Heat transfer devices and methods of transfering heat

Heat transfer devices, electronic devices, and methods for heat transfer with an external body. Heat transfer devices include a first disc, a second disc positioned adjacent to the first disc, and at least one spacer positioned between the first disc and the second disc. The first disc defines an aperture and comprises a pin cooling structure extending from around the aperture. The pin cooling structure comprises a distal end configured to facilitate heat exchange between the pin cooling structure and an external/adjacent/separate body and one or more side walls. At least one of the one or more side walls, the distal end, and the aperture at least partially define a pin volume. The second disc defines an inlet that is configured to (i) receive a fluid, and (ii) allow the fluid to flow from the inlet and into the pin volume.

FIELD

The present disclosure relates to heat transfer devices.

BACKGROUND

Some devices, especially electronic devices, generate extensive amounts of heat, in some cases wasted heat. This heat must be controlled and dissipated properly to prevent reduced performance and/or premature failures. Therefore, the thermal interaction of any device with its environment is a critical design feature to assure its proper functionality.

There are many commercial and military applications that require reliable thermal control systems for small components and/or surfaces. Not only must such thermal control systems be capable of withdrawing heat from small and/or delicate surfaces, they also must ensure that consistent contact is made between the components and/or surfaces and the heat transfer device so as to ensure that heat is reliably and/or optimally drawn from the small components and/or surfaces.

SUMMARY

Heat transfer devices, electronic devices, and methods for heat transfer with an external body are disclosed. A heat transfer device, referred to as a “Stacked Array of Pin Nodes (SPN)” includes a first disc, a second disc positioned adjacent to the first disc, and at least one spacer positioned between the first disc and the second disc. The first disc defines an aperture and comprises a pin cooling structure extending from around the aperture. The pin cooling structure comprises a distal end configured to facilitate heat exchange between the pin cooling structure and an external body and one or more side walls. At least one of the one or more side walls, the distal end, and the aperture at least partially define an internal pin volume. The second disc defines an inlet that is configured to (i) receive a fluid, and (ii) allow the fluid to flow from the inlet and into the internal pin volume. Additionally, a fluid channel is defined between the first disc and the second disc. The fluid channel is in fluid communication with the internal pin volume.

A method includes flowing a fluid from an inlet defined by a second disc of a heat transfer device and into an internal pin volume defined by a pin cooling structure that is a component of a first disc of the heat transfer device that is positioned adjacent to the second disc. The method further includes transferring heat between an external body and the fluid within the internal pin volume via the pin cooling structure, and flowing the fluid from the internal pin volume to a fluid channel that is defined between the second disc and the first disc.

DESCRIPTION

Heat transfer devices and methods for effectuating heat transfer with an external body are disclosed. Generally, in the figures, elements that are likely to be included in a given example are illustrated in solid lines, while elements that are optional to a given example are illustrated in broken lines. However, elements that are illustrated in solid lines are not essential to all examples of the present disclosure, and an element shown in solid lines may be omitted from a particular example without departing from the scope of the present disclosure.

FIG. 1is a schematic cross-sectional diagram representing heat transfer devices100according to the present disclosure. In some embodiments, heat transfer devices100may be referred to as a thermal management disc. Heat transfer device100may be configured to draw heat away from (i.e., cool) an external body102, provide heat to (i.e., heat) external body102, or both. External body102may include an active component that generates heat, such as an engine, an electronic device, an electronic component, etc. Alternatively, or in addition, external body102may include a component that passively acquires heat from another source, such as a heat shield, a heat sink, etc. In such embodiments, heat transfer device100may be configured to draw heat away from external body102.

As schematically illustrated inFIG. 1, heat transfer devices100include at least a first disc200, a second disc300positioned adjacent to first disc200, and at least one spacer400positioned between first disc200and second disc300. Additionally, first disc200and second disc300define a fluid channel500between first disc200and second disc300.

First disc200has an outer surface202proximate to external body102and an inner surface204located proximate to and that faces second disc300. In some embodiments, first disc200is circular. However, in various embodiments, first disc200may be different shapes, such as oval, ovoid, square, polygonal, etc. First disc200defines an aperture206that extends through the first disc200from outer surface202to inner surface204. First disc200further includes a pin cooling structure208extending from outer surface202around aperture206. In some embodiments, the angle between pin cooling structure208and outer surface202is configured to create optimal contact with external body102. For example, pin cooling structure208may be perpendicular with outer surface202of first disc200; however, other angular relationships are within the scope of the present disclosure, such as angular relationships based on the packaging (i.e., the arrangement) of heat transfer device100with external body102. Pin cooling structure208comprises a distal end210configured to facilitate heat exchange between pin cooling structure208and external body102. Distal end210may be composed of one or more materials having a high heat transfer coefficient to ensure efficient heat transfer between external body102and pin cooling structure208. An outer surface222of distal end210may be post-process machined to a mirror finish or a supermirror finish. Outer surface222of distal end210may also be in-situ machined to a mirror finish. Alternatively, or in addition, thermal grease may be applied to distal end210to improve the thermal conductivity between external body102and pin cooling structure208.

In some embodiments, pin cooling structure208is made of, comprises, or optionally includes an electrically conductive material. For example, pin cooling structures208may be electrically conductive and may be a component of an electric circuit. Such a circuit may comprise a singular pin cooling structure208, a plurality of pin cooling structures208, insulators, resistors, and/or some other element(s). In some embodiments, heating and/or cooling pin cooling structures208may alter its electrical properties, including but not limited to changing the resistance of the pin cooling structure and/or creating a break in a current path. As such, an array of pin cooling structures208may exhibit an electrical performance (including digital logic) in a low temperature environment (e.g., cryogenic, sub Antarctic or subarctic) that is distinct from an electrical performance in a heated environment (e.g., atmospheric re-entry). Additionally, where the electrical performance of pin cooling structures208is temperature dependent, the electrical performance may be altered via localized cooling and/or heating of individual pin cooling structures208within an array of pin cooling structures208. In this way, when pin cooling structures208are in contact with a surface of external body102, an electrical path between external body102and one or more pin cooling structures208may be broken by a change in temperature, rather than a breakage of physical contact between external body102and individual pin cooling structures208. Moreover, in some embodiments, pin cooling structures208may be responsive to magnetic fields. For example, individual pin cooling structures208may be constructed of a varied functionally gradient material blend that causes the corresponding pin cooling structures208to have a varied response to magnetic fields.

Distal end210may have a circular cross section. Alternatively, the cross section of distal end210may be another shape. For example, the cross section of distal end210may correspond to a 1:1 projection of portion of external body102that pin cooling structure208is cooling. Moreover, the cross section of distal end210may correspond to, or be different from, the cross sectional shape of one or more other regions of pin cooling structure208. For example, an internal pin volume214may have a circular cross-sectional shape while the cross sectional shape of distal end210may have a square cross-sectional shape.

Pin cooling structure208further includes one or more side walls212. Side walls212at least partially define internal pin volume214. Internal pin volume214may be further partially defined by one or more of distal end210, aperture206, and second disc300. In some embodiments, side walls212comprise a micro-bellows216. Micro-bellows216is an elastic region of pin cooling structure208that can be compressed when pressure is applied to the outside of pin cooling structure208and/or may be expanded when a pressure is applied to an internal surface218of distal end210. For example, expansion of micro-bellows216causes distal end210of pin cooling structure208to be translated away from the second disc300. When such pressure is released, micro-bellows216is configured to return to its original shape. Micro-bellows216may include one or more expansion regions220, such as chevrons, ribs, and/or other corrugated structures, which are capable of expanding or contracting in response to applied pressures. In some embodiments, internal surface218of distal end210comprises an inset surface211opposite outer surface222. In such embodiments, inset surface211may be configured to efficiently receive pressure from the fluid in internal pin volume214traveling away from aperture206. For example, the inset surface may be a conical surface, a dome surface, etc. In this way, inset surface211is able to increase the pressure applied to distal end210by the fluid in internal pin volume214. Alternatively, or in addition, the inset surface211may be configured to create turbulence in the flow of the fluid when the fluid strikes inset surface211. The turbulence of the fluid in internal pin volume214increases the amount of heat that is absorbed by the fluid from pin cooling structure208while the fluid is in internal pin volume214.

In some embodiments, micro-bellows216is configured to expand in response to a fluid being injected into internal pin volume214of pin cooling structure208. Additionally, micro-bellows216may be configured to deform in response to distal end210of pin cooling structure208making contact with external body102. For example, in response to a force (e.g., a normal force) being exerted on distal end210by a surface of external body102, expansion regions220of micro-bellows216may deform (i.e., expand, contract, or a combination thereof) so that outer surface222of distal end210is oriented to more closely parallel the surface of external body102. In some examples, this deformation of micro-bellows216causes outer surface222of distal end210to make flush contact with the surface of external body102. In this way, if the surface of external body102and outer surface222of distal end210are not parallel when contact is made between the bodies, micro-bellows216may deform so that outer surface222of distal end210becomes more parallel to the surface of external body102.

First disc200may be a monolithic structure, or may be comprised of multiple components. For example, first disc200may optionally comprise a surface layer224that includes pin cooling structure208, and a rigid layer226adjacent to surface layer224and disposed between surface layer224and second disc300. Surface layer224and rigid layer226may be composed of the same material, or may be composed of different materials. For example, rigid layer226may be composed of a material having a lower modulus of elasticity and/or a higher coefficient of thermal expansion than surface layer224.

As shown inFIG. 1, heat transfer devices100further include second disc300positioned adjacent to first disc200. In various embodiments, first disc200and second disc300are coupled together via at least one of a mechanical fastener, an adhesive, welding, and/or bonding. In other embodiments, first disc200and second disc300(as well as other components) may comprise a single body. In some embodiments, the single body may be formed using additive manufacturing, and may at least partially comprise one or more functionally gradient materials (e.g., a grading from Ti-6Al-4V to Vanadium, where the distal pin ends may be malleable).

Second disc300defines an inlet302that allows fluid to pass from inlet302and into internal pin volume214. The fluid may correspond to a gas or liquid having the ability to absorb and transport heat, such as a coolant. For example, the fluid may be, comprise, or optionally consist of methane and/or methanol gas. In various embodiments, the fluid may be selected based on many different characteristics such as its ability to efficiently transport heat, ability to remain in a stable condition, a boiling temperature, a freezing temperature, an ability to carry a voltage, etc. In some embodiments, the fluid may include component elements that improve the stability of the fluid. For example, the fluid may include a component element that is itself a fire retardant, or which, when combined with other components of the fluid, prevent the fluid from igniting. Alternatively, or in addition, the fluid may include component elements that improve and or provide a voltage-carrying capability of the fluid. For example, the fluid may optionally include a mixture of water and manganese sulfate.

Inlet302comprises at least one internal wall304that at least partially defines an internal volume306, and includes an aperture307through which fluid passes between inlet302and internal pin volume214. As schematically illustrated in dashed lines inFIG. 1, heat transfer devices100also may include one or more of a fluid reservoir310and a barrier element312. For example, heat transfer devices100optionally may include fluid reservoir310, where the fluid flows from fluid reservoir310into inlet302. The fluid may flow directly from fluid reservoir310to inlet302, or may indirectly flow from fluid reservoir310to inlet302via one or more conduits.

The fluid may flow from fluid reservoir310based on a passive driver, such as a passive pressure differential between the fluid and inlet302, and/or based on an applied pressure, such as a pressure applied by a pump. For example, the fluid may passively flow from fluid reservoir310to inlet302in response to the temperature of the fluid as stored in fluid reservoir310causing the fluid to have a fluid pressure that is greater than the pressure within inlet302. In some embodiments, the fluid may flow from fluid reservoir310to inlet302in response to a trigger event. For example, heat transfer device100may include one or more barrier elements312(e.g., burst discs, permeable membranes, plungers, release valves, pressure release valves, check valves, pyrotechnic valves, solenoid valves, ball and spring valves, etc.) that allow the fluid to flow from fluid reservoir310to inlet302when in an open configuration, and that restrict the fluid from flowing from fluid reservoir310to inlet302when in a closed configuration. Such barrier elements312may be configured to transform from the closed configuration to the open configuration in response to a trigger event. Example trigger events include heat transfer device100reaching a trigger temperature, the fluid reaching a trigger pressure, or an external stimulus triggering barrier element312to open.

For example, where barrier element312is a permeable membrane, a pressure that the fluid is exerting on the membrane may cause the fluid to flow across the membrane when the exerted pressure exceeds a threshold level. Alternatively, or in addition, barrier element312may be a burst disc that is configured to rupture when the fluid reaches a threshold pressure and/or temperature. Alternatively, or in addition, such a burst disc may be ruptured by a rupturing element, such as a puncture needle, a plunger, etc. when the fluid reaches a threshold pressure and/or temperature. In some embodiments, barrier element312may transition from a closed configuration to an open configuration in response to an outside stimulus, such as the initiation of an electronic device, a sensor detecting a threshold temperature, a cooling protocol being initiated, etc. The outside stimulus may be transmitted via a physical stimulus or an electronic stimulus/signal.

In one example, the barrier elements312may be formed from one or more of an elastomeric, polymeric, and metallic material. Alternatively or in addition, the barrier elements312may be formed from one or more of carbon steel, stainless steel, nickel-molybdenum alloys such as Hastelloy®, graphite, aluminum, silicone, and a high temperature rubber compound. In various embodiments, the barrier elements312may be located in an aperture that is shaped as a venturi, e.g., having a narrow section located between two wider sections. Alternatively, a corresponding aperture may be conically-shaped with a base of the cone positioned radially outward. In yet another embodiment, a corresponding aperture may be a cylindrical orifice. In such an embodiment, the cylindrical aperture functions as the narrow portion of a venturi.

Additionally, heat transfer devices100include fluid channel500defined between first disc200and second disc300. Fluid channel500is at least partially defined by inner surface204of first disc200and an inner surface318of second disc300. Fluid channel500is in fluid communication with internal pin volume214. For example, aperture206of first disc200may open into fluid channel500to allow for fluid to pass between aperture206and fluid channel500. Fluid channel500then allows the fluid to flow away from internal pin volume214. For example, fluid channel500may allow the fluid to flow radially away from the internal pin volume214. Alternatively, fluid channel500may further be partially defined by one or more channel walls502that restrict the fluid so that it flows away from internal pin volume214along one or more flow pathways. In some embodiments, heat transfer devices100include one or more exit interfaces320that partially define fluid channel500. Exit interface320allows fluid to flow from fluid channel500to an effusion region308(e.g. a storage receptacle, a sewer, an environment of the heat transfer device, etc.) via exit interface320. In this way, fluid flowing through fluid channel500may be exhausted from fluid channel500by passing through the at least one exit interface320and into effusion region308.

In some embodiments, heat transfer devices100include a chimney322through which the fluid is able to flow from fluid channel500and through one of first disc200and second disc300. In such embodiments, the fluid is exhausted from fluid channel500by flowing through chimney322and to an exhaustion, diffusion, and/or effusion region.FIG. 1shows chimney322as being defined by second disc300; however, in other embodiments, chimney322may be at least partially defined by first disc200, the second disc300, another component, or a combination thereof.

As schematically illustrated in dashed lines inFIG. 1, inlet302optionally may comprise an injector314extending from inlet302and into internal pin volume214. Injector314may define an internal pin channel316that is in fluid communication with both inlet302and internal pin volume214. In some embodiments, injector314may extend past fluid channel500and/or aperture307. In this way, internal pin channel316provides a flow path through which the fluid can pass from inlet302and into internal pin volume214at a location beyond fluid channel500and in some examples even beyond aperture307. In this way, the fluid will flow out of injector314and toward internal surface218of distal end210, preventing the fluid from partially and/or entirely flowing into fluid channel500. Thus, injector314increases the amount of fluid that applies pressure to internal surface218of distal end210as well as the amount of turbulence created within internal pin volume214.

Heat transfer devices100further include at least one spacer400positioned between first disc200and second disc300. At least one spacer400may be in contact with inner surface204of first disc200and inner surface318of second disc300. One or more spacers400define a separation402between inner surface204of first disc200and inner surface318of second disc300. The at least one spacer400is configured to allow fluid to pass from internal pin volume214to fluid channel500. That is, at least one spacer400both defines separation402of fluid channel500while also providing a flow path between internal pin volume214and fluid channel500. In an example embodiment, at least one spacer400is a plurality of separate spacers, where the spacers partially define a spacer flow pathway404between internal pin volume214and fluid channel500. For example, spacer flow pathway404may correspond to a volume partially defined by two spacers of the plurality of separate spacers. Alternatively, or in addition, spacer flow pathway404may correspond to an internal flow way406defined within a spacer, and at least partially defined by the corresponding spacer. In this way, internal flow way406allows the fluid to flow from internal pin volume214and fluid channel500by passing through the corresponding spacer.

One or more component elements of heat transfer device100may be formed from plastics, polymers and/or elastomers including but not limited to Nylon, acrylonitrile butadiene styrene, polyactic acid, polyetherimide (ULTEM®), Carbon fiber, para-aramid synthetic fibers (Kevlar®), polychlorotrifluoroethylene, polytetrafluoroethylene (Teflon™), and polyethylene terephthalate. Alternatively, or in addition, portions of the structure may be constructed of flexible material for purposes of resiliency to high-vibration regimes, flexure in aero elastic applications. Alternatively, or in addition, component elements of heat transfer device100may be constructed with non-thermoplastic materials, including epoxies, including high-temp resistant epoxies. In some embodiments, one or more component elements of heat transfer device100may partially and/or completely comprise one or more shape memory alloys.

Further, component elements of heat transfer device100may optionally include support materials, such as support materials for plastics, polymers and/or elastomers like PVA or metallic materials, including water-soluble crystals and other melt-aways, including, but not limited to Cu, Ag, Al, Sb, Zn, and Sn. Such support materials may also include other alloys having a low soldering point and/or melting point such as Ag alloy solder (Ag—Sn—Pb, Ag—Pb, Ag—Sn, Ag—Sn—Cu, Ag—Cd—Zn, Ag—Cd), polyethylene, polyamide, polyimide, polyolefin, polyprophylene, polypropylene, polystyrene, PMMA, polyether sulfone, thermoplastic polyester, copolymer or polyhexafluroropropylene and polytetrafluoroethylene, polyfluorovinylidene, and other organic composite photoresist materials (including but not limited to dry film type resist).

As discussed above, one or more component elements of heat transfer device100may be constructed via additive manufacturing. Example additive manufacturing methods and printers include, but are not limited to, VAT photopolymerization, powder bed fusion, binder jetting, bronze infusion/infiltration, material jetting, sheet lamination, material extrusion, directed energy deposition, directed metal laser sintering, direct metal printing, electron beam additive manufacturing, electron beam melting, electron beam powder bed, fused deposition modeling, indirect power bed, laser cladding technology, laser deposition technology, laser deposition welding, laser deposition welding with integrated milling, laser engineering net shape, laser freeform manufacturing technology, laser metal deposition-powder, laser metal deposition-wire, laser powder bed, laser puddle deposition, laser repair technology, powder directed energy deposition, stereolithography, selective laser melting, selective laser sintering, small puddle deposition, atomic diffusion additive manufacturing, Big Area Additive Manufacturing, Bound Metal Deposition, composite-based additive manufacturing, digital light processing, digital light synthesis, gel dispensing printing, high-speed sintering, laminated object manufacturing, multi-jet fusion, Quantum & Nano-pico-femto-atto-scale Manufacturing (QUN), Rapid Plasma Deposition, Selective Deposition Lamination, Single-Pass Jetting, Ultrasonic Additive Manufacturing, Ytterbium In-situ Manufacturing (YIM), as well as hybrid processes thereof. For example, powder may be formed as collected waste powder or produced powder from Electrical Discharge Machining (EDM) machining processes.

Turning now toFIGS. 2-9, illustrative non-exclusive examples of heat transfer devices100are illustrated. Where appropriate, the reference numerals from the schematic illustrations ofFIG. 1are used to designate corresponding parts of the examples ofFIGS. 2-9; however, the examples ofFIGS. 2-9are non-exclusive and do not limit heat transfer devices100to the illustrated embodiments ofFIGS. 2-9. That is, heat transfer devices100are not limited to the specific embodiments depicted inFIGS. 2-9, and heat transfer devices100may incorporate any number of the various aspects, configurations, characteristics, properties, etc. of heat transfer devices that are illustrated in and discussed with reference to the schematic representations ofFIG. 1and/or the embodiments ofFIGS. 29, as well as variations thereof, without requiring the inclusion of all such aspects, configurations, characteristics, properties, etc. For the purpose of brevity, each previously discussed component, part, portion, aspect, region, etc. or variants thereof may not be discussed, illustrated, and/or labeled again with respect to the examples ofFIGS. 2-9; however, it is within the scope of the present disclosure that the previously discussed features, variants, etc. may be utilized with the examples ofFIGS. 2-9.

FIG. 2illustrates a cross section of an example embodiment120of heat transfer devices100comprising micro-bellows216and constructed of multiple component elements. As shown inFIG. 2, example embodiment120of heat transfer device100includes surface layer224that includes pin cooling structure208, rigid layer226adjacent to surface layer224, and second disc300defining inlet302and positioned adjacent to rigid layer226such that rigid layer226is disposed between surface layer224and second disc300. In some embodiments, the component elements of heat transfer device100(i.e., surface layer224, rigid layer226, and second disc300) may be assembled separately and then assembled together to form example embodiment120of heat transfer device100shown inFIG. 2. For example, individual components may be printed using additive manufacturing. When the component elements are generated separately, this allows a quality control check to be conducted to ensure proper formation before assembly of the heat transfer device100.

The component elements of heat transfer device100may individually be composed of a same material, may be composed of different materials, or a combination thereof. For example, rigid layer226and second disc300may be composed of a material having a lower modulus of elasticity and/or a higher coefficient of thermal expansion than surface layer224. In another example, surface layer224may be composed of a material having a higher thermal conductivity and/or electrical conductivity, allowing pin cooling structures208to be a better conduit for the flow of heat and/or electricity between external body102and heat transfer device100.

FIG. 2also shows the fluid pathway of fluid within heat transfer device100. For example,FIG. 2shows fluid flowing into inlet302. In various embodiments, the fluid may flow into inlet302directly or indirectly from fluid reservoir310. The fluid then flows out of injector314extending from inlet302and into internal pin volume214.FIG. 2shows the fluid pathway as optionally narrowing between inlet302and injector314. This narrowing causes an increase in the velocity of the fluid as it enters internal pin volume214.

The increase in velocity of the fluid as it enters internal pin volume214increases the pressure applied to distal end210of pin cooling structure208when the fluid impacts internal surface218of distal end210. This pressure applied to the distal end causes micro-bellows216to expand, which in turn causes distal end210of pin cooling structure208to be translated away from second disc300. For example, in response to a pressure being applied to internal surface218of distal end210, one or more expansion regions220(e.g., chevrons and/or ribs) of micro-bellows216expand. This translation increases the amount of heat that flows into pin cooling structure208from external body102. For example, the translation may cause distal end210to be more proximate to external body102, increasing the amount of heat transmitted via radiation and/or convection to pin cooling structure208from external body102. Alternatively, or in addition, the translation may cause distal end210to make physical contact and/or make a more flush contact with a surface of external body102, allowing and/or increasing the heat transmitted between pin cooling structures208from external body102via conduction.

As shown inFIG. 2, the fluid impacting internal surface218of distal end210also causes flow turbulence within internal pin volume214. This turbulence increases the opportunity for heat to flow from pin cooling structure208and into the fluid in internal pin volume214.FIG. 2further shows the fluid (and the heat absorbed from pin cooling structure208while the fluid was in internal pin volume214) flowing out of internal pin volume214and into fluid channel500. When flowing into fluid channel500, the fluid may flow past, between, and/or through one or more spacers400. The fluid and the heat then flow within fluid channel500away from pin cooling structure208. In some embodiments, the fluid and the heat may flow into chimney322and/or exit interface320where it is exhausted into effusion/diffusion region308, such as a storage receptacle, a sewer, an environment of the heat transfer device, etc.

FIG. 3illustrates a cross section of an example embodiment130of heat transfer devices100showing a plurality of pin cooling structures208, and composed of a monolithic structure. As shown inFIG. 3, each of first disc200, second disc300positioned adjacent to rigid layer226, and one or more spacers400of example embodiment130of heat transfer device100are formed of a single body. In some embodiments, the single body may be formed using additive manufacturing, and may at least partially comprise one or more functionally gradient materials and/or shape memory alloys.FIG. 3also shows first disc200as defining a plurality of apertures206and a plurality of pin cooling structures208, wherein individual pin cooling structures208extend from corresponding aperture206.FIG. 3further shows second disc300as comprising a plurality of inlets302, wherein each inlet302of the plurality of inlets302is configured to allow the fluid to flow from inlet302and into a corresponding internal pin volume214defined by a corresponding pin cooling structure208of the plurality of pin cooling structures208.

FIGS. 4-5illustrate cross sections of the unique AM heat transfer device100that illustrate the flow of fluid into fluid channel500.FIG. 4illustrates cross sections of an example embodiment of the aperture206of first disc200according to the present disclosure. Specifically,FIG. 4illustrates a cross section of first disc200and aperture206which depicts inlet302defined by second disc300, and a plurality of spacers400.FIG. 4also shows fluid pathways where the fluid is able to flow into fluid channel500around and/or between spacers400.FIG. 5illustrates cross sections of an example embodiment of fluid channel500according to the present disclosure. Specifically,FIG. 5illustrates a cross section of the plurality of spacers400and fluid channel500which depicts inlet302defined by second disc300.FIG. 5further illustrates fluid pathways along which the fluid is able to flow through fluid channel500away from inlet302.FIG. 5further shows optional channel walls502that restrict the fluid so that it flows away from inlet302through a particular channel flow pathway600.

FIGS. 6-7are a perspective view and a side view of heat transfer device100.FIGS. 6-7show first disc200coupled to second disc300via a plurality of attaching mechanisms610.FIGS. 6-7illustrate attaching mechanisms610as being counter sunk threaded fasteners, which enable the attaching mechanisms610to be flush with outer surface202of first disc200. However, in various embodiments attaching mechanisms610may correspond to any combination of mechanical fasteners, adhesives, welding, and/or bonding between first disc200and second disc300. In some embodiments, heat transfer device100further comprises an adapter configured to affix the heat transfer device to a separate component. Also as shown inFIGS. 6-7, first disc200may be made up of surface layer224and rigid layer226.

FIGS. 6-7also show a plurality of pin cooling structures208that extend from outer surface202of first disc200.FIG. 6shows heat transfer device100as having a circular shape. However, in other embodiments the heat transfer device may have another shape, such as oval, ovoid, square, polygonal, etc. In some embodiments, the shape of heat transfer device100may reflect or otherwise be based on a shape and/or characteristics of a separate body102. Moreover, in some embodiments, heat transfer device100may conformably wrap about a toroid, Vesica Pisces and/or thruster shape. The plurality of pin cooling structures208are illustrated inFIG. 6as being arranged in a matrix array. However, in alternative embodiments, pin cooling structures208may be arranged in any number of arrays such as radially symmetric patterns, offset matrix arrays, circular arrays, polygonal arrays, etc. Additionally, the arrangement of pin cooling structures208may be designed to reflect and/or align with external/separate body102. For example, pin cooling structures208may be positioned so that they align with and/or contact regions of external/separate body102that generate and/or absorb excess heat.

FIG. 8is a perspective view of example embodiment120of heat transfer device100ofFIG. 2illustrating a temperature based deformation thereof. Specifically,FIG. 8shows a deformation pattern (i.e., an altered shape or geometry) of example embodiment120of heat transfer device100based on a temperature of heat transfer device100. As heat transfer device100absorbs heat, first disc200, second disc300, or both may deform. That is, first disc200and/or second disc300may be composed of materials that deform responsive to a temperature change. In some embodiments, materials of first disc200and/or second disc300may be configured to so that heat transfer device100achieves a target deformation pattern (i.e., a desired shape or geometry) when heat transfer device100reaches a target temperature. For example, one or both of first disc200and second disc300may be composed of functionally gradient materials, where the properties (e.g., the coefficient of thermal expansion) of the functionally gradient materials are varied such as to cause one or both of first disc200and second disc300to achieve a target geometry when heat transfer device100reaches a target/threshhold temperature.

In some embodiments, the component materials of first disc200and/or second disc300are configured such that the patterns of the deformation of first disc200and/or second disc300responsive to a temperature change may be characterized by one or more mathematical representations, such as, for example, via a periodic convolution and/or periodic summation of one or more Zernike polynomials. Example Zernike polynomials may include sec spherical, primary septafoil, sec trefoil, sec tetrafoil, etc. For further discussion on the modeling of deformations see Doyle, Keith B, Genberg, Victor L., and Michels, Gregory J.Integrated Optomechanical Analysis, Bellingham, Wash.: SPIE Press, 2002. In some embodiments, the deformation of first disc200and/or second disc300causes pin cooling structures208to be translated as the temperature of heat transfer device100increases. Such a translation may correspond to pin cooling structures208moving to a position more proximate to and/or better aligning with external body102.

FIG. 9is a perspective view of example embodiment120of heat transfer device100as a component portion of a heat transfer puck150according to the present disclosure. Specifically,FIG. 9illustrates heat transfer apparatus700where heat transfer device100is mounted to the heat transfer puck150. The heat transfer puck150may include a mechanism for releasing fluid. Once the fluid is released by heat transfer puck150, the fluid may flow into inlet302of heat transfer device100. The fluid may then flow along a fluid pathway through heat transfer device100. In this way, in response to heat transfer puck150releasing the fluid, heat transfer device100may cool external body102. In some embodiments, heat transfer puck150may include one or more reservoirs for storing fluid. Alternatively, heat transfer puck150may selectively receive fluid from an external reservoir, and allow the fluid to subsequently flow to the heat transfer device100.

Heat transfer device100may comprise an adapter configured to affix heat transfer device100to heat transfer puck150or other device(s). The adapter may correspond to, or be separate from attaching mechanisms610. Heat transfer device100may be located within and/or affixed to a structure that is impenetrable by non-destructive Inspection (NDI) devices, including, but not limited to, x-ray (radiography), computed tomography (CT) scanning, ultrasonic testing (UT), etc. Moreover, heat transfer device100may be connected (including electrically) to one or more other devices that are identical or non-identical in properties including electrical and/or mechanical performance. Heat transfer device100may rotate, revolve, and/or translate with respect to an attaching surface and/or other devices (such as via bearings and/or electrically conductive bearings).

In embodiments where heat transfer device100may rotate, revolve, and/or translate, heat transfer device100may be functional in a singular position with respect to another surface, and/or in a plurality of positions with respect to the another surface. Additionally, the heat transfer device100may exhibit an altered performance (including mechanical performance and/or electrical performance) when based on the position of heat transfer device100of the plurality of positions.

FIG. 10schematically provides a flowchart that represents illustrative, non-exclusive examples of methods1000according to the present disclosure. InFIG. 10, some steps are illustrated in dashed boxes indicating that such steps may be optional or may correspond to an optional version of a method according to the present disclosure. That said, not all methods according to the present disclosure are required to include the steps illustrated in solid boxes. The methods and steps illustrated inFIG. 10are not limiting and other methods and steps are within the scope of the present disclosure, including methods having greater than or fewer than the number of steps illustrated, as understood from the discussions herein.

FIG. 10is a flowchart schematically representing methods for conducting heat transfer with an external/separate body according to the present disclosure. Methods1000include flowing a fluid from inlet302and into internal pin volume214at1002. For example, the fluid may be flowed from inlet302defined by second disc300of heat transfer device100and into internal pin volume214defined by pin cooling structure208. Pin cooling structure208is a component of first disc200of heat transfer device100. First disc200is positioned adjacent to second disc300. The fluid may flow from inlet302based on a passive driver, such as a passive pressure differential between the fluid and inlet302, and/or based on an applied pressure, such as a pressure applied by a pump. In embodiments where heat transfer device100includes fluid reservoir310, the flowing of the fluid from inlet302in step1002may further comprise flowing the fluid from fluid reservoir310and into inlet302. The fluid may flow directly from fluid reservoir310to inlet302, or may indirectly flow from fluid reservoir310to inlet302via one or more conduits.

Where heat transfer device100includes barrier element312(e.g., a burst disc, a permeable membrane, a plunger, a release valve, a pressure release valve, a check valve, a pyrotechnic valve, a solenoid valve, a ball and spring valve, etc.), the flowing of the fluid from inlet302may be in response to a trigger event. Example trigger events may include heat transfer device100reaching a trigger temperature; the fluid reaching a trigger pressure; or an external stimulus triggering barrier element312to open.

Methods1000optionally may include translating distal end210of the pin cooling structure208away from first disc200. The translating of distal end210may include causing the distal end210to contact an external body102. In some embodiments, the translation of distal end210may be based at least in part on the fluid flowing into internal pin volume214. In some embodiments, pin cooling structure208comprises micro-bellows216, and wherein the translating distal end210of pin cooling structure208toward external body102corresponds at least in part to micro-bellows216expanding. Micro-bellows216is an elastic vessel that can be expanded when a pressure is applied to internal surface218of distal end210. For example, expansion of micro-bellows216causes distal end210of pin cooling structure208to be translated away from second disc300. Micro-bellows216may include one or more expansion regions220, such as chevrons and/or ribs, which are capable of expanding or contracting in response to applied pressures. In some embodiments, internal surface218of distal end210comprises inset surface211opposite aperture206. In such embodiments, inset surface211may be configured to efficiently receive pressure from the fluid in internal pin volume214traveling away from aperture206.

Methods1000also may optionally include deforming at least one of first disc200and second disc300based on a change in temperature at step1006. For example, first disc200and/or second disc300may be composed of materials that deform responsive to a temperature change. Thus, in some embodiments, materials of first disc200and/or second disc300may be configured so that heat transfer device100achieves a target shape when heat transfer device100reaches a target temperature. For example, one or both of first disc200and second disc300may be composed of functionally gradient materials, where the properties of the functionally gradient materials cause one or both of first disc200and second disc300to achieve a target shape when heat transfer device100reaches a target/threshold temperature. Such a deformation of first disc200and/or second disc300responsive to a temperature change may be characterized by one or more mathematical representations, such as, for example, one or more Zernike polynomials. Additionally, the deformation may cause pin cooling structures208extending from first disc200to be translated as the temperature of heat transfer device100increases.

At step1008, heat is transferred between external body102and the fluid within internal pin volume214via pin cooling structure208. For example, heat may first be transferred between external/separate body102and pin cooling structure208, and then subsequently transferred from pin cooling structure208and to the fluid within internal pin volume214. The heat may be transferred by any combination of conduction, radiation, and convection.

At step1010, the fluid is flowed from internal pin volume214and into fluid channel500. Fluid channel500is at least partially defined by second disc300and first disc200. In some embodiments, the fluid flows through a spacer flow pathway404defined by a combination of inner surface204of first disc200, inner surface318of second disc300and a plurality of spacers400. For example, spacer flow pathway404may correspond to a volume partially defined by two spacers of the plurality of separate spacers400. Alternatively, or in addition, spacer flow pathway404may correspond to an internal flow way406defined within spacer400, and at least partially defined by corresponding spacer400. In this way, internal flow way406allows the fluid to flow from internal pin volume214and fluid channel500by passing through corresponding spacer400.

At step1012, methods1000also may optionally include exhausting the fluid from heat transfer device100. For example, the fluid may flow within fluid channel500until it reaches exit interface320and/or chimney322. The fluid may then be exhausted into effusion/diffusion region308, such as a storage receptacle, a sewer/chimney, an environment of the heat transfer device, etc. In this way, by exhausting the fluid, the heat absorbed from external body102is exhausted from the heat transfer device100along with the fluid.

A1. A heat transfer device, comprising: a first disc defining an aperture and comprising a pin cooling structure extending from around the aperture, the pin cooling structure comprising:

a distal end configured to facilitate heat exchange between the pin cooling structure and an external body; and one or more side walls, wherein at least one of the one or more side walls, the distal end, and the aperture at least partially define an internal pin volume;

a second disc positioned adjacent to the first disc defining an inlet, wherein the inlet is configured to: receive a fluid; and allow the fluid to flow from the inlet and into the internal pin volume;

at least one spacer positioned between the first disc and the second disc; and

wherein a fluid channel is defined between the first disc and the second disc, and wherein the fluid channel is in fluid communication with the internal pin volume.

A2. The heat transfer device of paragraph A1, wherein the first disc, the second disc, and the at least one spacer are formed of a single body.

A3. The heat transfer device of paragraph A2, wherein the single body is formed using additive manufacturing.

A4. The heat transfer device of any of paragraphs A1-A3, wherein the heat transfer device is composed of one or more functionally gradient materials.

A5. The heat transfer device of any of paragraphs A1-A4, wherein the second disc further comprises an injector extending from the inlet and into the internal pin volume.

A6. The heat transfer device of paragraph A5, wherein the injector defines a pin channel configured to allow the fluid to flow from the inlet and into the internal pin volume.

A7. The heat transfer device of any of paragraphs A1-A6, wherein the internal pin volume is further defined by the second disc.

A8. The heat transfer device of any of paragraphs A1 and A5-A7, wherein the first disc and the second disc are coupled together via at least one of a mechanical fastener, an adhesive, welding, and/or bonding.

A9. The heat transfer device of any of paragraphs A1-A8, wherein the fluid channel is further defined by one or more channel walls that direct the flow of fluid away from the internal pin volume and along a flow pathway.

A10. The heat transfer device of any of paragraphs A1-A8, wherein the fluid channel is configured to direct the fluid to flow radially away from the internal pin volume in all directions.

A11. The heat transfer device of any of paragraphs A1-A10, wherein the one or more side walls of the pin cooling structure comprise a micro-bellows.

A12. The heat transfer device of paragraph A11, wherein the micro-bellows is configured to expand.

A13. The heat transfer device of paragraph A12, wherein expansion of the micro-bellows causes the distal end of the pin cooling structure to be translated away from the second disc.

A14. The heat transfer device of any of paragraphs A12-A13, wherein the micro-bellows is configured to expand in response to the fluid being injected into the internal pin volume of the pin cooling structure.

A15. The heat transfer device of any of paragraphs A11-14, wherein the micro-bellows is configured to deform in response to the distal end of the pin cooling structure making contact with the external body, and wherein the contact between the distal end of the pin cooling structure and the external body is flush based on the deformation of the micro-bellows.

A16. The heat transfer device of paragraph A15, wherein the micro-bellows is configured to deform in response to a normal force received by the distal end of the pin cooling structure and from the external body.

A17. The heat transfer device of any of paragraphs A1-A16, further comprising a fluid reservoir configured to allow the fluid to flow into the inlet from the fluid reservoir.

A18. The heat transfer device of paragraph A17, wherein the heat transfer device is configured to allow the fluid to flow into the inlet from the fluid reservoir in response to a trigger event.

A18.1. The heat transfer device of paragraph A18, wherein the trigger event corresponds to at least one of:

the heat transfer device reaching a trigger temperature;

the fluid reaching a trigger pressure; or

an external stimulus triggering a fluid barrier to open.

A19. The heat transfer device of any of paragraphs A1-A18.1, wherein an internal surface of the distal end of the pin cooling structure comprises a conical surface opposite the inlet.

A20. The heat transfer device of any of paragraphs A1-A19, wherein the first disc further defines a plurality of apertures and further comprises a plurality of corresponding pin cooling structures.

A21. The heat transfer device of paragraph A20, wherein the second disc further comprises a plurality of inlets, wherein each inlet of the plurality of inlets is configured to allow the fluid to flow from the inlet and into a corresponding internal pin volume defined by a corresponding pin cooling structure of the plurality of pin cooling structures.

A22. The heat transfer device of any of paragraphs A20-A21, wherein the plurality of pin cooling structures are arranged in a matrix array.

A23. The heat transfer device of any of paragraphs A20-A21, wherein the plurality of pin cooling structures are arranged in an offset matrix array.

A24. The heat transfer device of any of paragraphs A20-A21, wherein arrangement of the plurality of pin cooling structures on the first disc is based on one or more characteristics of the external/separate body.

A25. The heat transfer device of any of paragraphs A1-A24, wherein the pin cooling structure is electrically conductive, and is further configured to provide an electrical path between the external body and the heat transfer device.

A26. The heat transfer device of any of paragraphs A1-A25, wherein the heat transfer device further comprises an adapter configured to affix to an external/separate component.

A27. The heat transfer device of any of paragraphs A1-A21, wherein the first disc and the second disc are configured to deform responsive to a temperature change of the heat transfer device.

A28. The heat transfer device of paragraph A27, wherein the first disc and the second disc are configured such that deformation of the first disc and the second disc responsive to the temperature change of the heat transfer device comprises causing the pin cooling structure to be transformed as the temperature of the heat transfer device increases.

A29. The heat transfer device of any of paragraphs A27-A28, wherein the first disc and the second disc are configured such that the deformation of the first disc and the second disc responsive to the temperature change is characterized by one or more Zernike polynomials.

A30. The heat transfer device of any of paragraphs A27-A29, wherein the first disc and the second disc are configured such that the deformation of the first disc and the second disc causes the heat transfer device to achieve a target shape when the heat transfer device reaches a target temperature.

A31. The heat transfer device of any of paragraphs A27-A30, wherein at least one of the first disc and the second disc is composed of functionally gradient materials.

A32. The heat transfer device of paragraph A31, wherein the properties of the functionally gradient materials are configured to cause the heat transfer device to achieve a/the target shape when the heat transfer device reaches a/the target/threshold temperature.

A33. The heat transfer device of any of paragraphs A1-A32, wherein the pin cooling structure is perpendicular with a surface of the first disc.

A34. The heat transfer device of any of paragraphs A1-A33, wherein an angle between the pin cooling structure and a/the surface of the first disc is configured to create optimal contact with the external/separate body when the heat transfer device is deformed.

A35. The heat transfer device of any of paragraphs A1-A34, wherein the fluid comprises, and optionally is or consists of, methane.

A36. The heat transfer device of any of paragraphs A1-A35, further comprising a chimney through which the fluid is able to flow from the fluid channel to an exhaustion, diffusion, and/or effusion region, and wherein exhausting the fluid from the fluid channel comprises the fluid flowing through the chimney and to the exhaustion, diffusion, and/or effusion region.

A37. The heat transfer device of any of paragraphs A1-A36, further comprising at least one exit interface that enables the fluid to flow from the fluid channel to a/the exhaustion, diffusion, and/or effusion region, and wherein exhausting the fluid from the fluid channel comprises the fluid flowing through the at least one exit interface and to the exhaustion, diffusion, and/or effusion region.

A38. The heat transfer device of any of paragraphs A36-A37, wherein the exhaustion, diffusion, and/or effusion region is the environment of the heat transfer device.

A39. The heat transfer device of any of paragraphs A1-A38, wherein the external body is one of an electronic device and an electronic component.

A40. The heat transfer device of any of paragraphs A1 and A5-A39, wherein the first disc comprises:

a surface layer including the pin cooling structure; and

a rigid layer adjacent to the surface layer and disposed between the surface layer and the fluid channel wherein the rigid layer partially defines the fluid channel.

A41. The heat transfer device of paragraph A40 wherein the rigid layer is composed of a material having a lower modulus of elasticity and/or a higher coefficient of thermal expansion than the surface layer.

B1. A combination of the heat transfer device of any of paragraphs A1-A40 and an electronic device, wherein the electronic device comprises the external body.

B2. The combination of paragraph B1 when depending from paragraph A12, wherein an/the expansion of the micro-bellows causes the distal and distended end of the pin cooling structure to make contact with the external body.

B3. The combination of any of paragraphs B1-B2 when depending from paragraph A27, wherein a/the deformation of the first disc and the second disc causes the distal end of the pin cooling structure to make contact with the external/separate body.

C1. An electronic device, comprising: the heat transfer device of any of paragraphs A1-A40; and the external body.

D1. The use of the heat transfer device of any of paragraphs A1-A40 to cool an external body.

E1. The use of the heat transfer device of any of paragraphs A1-A40 to heat an external body.

F1. A method for conducting a heat exchange with an external body, comprising:

flowing a fluid from an inlet defined by a second disc of a heat transfer device and into an internal pin volume defined by a pin cooling structure, wherein the pin cooling structure is a component of a first disc of the heat transfer device, and wherein the first disc is adjacent to the second disc;

transferring heat between the external body and the fluid within the internal pin volume via the pin cooling structure; and

flowing the fluid from the internal pin volume to a fluid channel, wherein the fluid channel is defined by the second disc and the first disc.

F2. The method of paragraph F1, wherein transferring the heat flow between the external body and the fluid within the internal pin volume comprises:

receiving heat from the external body by the pin cooling structure; and

transferring the heat to flow from the pin cooling structure to the fluid within the internal pin volume.

F3. The method of any of paragraphs F1-F2, further comprising exhausting the fluid from the heat transfer device.

F4. The method of paragraph F3, wherein the exhausting the fluid further comprises exhausting the heat from the heat transfer device.

F5. The method of any of paragraphs F1-F4, further comprising translating a distal end of the pin cooling structure away from the first disc based on the fluid flowing into the internal pin volume.

F6. The method of paragraph F5, wherein the pin cooling structure comprises a micro-bellows, and wherein the translating the distal end of the pin cooling structure toward the external body corresponds at least in part to the micro-bellows expanding.

F7. The method of paragraph F5, further comprising deforming at least one of the second disc of the heat transfer device and the first disc of the heat transfer device based on a change in temperature of the heat transfer device, and wherein the translating the distal end of the pin cooling structure is based at least in part on the deforming.

F8. The method of any of paragraphs F1-F7, performed by the heat transfer device of any of paragraphs A1-A41.

As used herein, the term “and/or” placed between a first entity and a second entity means one of (1) the first entity, (2) the second entity, and (3) the first entity and the second entity. Multiple entries listed with “and/or” should be construed in the same manner, i.e., “one or more” of the entities so conjoined. Other entities optionally may be present other than the entities specifically identified by the “and/or” clause, whether related or unrelated to those entities specifically identified. Thus, as a non-limiting example, a reference to “A and/or B,” when used in conjunction with open-ended language such as “comprising,” may refer, in one example, to A only, as well as reoccurring absence/presence of A only, (optionally including entities other than B); in another example, to B only, as well as reoccurring absence/presence of B only, (optionally including entities other than A); in yet another example, to both A and B, as well as reoccurring absence/presence of A and B, (optionally including other entities). These entities may refer to elements, actions, structures, steps, operations, values, and the like.