coupled to the heat exchanger via at least one fluid tube. The system also includes a first mount which secures the heat exchanger to the electronic device at the interface and a second mount which secures the heat rejector and/or pump thereupon, wherein the first mount and the second mount are independently moveable with respect to each other.

Another aspect of the invention includes a mounting assembly which is adapted to secure a closed loop cooling system. The closed loop system preferably has a heat exchanger that is in contact with an electronic device, whereby the heat exchanger is coupled to a heat rejector via at least one fluid line. The mounting assembly comprises a first mount. The first mount further comprises at least one substantially vertical member that is coupled to the surface and a flexible feature that is coupled to the at least one substantially vertical member and is configured to press or urge the heat exchanger against the electronic device. The resilient feature applies a substantially constant downward force to the heat exchanger. The mounting assembly further includes a second mount which comprises a platform that is configured to receive the heat rejector. The first mount and the second mount move independently of one another and have a stiffness value that is as least as high as that of the at least one fluid line.

Another aspect of the invention includes a method of securing a closed loop fluid system which is configured to control a temperature of an electronic device coupled to a mounting surface. The closed loop fluid system includes a heat exchanger that is in contact with the electronic device and a heat rejector that is coupled to the heat exchanger via at least one fluid tube. The method comprises the steps of forming a first support bracket structure, coupling the first support bracket structure to the mounting surface and coupling a spring loaded clip to the first support bracket structure, wherein the clip is adapted to secure the heat exchanger to the electronic device. The method further comprises the steps of forming a second support bracket structure which has a second support bracket platform and coupling the second-support bracket structure to the mounting surface, wherein the second support bracket platform is configured to hold the heat rejector thereupon.

In each of the above embodiments, the heat exchanger is coupled to at least one heat rejector and pump via at least one fluid line which has a fluid line stiffness value. The clip has a clip stiffness value greater than the stiffness value of the fluid line in each of the six possible degrees of freedom of the system. The clip is preferably in contact with a top surface of the heat exchanger, whereby the clip applies a downward force to the heat exchanger and consistently urges the heat exchanger in contact with the heat source irrespective of movements at the fixed location.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

It is apparent that although the present invention is described in relation to a cooling system, the present invention is alternatively applied to a heating system. In general, the present invention is directed to a mounting assembly which applies a substantially constant securing force to the heat exchanger, thereby securing the heat exchanger in contact with the heat source. In addition, the securing force remains constant along the interface between the heat exchanger and heat source irrespective of sudden forces and/or movements experienced by the assembly. In addition, the assembly is configured to additionally secure the heat rejector and pump components of the system, thereby allowing the components to be independently moveable or decoupled so that the system is flexible and able to withstand sudden movements. Although the present invention is described in relation to a system for cooling a microprocessor in a computer, it should be noted that the present invention can be used with systems which cool other electronic devices or circuits.

FIG. 2Aillustrates a schematic of the preferred embodiment of the mounting assembly in accordance with the present invention.FIG. 2Billustrates an exploded view of the preferred mounting assembly in accordance with the present invention. The mounting assembly is preferably contained within an electronics package (e.g. computer), along with the closed loop system. In particular,FIG. 2Aillustrates a printed circuit board surface101having a socket102for receiving and engaging a grid array104, including but not limited to a pin grid array (PGA), ball grid array (BGA) and land grid array (LGA). The grid array104includes an interface for accepting an electronic device such as a microprocessor106. It should be noted that other known methods and devices to couple the electronic device106to the grid array104is contemplated by one skilled in the art.

The sealed closed loop system is configured to cool the electronic device106or other electronic device. The heat exchanger108and electronic device106are preferably coupled together with an adhesive or thermal interface material therebetween. The heat exchanger108is preferably coupled to the top surface of the electronic device106and includes one or more fluid ports which allow fluid to enter and exit the heat exchanger108via fluid tubes, couplings or connections110. It should be noted that any type of appropriate heat exchanger is used in the present cooling system shown inFIG. 2A. The fluid tubes110from the heat exchanger108are coupled to the heat rejector112and pump132. Alternatively, the fluid tubes110are coupled only to the pump132or only the heat rejector112. It should be noted thatFIG. 2Aonly illustrates one fluid tube100for clarity purposes, although multiple fluid tubes110are preferred and referred to herein. As shown inFIG. 2B, the fluid tubes110pass through apertures105in the bracket118from the heat exchanger108. In addition, the fluid tubes110pass through apertures133in the mount bracket116to couple the heat exchanger108to the pump132. It should be noted that any type of appropriate heat rejector112is used in the present cooling system shown inFIG. 2A. In addition, the system includes a pump132which pumps the fluid through the cooling system, whereby the pump132is coupled to the heat rejector112and heat exchanger108. Preferably, the pump132is an electro-kinetic pump, although any type of pump is contemplated.

The heat exchanger108is securely held against the top surface of the electronic device106by a mounting assembly114shown inFIG. 2A. In the preferred embodiment, the mounting assembly114includes a bracket118as well as a spring loaded clip124coupled thereto. The bracket118is preferably coupled to a base, such as the grid array104as shown inFIG. 2A. It is apparent to one skilled in the art that the base is alternatively any other appropriate surface, such as the printed circuit board101itself. The bracket118preferably has an upper lip120A, a lower lip120B and a vertical wall122extending between the upper lip120A and the lower lip120B. Preferably, the vertical wall122of the bracket118substantially surrounds the heat exchanger108and electronic device106as shown inFIG. 2B. The bracket118has a top opening defined as the area in between the upper lips120A, as well as a bottom opening defined as the area in between the lower lips120B. The bracket118is preferably rectangular shaped, as shown inFIGS. 2A and 2B. Alternatively, the bracket118has any other appropriate shape. Alternatively, the bracket118includes a number of vertical posts with the clip coupled to each post as shown inFIG. 3.

Referring toFIG. 2A, the lower lip120B of the bracket118preferably fits under the bottom edge of the grid array104and extends vertically upward an appropriate distance to compress or energize the clip124. Thus, the clip124is coupled to the bracket118by preferably fitting within the area enclosed by the vertical wall122of the bracket118. The clip124preferably includes an outer surface125as well as a curved or rounded surface123which extends from the outer surface125, as shown inFIGS. 2A and 2B. Alternatively, the clip124has any other appropriate shape to perform in the manner consistent with the present invention. The clip124is made from one or more of a variety of materials including, but not limited to, stainless steel spring material, spring steel, high Carbon steel, Beryllium-Copper spring material, Phosphor-Bronze spring material, Chrome-Vanadium or Chrome-Silicon alloys.

In the preferred embodiment, the clip124is compressed in between the top surface of the heat exchanger108and the top lip120A of the bracket118. In particular, the outer surface125of the clip124is coupled to the bracket118by fitting underneath the upper lip120A of the bracket118as shown inFIG. 2A. The clip124is preferably mechanically coupled to the bracket118by screws and fasteners. Alternatively, the clip124is coupled to the bracket118by brazing, soldering, crimping, applying adhesive or any other coupling method. As shown inFIG. 2A, the semi-circular surface123of the clip124presses against the top surface of the heat exchanger108when the bracket118is coupled to the base. In particular, the vertical distance between the outer surface125and the curved portion123of the clip, in the unloaded pre-assembled state, is greater than the vertical distance between the top surface of the heat exchanger108and the upper lip120A. This difference in vertical distance thus compresses the clip124when placed within the bracket118, wherein the clip124is energized by the compression and applies a downward force against the top surface of the heat exchanger108.

Preferably, a substantial portion of the semi-circular surface123applies a consistent force onto the top surface of the heat exchanger108, whereby the force maintains or urges the heat exchanger108securely against the electronic device106. The clip124thus complies to uneven forces by consistently applying a substantially constantly distributed securing force to the heat exchanger108. The heat exchanger108and the electronic device106are thus effectively suspended and are held together by a consistent force irrespective of whether the packaging, which houses the assembly100and cooling system, is disturbed, dropped, vibrated, turned upside down or sideways, or subjected to any other sudden movements and/or forces.

The clip124is made of a spring loaded or other flexible material that has the property of exerting a sufficient, constant force downward onto the heat exchanger108at all times, independent of brief displacements or sudden movements. As stated above, during the assembly process, it is common for the fasteners (not shown) between the system and the printed circuit board to be applied sequentially. As a result, the cooling system100will shift and/or tilt some amount of distance at various moments during the assembly process, thereby causing the gap between the electronic device106and the heat exchanger108to increase momentarily. In addition, after assembly, it is possible that the assembly100or packaging will briefly shift as a result of some external shock or sudden movement during handling or installation. At the end of these disturbances or movements, the clip124urges or maintains the heat exchanger108in contact with the electronic device106with the same force as before the disturbances had occurred. However, it is preferred that the force exerted by the clip124upon the heat exchanger108not be significantly larger during the disturbance or movements than before or after the movements occur.

It is preferred that the clip124have a modest stiffness and be adequately loaded to provide a substantially constant force upon the heat exchanger108which is independent of the displacement to the assembly100or packaging. The clip124has a spring-like characteristic in which the force applied by the clip124is substantially proportional to the compression that the clip124undergoes. Similar characteristics are found in springs in which the proportionality constant is called the spring constant or the stiffness valve. In order for the clip124to apply a large force over a range of compression as well as undergo significant compression when coupled to the bracket116, the clip124has a modest spring constant or stiffness. As stated above, sudden movements and/or forces can cause small changes in the positions of the components in the assembly100. The modest stiffness of the clip124causes the clip124to exhibit small changes in its applied force in response to such small positional changes. Nonetheless, the stiffness of the clip124continues to allow the clip124to exert the appropriate amount of force onto the heat exchanger108to maintain the heat exchanger108in contact with the electronic device106.

The loading force applied by the clip124is preferably within the range of and including 1 to 100 pounds or 4.45 to 445 Newton. The advantage of the clip124applying a lower force is that the possible damage to the electronic device106and/or the interconnect to the substrate is avoided. In contrast, the advantage of the larger force is that the thermal resistance between the electronic device106and the heat exchanger108is reduced, thereby improving the performance of the cooling system. Typically, displacements of 1 millimeter occur to the components in the assembly during the assembling process or when sudden movements are experienced. However, the clip124alternatively has an appropriate stiffness value such that the force applied by the clip124varies less than 50% for displacements of 1 mm or more. Accordingly, the stiffness of the clip124is preferably less than 200 N/mm. For example, a clip having a stiffness value of 50 N/mm and applying a force of 200 N would have to be loaded or compressed by at least 4 mm during the assembly to operate effectively. In another embodiment, the stiffness of the clip124is less than 50 N/mm to allow the clip124to provide a consistent force between the electronic device106and the heat exchanger108for displacements greater than 1 mm. However, a clip having a low-stiffness values will require a significant amount of compression during the assembly process which adds to the complexity of the assembly process and the cost of the structure. It is preferred that the clip124is designed to based the cost of the clip, the cost of the assembly process and the uniformity of the loading force over a range of displacements.

For illustration purposes, an alternate, undesirable design would utilize a stiff screw pressed onto the back of the heat exchanger. Since a screw is very stiff along its axis, the loading force applied to the heat exchanger increases very quickly with displacement of the screw. Such a design has an undesirable feature, because the slight adjustments in the rotation of the screw give rise to very large changes in the loading force. In addition, the heat exchanger displacing a very slight amount of distance also give rise to very large forces. Thus, a design utilizing a screw would produce forces that are large enough to crack the electronic device during assembly or handling.

The forces that arise during assembly of the system and sudden movements to the system are mostly transmitted from the pump132and heat rejector112to the heat exchanger108and electronic device106along the fluid tubes110. As discussed above, it is desirable for the spring-loaded clip124to exert the appropriate amount of force onto the heat exchanger108to maintain thermal contact between the heat exchanger108and-the electronic device106. As a result, the spring-loaded clip124exerts the desired force onto the heat exchanger108to overcome the forces which are transmitted by the fluid tubes110. In one embodiment, the clip124provides a specified pressure to the heat exchanger108and maintains the pressure irrespective of sudden movements. In another embodiment, the stiffness of the clip124exceeds the stiffness of the fluid tubes110to allow some flexibility in the tubes110. The stiffness values of the fluid tubes110, clip124, and strain relief device134(FIG. 2A) are determined based on the type of material used for the respective component by one skilled in the art.

In addition, to reduce the forces exerted on the heat exchanger108and electronic device106by other components in the cooling system, it is desirable to reduce the stiffness of the fluid tubes110themselves. The stiffness of the fluid tubes1110are reduced in a number of ways, including but not limited to, increasing the length of the tubes110, reducing the tube110wall thickness and diameter, and introducing bends into the path of the tubes110, as shown inFIG. 2A. In particular, as shown inFIG. 2A, fluid tube110extends from the heat exchanger108out through the opening105(FIG. 2B) in the bracket118and preferably has three 90-degree turns to form a “S” configuration. The bends in the fluid lines110exerts small forces upon the heat exchanger when the pump132and the rejector112undergo displacements. This is due to the tube110being more flexible upon all six axes and utilizing the six degrees of freedom. In other words, the bends in the fluid tube110absorb much of the movement caused by the components and contain the forces to the fluid tube110instead of transmitting the forces to the heat exchanger108. It should be noted that although the fluid tube110has three bends, the fluid tube110alternatively has any number bends.

Alternatively, it is possible to reduce the transmission of forces from the pump132and heat rejector112along the fluid tube110by utilizing a strain relief structure134as shown inFIG. 2A. The strain relief structure134is stiff and rigid, whereby the strain relief structure134anchors a portion of the fluid tube110to the circuit board101. In particular, the fluid tube110extends through the strain relief structure134, whereby a small portion of the fluid tube110extends to the heat exchanger108and the remaining portion extends to the pump132and rejector112. The strain relief structure134is positioned close to the heat exchanger108, whereby the amount of the fluid tube110between the strain relief structure134and the heat exchanger108is relatively small compared to the amount of tube110between the structure134and the pump132. It should be noted that although the strain relief structure134is shown positioned adjacent to the bracket118, the structure134is alternatively positioned anywhere else along the length of the fluid tube110. The relief structure134is preferably made of an appropriate material which has a stiffness value greater than the stiffness value of the fluid lines110. Thus, the stiffness of the relief structure134restrains movement of the smaller portion of the fluid lines110. The strain relief structure134thereby reduces the stress, strain and torsion forces that can be exerted upon the heat exchanger108via the fluid tubes110, because the smaller distance portion of the fluid tubes110is between the strain relief structure134and the heat exchanger108is restrained from moving. With the strain relief structure134in place, the design requirements for the lower-stiffness, spring-loaded clip124are relaxed, and it is possible to utilize a stiffer clip124with less compression. The use of the strain relief device134offers reduced cost and easier assembly of the mounting assembly100.

As shown inFIGS. 2A–2B, the assembly100of the present invention also includes a mount bracket116which is configured to hold the other component or components in the system independently of the mounting assembly114. Although one mount bracket116is shown inFIGS. 2A–2B, it is apparent to those skilled in the art that multiple mount brackets116are alternatively used. The mount bracket116includes a platform130which preferably holds the heat rejector112and pump132thereupon. Alternatively, the mount bracket116only holds either the heat rejector112or the pump132thereupon. The mount bracket116preferably includes a plurality of screw holes132in the legs128which allow the mount bracket116to be coupled to the printed circuit board106or to the external chassis. It is apparent to one skilled in the art that the mount bracket116alternatively has any other appropriate coupling mechanism and is not limited to screw holes. The mount bracket116preferably holds the heat rejector112above the mounting assembly114to make efficient use of the printed circuit board101space. Alternatively, the mount bracket116is positioned adjacent to the mounting assembly114. The mount bracket116is made of a material having sufficient rigidity and stiffness to hold the heat rejector112and pump132above the heat exchanger108without applying a significant amount of force to the fluid tubes110. In other words, the mount bracket116has sufficient rigidity to prevent any force from being applied to the fluid tubes110and the mounting assembly114in response to sudden movements experienced by the system assembly.

The entire assembly100of the present invention is formed using the one or more mounting assemblies114and mount brackets116coupled to the one or more fixed locations. The heat exchanger108and electronic device104are thus supported by the mounting assembly114which is independently suspended from the mount bracket116which supports the heat rejector112and pump132. In other words, the mounts of the system100independently supports the heat exchanger108and the electronic device106as well as the heat rejector112and pump132. The mounting assembly114creates a controlled interface force between the heat exchanger108and the electronic device106without applying any additional force to the heat rejector112, pump132and fluid lines110. Similarly, the mount bracket116applies a separate force to hold and secure the heat rejector112in place without applying any additional force or pressure to the heat exchanger108and electronic device106as well as the fluid lines110. Therefore, the heat exchanger108and electronic device106are independently moveable from the heat rejector112and the pump132.

FIG. 3illustrates a schematic of an alternative embodiment of the mounting assembly300in accordance with the present invention. The mounting assembly system300shown inFIG. 3includes a mount bracket304which is coupled to a mounting surface302, such as a printed circuit board, whereby the mount bracket304secures the heat rejector316and pump318above the heat exchanger320. As shown inFIG. 3, the heat rejector316and pump318are placed on top of the heat rejector mount304. In addition, the system300includes a mounting assembly306which includes vertical posts308which are also coupled to the mounting surface302. The heat exchanger320is coupled to the electronic device322, whereby the electronic device322is coupled to the grid array310. The vertical posts308each include an engaging port311which is configured to receive the clip312and engage the clip312thereto. The clip312applies a securing force to the interface between the heat exchanger320and the electronic device322when coupled to the vertical posts308. The mounting assembly306is not rigidly coupled to the mount bracket304, although the fluid lines314couple the heat exchanger320to the heat rejector316and pump318. The alternative system300shown inFIG. 3operates in the same manner as the preferred system100inFIGS. 2A–2Band is not discussed in more detail herein. It should be noted that the system alternatively has any other appropriate configuration or design which provides a consistent force to the interface between the heat exchanger and the electronic device which is not affected by sudden movements which may cause the heat rejector and/or pump to move.

FIG. 4illustrates a flow chart of the preferred method of manufacturing the mounting assembly system with the closed loop fluid system in accordance with the present invention. The mounting assembly114and mount bracket116are formed (steps200and202) using a variety of known methods, including but not limited to, stamping or bending of sheet metal, machining, extrusion, die-casting of zinc, aluminum or magnesium, and forging. The mounting assembly114and mount bracket116are preferably manufactured separately, whereby the components are attached to the mounting surface(s) separately. Alternatively, the mounting assembly114and mount bracket116are manufactured and are attached to the mounting surface(s) as one mounting system, wherein the mounting assembly114and mount bracket116are independently suspended and moveable with respect to one another.

As stated above, the grid array104is coupled to the socket102in the printed circuit board101whereby the electronic device106is coupled to the grid array104(step204). Preferably, the heat exchanger108is placed in contact with the electronic device106as in step206(FIG. 2B). It is apparent to one skilled in the art that an intermediate material such as a thermal interface material, heat spreader or any other appropriate material is alternatively applied in between the heat exchanger108and electronic device106. The appropriate amount of intermediate material that is placed in between the heat exchanger108and electronic device106depends on the heat transfer capabilities and adhesive strength of the intermediate material as well as the amount securing force applied to the heat exchanger by the clip124. For example, a less amount of thermal interface material may be applied in between the heat exchanger108and electronic device106in which the amount of force applied by the clip124is higher than another clip (not shown).

Following, the clip124is coupled to the bracket118as in step208(FIG. 2B). As stated above, the outer edge of the clip124is placed in contact with the underside of the upper lip120A. The bracket118of the mounting assembly114along with the clip124is coupled to the grid array.104or other mounting surface in step210(FIG. 2B). In particular, the lower lip120B of the bracket118is snapped under the extending ledge of the grid array104, as inFIG. 2A. Alternatively, an adhesive is applied between the lower lip120B and the ledge of the grid array104to securely couple the bracket118to the grid array104. The semi circular portion123of the clip124is then preferably in contact with the top surface of the heat exchanger108. As stated above, the dimensions of the clip124and bracket118are such that the clip124is loaded by the compressive forces exerted from the top lip120A which press the clip124against the top surface of the heat exchanger108. The compressive forces applied to the clip124thereby cause the clip to exert a consistent force upon the top surface of the heat exchanger108.

The fluid tubes110which are coupled to the heat exchanger108preferably passes through the apertures105in the bracket118, whereby the other end of the fluid tubes110are coupled to the pump132and heat rejector112as shown inFIG. 2B. In particular, the fluid lines110preferably extend through the apertures133in the surface130as shown inFIG. 2B. Alternatively, the fluid lines110extend through the bracket118and mount bracket116through any other apertures or passageways. As stated above, the clip124and bracket118configuration is not limited to that shown inFIGS. 2A-2Band alternatively has any other appropriate configuration in which the clip124applies a substantially constant, consistent force to secure the heat exchanger108in contact with the electronic device106irrespective of sudden movements.

Following, the mount116is coupled to the printed circuit board106by any conventional method as in step212(FIG. 2B). The heat rejector112and the pump132is coupled to the mount116as in step214(FIG. 2B). In one embodiment, the heat rejector112and pump132are already coupled to one another prior to being coupled to the mount116. In another embodiment, the heat rejector112and the pump132are coupled to the mount116separately and then coupled to one another. Preferably, the mount116is positioned to be over the mounting assembly114to reduce the amount of space used by the entire loop assembly100. Alternatively, the mount116is placed adjacent to the mounting assembly114. As shown inFIG. 2A, the platform130of the mount116holds the heat rejector112thereupon, whereby the heat rejector112is preferably held above the mounting assembly114. In addition, the platform130of the mount116is alternatively large enough to hold the pump (not shown) of the loop system thereupon. It is apparent to one skilled in the art that the above manufacturing steps are not limited to the order described above and illustrated inFIG. 4and may be alternatively be manufactured in any other appropriate order.

The present invention has been described in terms of specific embodiments incorporating details to facilitate the understanding of the principles of construction and operation of the invention. Such reference herein to specific embodiments and details thereof is not intended to limit the scope of the claims appended hereto. It will be apparent to those skilled in the art that modification s may be made in the embodiment chosen for illustration without departing from the spirit and scope of the invention.