Abstract:
A heat exchanger system may have a base, a mounting apparatus for attaching the base to a device, a gasket shelf for placing a gasket, a dissipation member for dissipating heat, and heat generator attachment sites for absorbing heat. A mounting apparatus may have finger-like extensions which flex and draw the base into contact with an underlying electronic device from which the system conducts heat. A base may also have an integrated heat pipe clamp attachment forming an aperture in the base into which a heat pipe may extend and may be clamped in thermal communication. The dissipation device may be a series of fins and troughs and a fan may direct air over the dissipation device to cool the apparatus.

Description:
FIELD 
       [0001]    The present disclosure relates to heat exchanger systems, and more specifically, to heat exchanger systems that may interface with more than one heat source. 
       BACKGROUND 
       [0002]    Many electronic devices produce significant heat, but design considerations typically only allow a small area of the device to be available for heat dissipation components. HI-eat exchangers are usually employed to dissipate heat; however, a typical heat exchanger uses semi-permanent/permanent methods such as soldering, crimping, or brazing to attach a heat pipe to the heat exchanger. Moreover, typical heat exchangers are limited in the number of heat sources with which they can interface, particularly in light of the small area often available for the heat exchanger. 
       SUMMARY 
       [0003]    In various embodiments, a heat exchanger system may comprise a base having a mounting apparatus configured to secure the base in substantially fixed position with respect to a first heat source, a gasket shelf surrounding the perimeter of the base and adapted to receive a gasket, a first heat generator attachment site formed in the base and configured to be positioned in thermal communication with a first heat source and conduct heat to the base, and a dissipation member configured to conduct heat away from the base. 
         [0004]    In various embodiments, a heat exchanger system may have a base having a mounting apparatus configured to secure the base in substantially fixed position with respect to a first heat source, a gasket shelf surrounding the perimeter of the base and adapted to receive a gasket, a first heat generator attachment site formed in the base and configured to be positioned in thermal communication with a first heat source and conduct heat to the base, a dissipation member configured to conduct heat away from the base, a second heat generator attachment site formed in the base and configured to be positioned in thermal communication with a second heat source and conduct heat to the base, and a third heat generator attachment site formed in the base and configured to be positioned in thermal communication with a third heat source and conduct heat to the base, wherein the first heat generator attachment site comprises an integrated heat pipe clamp attachment, wherein the second heat generator attachment site comprises a bolt-on heat pipe attachment, and wherein the third heat generator attachment site comprises a pressure mount attachment site. 
         [0005]    In various embodiments, a method of provisioning a heat source with a cooling system may comprise securing a base of the cooling system in substantially fixed position with respect to a first heat source via a mounting apparatus, installing a gasket on a gasket shelf surrounding the perimeter of the base and adapted to receive a gasket, positioning a first heat generator attachment site formed in the base in thermal communication with a first heat source, conducting heat from the first heat source to the base, and conducting heat from the base to a dissipation member configured to conduct heat away from the base. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    The subject matter of the present disclosure is particularly pointed out and distinctly claimed in the concluding portion of the specification. A more complete understanding of the present disclosure, however, may best be obtained by referring to the detailed description and claims when considered in connection with the drawing figures, wherein like numerals denote like elements. 
           [0007]      FIG. 1  illustrates a heat exchanger having an integrated heat pipe attachment and integrated spring mount in accordance with various embodiments; 
           [0008]      FIG. 2  illustrates a side view of a heat exchanger having an integrated heat pipe attachment and integrated spring mount in accordance with various embodiments; 
           [0009]      FIG. 3  illustrates a bottom view of a heat exchanger having an integrated heat pipe attachment and integrated spring mount in accordance with various embodiments; 
           [0010]      FIG. 4  illustrates a heat exchanger having an integrated heat pipe attachment and integrated spring mount in accordance with various embodiments; 
           [0011]      FIG. 5  illustrates a side view of a heat exchanger having an integrated heat pipe attachment in accordance with various embodiments; 
           [0012]      FIG. 6  illustrates a bottom view of a heat exchanger having an integrated heat pipe attachment in accordance with various embodiments; 
           [0013]      FIG. 7  illustrates a heat exchanger installed in an electronic device in accordance with various embodiments; 
           [0014]      FIG. 8  illustrates a heat exchanger and a cooling fan installed in an electronic device in accordance with various embodiments; and 
           [0015]      FIG. 9  illustrates a heat exchanger and a cover installed in an electronic device in accordance with various embodiments. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    The detailed description of exemplary embodiments herein makes reference to the accompanying drawings, which show exemplary embodiments by way of illustration and their best mode. While these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the inventions, it should be understood that other embodiments may be realized and that logical, chemical and mechanical changes may be made without departing from the spirit and scope of the disclosure. Thus, the detailed description herein is presented for purposes of illustration only and not of limitation. For example, the steps recited in any of the method or process descriptions may be executed in any order and are not necessarily limited to the order presented. 
         [0017]    Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected or the like may include permanent, removable, temporary, partial, full and/or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact. 
         [0018]    As used herein, phrases such as “make contact with,” “coupled to,” “touch,” “interface with” and “engage” may be used interchangeably. 
         [0019]    In various embodiments, the present disclosure provides a heat exchanger system with improved heat transfer and an ability to dissipate heat from multiple sources with a reduced footprint. In this regard, a single heat exchange system may accept heat originating from multiple sources throughout a device. In various embodiments, this functionality beneficially decreases the footprint occupied by heat exchanger hardware. 
         [0020]    In various embodiments, a heat exchanger system may comprise a base, a mounting apparatus, a dissipation member, and a heat generator attachment site. A heat exchanger system may further comprise a gasket shelf. 
         [0021]    For example, with reference to  FIG. 1 , in various embodiments, a heat exchanger system  10  may comprise a base  30 , integrated spring mount  40 , a gasket shelf  60 , a dissipation member  70 , and heat generator attachment sites, for example, a bolt-on heat pipe attachment  80  and an integrated heat pipe clamp attachment  100 . In various embodiments, integrated spring mount  40  may comprise any suitable mounting apparatus. However, a heat exchanger system may comprise any number or configuration of heat generator attachment sites. For example, with reference to  FIG. 3 , a heat exchanger system  10  may also comprise a pressure mount attachment site  90 . 
         [0022]    Moreover, with reference to  FIG. 4 , aspects of various other embodiments are disclosed wherein these embodiments share many of the features discussed with respect to various embodiments according to  FIG. 1  and wherein these embodiments may comprise a different number and configuration of heat generator attachment sites. In various embodiments, a heat exchanger system  20  may comprise a base  30 , a mounting apparatus comprising a static mount  45 , a gasket shelf  60 , a dissipation member  70 , and heat generator attachment sites, for example, a bolt-on heat pipe attachment  80 , and an integrated heat pipe clamp attachment  100 . Thus, as illustrated herein, a heat exchanger system may comprise any number or configuration of heat generator attachment sites adapted to accept heat originating from one or more sources throughout a device. 
         [0023]    In accordance with various embodiments, a base  30  may comprise a unitary milled block of material. For example, a base  30  may be formed through destructive manufacturing processes performed on a piece of billet metal. For example, a solid block of copper or other material may be milled, machined, or otherwise manufactured whereby it is shaped into base  30 . In various embodiments, however, a base  30  may be manufactured through additive manufacturing processes, for example, 3D printing. Moreover, a base  30  may be comprised of copper. In various embodiments a base  30  may be comprised of aluminum, or steel, or any thermally conductive material. 
         [0024]    With reference to  FIG. 1 , in accordance with various embodiments, the system  10  may comprise a mounting apparatus comprising an integrated spring mount  40 . For example, base  30  may incorporate one or more integrated spring mounts  40  wherein the integrated spring mounts  40  can be attached to an electronic device via one or more fastening apparatus  50 . Fastening apparatus  50  may comprise an aperture. In various embodiments, fastening apparatus  50  may comprise a fastener, a threaded hole, a captive bolt, a captive nut and/or any other apparatus or combination of apparatuses suitable for holding, maintaining, or otherwise coupling, or retaining the base  30  in thermal communication with an underlying device. The underlying device may comprise a first heat source. In various embodiments, the underlying device may comprise a processor, or SOIC, ASIC, or IC, or transistor, or any device requiring heat exchange. 
         [0025]    In various embodiments, integrated spring mount  40  comprises a finger-like extension which may flex and draw the base  30  into contact with the underlying device, thereby maintaining a contact force upon the underlying device. In various embodiments, a base  30  may have three integrated spring mounts  40 , for example, one centered along the one side of the base  30 , for example, a side parallel to the Y-axis and perpendicular to the X-axis, crossing the negative X-axis. For further example, two integrated spring mounts  40  may then be located along another side of the base  30 , for example, a side parallel to the Y-axis and perpendicular to the X-axis, crossing the positive X-axis, wherein one integrated spring mount  40  is positioned at each end of the side, for instance, +Y end of the side and at the −Y end of the side, with reference to a coordinate system originating from a point at the center of the base  30 . 
         [0026]    With reference to  FIG. 4 , in various embodiments, the system  20  may comprise a mounting apparatus comprising a static mount  45 . For example, base  30  may incorporate a static mount  45  wherein the static mount  45  can be attached to an electronic device via one or more fastening apparatus  50 . In various embodiments, a base may have two static mounts  45 . For example, a first static mount  45  may be centered along the one side of the base, for example, a side parallel to the Y-axis and perpendicular to the X-axis, crossing the negative X-axis, wherein this static mount  45  has one fastening apparatus  50 . For further example, a second static mount  45  may also extend along another side of the base, for example, the length of a side parallel to the Y-axis and perpendicular to the X-axis, crossing the positive X-axis, wherein one fastening apparatus  50  is positioned at each end of the length, for instance, +Y end of the side and at the −Y end of the side, with reference to a coordinate system originating from a point at the center of the base  30 . 
         [0027]    In various embodiments, a heat generator attachment site may be an integrated heat pipe clamp attachment  100 . For example, with reference to  FIGS. 1 ,  2 ,  4 ,  5 , and  7 , in various embodiments, a heat pipe clamp attachment  100  may comprise a cylindrical aperture in base  30 . The aperture may traverse the entire length of a side of the base  30 , or a portion of the length of a side of the base  30 . In various embodiments, the aperture may traverse the entire length of a side of the base  30  wherein the aperture traverses a side parallel to the Y axis, and extends through the entire body of the base  30  from the negative most point the base occupies along the X axis, to the positive most point the base occupies along the X axis. In various embodiments, the aperture may lie parallel to the Y-axis, and may extend into the body of base  30 . In various embodiments, the aperture may penetrate in any depth and any direction suited to retain a heat pipe in thermal conduction with base  30 . In various embodiments, the aperture may extend from the edge of the base  30  crossing the negative X-axis to the edge of the base  30  crossing the positive X-axis. Moreover, the aperture may be trapezoidal, square, rectangular, or any shape adapted to interface in mechanical and thermal communication with a heat pipe. The aperture may have any depth or shape adapted to interface in mechanical and thermal communication with a heat pipe. 
         [0028]    With reference to  FIGS. 1 ,  4 , and  6 , a groove may traverse the length of the aperture, traversing parallel to the aperture which in various embodiments parallels the Y-axis, whereby one or more fastening apparatus  110  may permit fasteners to compress the integrated heat pipe clamp attachment  100  thereby retaining a heat pipe  120  in mechanical and thermal communication with the base  30 . As used herein, thermal communication means capability for any form of heat transfer, such as conduction, convection, and radiation, whether directly, or through another body. In various embodiments, fastening apparatus  110  may comprise an aperture and a threaded hole. In various embodiments, fastening apparatus  110  may comprise a fastener, or a captive bolt, or a captive nut or any other apparatus or combination of apparatuses suitable for holding, maintaining, or otherwise coupling, or retaining a heat pipe  120  in mechanical and thermal communication with the base  30 . 
         [0029]    In various embodiments, a heat generator attachment site may be a bolt-on heat pipe attachment  80 . For example, with reference to  FIGS. 1-3  and  4 - 6 , and with particular reference to  FIGS. 2 and 5 , an aperture may be formed in the base  30  wherein a heat pipe may be placed and attached via one or more fastening apparatus  50  (see  FIGS. 2 and 5 ). 
         [0030]    In various embodiments, a heat generator attachment site may be a pressure mount attachment site  90 . For example, with reference to  FIG. 3 , a pressure mount attachment site  90  may be formed in the underside of the base  30 . In various embodiments, a pressure mount attachment site  90  comprises a flat recessed region suitable for contacting an electronic device, for example, a processor, or a SOIC, or ASIC, or an IC, or a transistor, or any device that requires heat exchange. In this regard, with additional reference to  FIG. 1 , integrated spring mounts  40  may provide a mating force whereby base  30  is held in mechanical and thermal communication with the processor, or SOIC, ASIC, or IC, or transistor, or any device requiring heat exchange. 
         [0031]    In various embodiments, a heat exchanger system may comprise multiple heat generator attachment sites. For example, with reference to  FIGS. 1-3 , a heat exchanger system  10  may comprise a bolt-on heat pipe attachment  80 , an integrated heat pipe clamp attachment  100 , and a pressure mount attachment site  90 . With reference to  FIGS. 4-6 , a heat exchanger system  20  may comprise a bolt-on heat pipe attachment  80  and an integrated heat pipe clamp attachment  100 . However, a heat exchanger system may comprise any number, arrangement, or selection of heat generator attachment sites. 
         [0032]    In various embodiments, a dissipation member  70  may be a set of fins and troughs, for example, for air cooling. With reference to  FIGS. 1 and 4 , a set of fins may extend upward in the direction of the positive Z-axis from base  30 . With reference to  FIGS. 2 and 5 , a set of fins may terminate in a plane substantially parallel to a plane defined by the bottom face of base  30 . A set of troughs may alternate between the fins. The dissipation member  70  may join base  30  according to a curve, for example, to make room for integrated heat pipe clamp attachment  100 , yet provide sufficient material to conduct heat away from integrated heat pipe clamp attachment  100 . For example, with reference to  FIGS. 1 and 4 , line  12  may define the curve, for example, line  12 , along which dissipation member  70  and base  30  interface. In this regard, the troughs may extend no deeper than line  12 . Thus, base  30  may comprise sufficient material in proximity to integrated heat pipe clamp attachment  100  to conduct sufficient heat away from integrated heat pipe clamp attachment  100  and into dissipation member  70 . In various embodiments, dissipation member  70  and base  30  comprise a unitary piece of material. 
         [0033]    In various embodiments, the troughs may be oriented perpendicular to an integrated heat pipe clamp attachment  100 , and wherein the troughs comprise a radiused end whereby the profile of the troughs is shallower near to the integrated heat pipe clamp attachment  100  and deeper extending away from the integrated heat pipe clamp attachment  100 . 
         [0034]    In various embodiments, a gasket shelf  60  may surround the perimeter of base  30 . For example, with reference to  FIGS. 1 and 4 , a gasket shelf  60  may surround the perimeter of base  30 . The gasket shelf  60  follows an angle whereby the gasket shelf  60  lies above the integrated heat pipe clamp attachment  100  (in the positive Z direction), yet declines in a negative Z direction as it extends about the parameter of base  30  in the positive X direction. In this manner, the exposure of dissipation member  70  above gasket shelf  60  may be maximized, without causing integrated heat pipe clamp attachment  100  to be exposed above the gasket shelf  60 . However, any shape or configuration of gasket shelf  60  may be implemented wherein a gasket may be placed on the gasket shelf  60  to seal the dissipation member  70  and fan  130  (see  FIG. 8 ) from various surrounding hardware. 
         [0035]    With reference to  FIG. 8 , in various embodiments, a heat exchanger system may also comprise a fan  130 . In various embodiments, fan  130  may intake air and blow the air across the dissipation member  70  of a heat exchanger system. With reference to  FIGS. 8 and 9 , this air may travel into and out of the system according to direction of airflow  81 . In various embodiments, the direction of airflow  81  comprises parallel paths lying normal to the surface of the device in which the system is installed (e.g., normal to the plane of cover  140 ). In various embodiments, dissipation member  70  comprises fins and troughs, the troughs having a radius, for example, according to line  12 . In this regard, the air travels down the troughs of the dissipation member  70 , and conveys heat away from the heat exchanger. In various embodiments, the radius redirects the air to exit along a path substantially parallel to the path along which the air entered the fan, for example along a path normal to the plane of the outer face of fan  130 , for example, according to direction of airflow  81 . In this manner, the air may enter and exit the heat exchanger system through the same side of the system. As a result, various benefits may be realized, for example, only one side of the system is utilized for entry/exit of cooling air, airflow through the heat exchanger may be improved and noise may be ameliorated, for example, as a result of the radiusing of the troughs, external transmission of noise may be ameliorated, and various other benefits. With reference to  FIG. 9 , in various embodiments, a heat exchanger system may further comprise a cover  140 . In various embodiments, cover  140  comprises apertures through which air may flow. 
         [0036]    Now, having described various components of heat exchanger systems, a heat exchanger system may be manufactured by various methods. For example, with reference to  FIGS. 1 and 4 , a dissipation member  70  comprising a set of fins and troughs may be manufactured by a ganged slot cutter tool. In various embodiments, a series of slot cutters are ganged together to create a ganged slot cutter tool, for example, to create all the fins and troughs in a single pass. In various embodiments, a series of slot cutters are shaped to cut troughs having a radius. However, any tool or process may be implemented whereby the fins and toughs are created in a single pass and the troughs are created having a radius, for example, according to line  12 . 
         [0037]    Gasket shelf  60  may be manufactured by a cutting tool traversing an inclined tool path. For example, a cutting tool may transit the perimeter of base  30  creating an inclined gasket shelf. In this regard, the gasket shelf may follow an angle whereby the gasket shelf  60  lies above the integrated heat pipe clamp attachment  100  in the positive Z direction, yet declines in a negative Z direction as it extends in the positive X direction so as to lie beneath the dissipation member  70  at fan  130 . 
         [0038]    Now, having described various components of heat exchanger systems, a heat exchanger system may be manufactured from various materials. In various embodiments, a heat exchanger system may comprise copper. However, in further embodiments, a heat exchanger system may comprise other metals, such as aluminum, titanium, tungsten, carbon steel, or stainless steel, though it may further comprise numerous other materials configured to provide thermal conductivity. In various embodiments, various portions of heat exchanger systems as disclosed herein are made of different materials or combinations of materials, and/or may comprise coatings. 
         [0039]    In various embodiments, heat exchanger systems may comprise multiple materials, or any material configuration suitable to enhance or reinforce the resiliency and/or support of the system when subjected to wear in an operating environment or to satisfy other desired electromagnetic, chemical, physical, or biological properties such as heat capacity, thermal dissipation, and footprint constraints, among others. 
         [0040]    In various embodiments, the present disclosure provides a heat exchanger system with improved heat transfer and an ability to dissipate heat from multiple sources with a reduced footprint. Moreover, the heat exchanger system provides for airflow input and airflow output across a single plane. 
         [0041]    In various embodiments, while the heat exchanger systems described herein have been described in the context of electronic device applications, one will appreciate in light of the present disclosure, that the heat exchanger systems described herein may be used on various other applications such as, for example, air conditioning systems, heating systems, and industrial systems or processes. Moreover, the heat exchanger systems described herein may be employed with any heat source in any installation. In various embodiments, the heat exchanger systems described herein are used in the context of a cockpit device for use in an aircraft. Thus, in various embodiments, the heat exchanger systems described herein provide a cost effective and compact heat exchange system. 
         [0042]    Benefits, other advantages, and solutions to problems have been described herein with regard to specific embodiments. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the inventions. The scope of the inventions is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, where a phrase similar to “at least one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C. 
         [0043]    Systems, methods and apparatus are provided herein. In the detailed description herein, references to “one embodiment”, “an embodiment”, “various embodiments”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments. 
         [0044]    Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112(f), unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises”, “comprising”, or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.