Patent Description:
Cold plate cooling systems are typically used to actively cool electronic components or electronic devices, for example within a vehicle.

The electronic systems within an automotive vehicle are becoming increasing numerous and complex, with vehicles often being equipped with multiple electronic systems to control various vehicle functionalities. Accordingly, domain control units (DCUs) are becoming more common, as the DCU controls a set of vehicle functions related to a specific area or domain. These systems (such as a DCU) include a high number of electronics which require cooling in order to function optimally. Liquid cooling with heat exchangers, where coolant flow absorbs heat from the electronics and transfers the heat away, is one of the most effective cooling system for electronics.

An example of a heat exchanger design that can be used in cooperation with liquid cooling systems is a plate heat exchanger. This is referred to in the present disclosure as a cold plate cooling system.

There is a need to provide a more efficient and effective cold plate cooling system.

The following documents may provide technical background to the present disclosure: <CIT> directed to an inlet header duct design; <CIT> directed to a cooling device for a rechargeable battery; <CIT> directed to a fluid supply box for a heat exchanger; <CIT> directed towards a tank and spout interface for a heat exchanger; and <CIT> directed towards a heat exchanger.

Aspects of the present disclosure are set out in the accompanying independent and dependent claims. Combinations of features from the dependent claims may be combined with features of the independent claims as appropriate and not merely as explicitly set out in the claims.

According to an first aspect of the present disclosure, as defined in appended claim <NUM>, there is provided a coolant fluid manifold for coupling to a cold plate, wherein the manifold comprises an input channel comprising an inlet and an outlet, the inlet configured to receive input coolant fluid, wherein the input channel comprises a guide element that projects from a wall of the input channel, wherein the guide element is configured to guide fluid flow from the outlet.

The guide element can advantageously guide fluid flow of the coolant fluid from the outlet to preferentially direct the coolant fluid in a given direction. This can provide more efficient cooling in selected cold plate regions.

The guide element may be configured to improve uniformity of fluid flow output from the input channel inlet.

The inlet may be in fluid communication with an inlet pipe for receiving input coolant fluid.

Optionally, the manifold may comprise a return channel comprising an inlet and an outlet. The outlet may be in fluid communication with an outlet pipe for outputting returned coolant fluid. The return channel may be adjacent to the input channel.

It will be appreciated that both the input channel and the output channel receive and output coolant fluid during use. The input channel inlet in the present disclosure receives coolant fluid 'input' into the cooling system.

In use, the output channel in the present disclosure receives coolant fluid that is output from the input channel and has passed through the cold plate. The output channel then outputs this returned coolant fluid, for example via an output pipe. The present disclosure is mainly concerned with the input channel. It will be appreciated that the output channel may have the same configuration as the input channel, but without the guide element.

The guide element partially occludes or blocks the input channel outlet.

Optionally, a gap is provided between the guide element and a top wall or a base wall of the input channel.

Optionally, the guide element has a height that is approximately half a height of the input channel.

Thus, the input channel may have a first height and the guide element may have a maximum height equal to a second height, wherein the second height is less than the first height. Thus, the guide element may not block the entire height of the input channel, such that an amount of fluid flow is permitted between the guide element and a base or top wall of the input channel. Optionally, the second height is approximately half the first height.

The height of the guide element varies across the width of the guide element.

Optionally, the guide element has a leading contact surface and a trailing contact surface. The leading contact surface may project from a top wall or a base wall of the input channel. The leading contact surface may extend from the input channel outlet to a sidewall of the input channel.

Optionally, the trailing contact surface tapers from the leading contact surface towards a sidewall of the input channel.

Optionally, the leading contact surface is inclined at a steeper angle than the trailing contact surface relative to the wall of the input channel from which the guide element projects.

Optionally, the leading contact surface is inclined at an angle between <NUM>° and <NUM>° with respect to the wall of the input channel from which the guide element projects. In some embodiments, the leading contact surface may be perpendicular to the top wall or base wall of the input channel.

Optionally, the leading contact surface may have a height equal to the second height. The height of the trailing contact surface may taper towards a sidewall of the input channel.

Optionally, the guide element may comprise a fin or rib projection. The guide element may have a wedge shape, or a curved wedge shape. The guide element may be a three-dimensional structure.

The guide element is shaped and positioned to at least partially direct fluid flow from the input channel inlet towards a centre or a midpoint of the input channel outlet. This may improve uniformity of the fluid flow output if there is an uneven distribution of fluid flow from the inlet towards an edge of the input channel inlet. The guide element may limit the amount of fluid flow towards that edge of the input channel.

The input channel may have a width defined between a first sidewall and a second sidewall. The guide element may project from a top wall or a base wall of the input channel at a position between the first sidewall and the second sidewall.

The guide element may, proximate the outlet, project from a top wall or a base wall of the input channel at a position between a midpoint of the first and second sidewalls, and the first or second sidewall. The guide element may be offset from the input channel inlet.

The guide element may extend along the entire length of the input channel from the position proximate the outlet between the midpoint of the first and second sidewalls, and the first or second sidewall, towards the inlet.

Optionally, the guide element may extend along substantially the entire length of the input channel.

The input channel may have a first (or maximum) length extending from the outlet to the inlet. The guide element may have a second length that that is less than the first length. The second length may be parallel to the first length.

Optionally, a longitudinal cross-section of the input channel may have a v-shape, or a curved v-shape.

The input channel may have a first sidewall and a second sidewall that each extend from the input channel outlet to a vertex. The input channel inlet may be provided proximate the vertex.

Optionally, the guide element is offset from the input channel inlet, such that the guide element may not be aligned with the vertex.

Optionally, proximate the inlet channel outlet the leading contact surface projects from a top wall or a base wall of the input channel at a position between the first sidewall and a midpoint between the first sidewall and the second sidewall. The leading contact surface may extend along a length of the input channel towards the input channel inlet until it contacts to the first sidewall.

The leading contact surface may be approximately perpendicular to the plane of the input channel outlet.

Optionally, the input channel outlet has a first width. The first width may be defined as the distance between the first sidewall and the second sidewall at the outlet.

The guide element may have a second width at the outlet that is less than the first width. Optionally, the second width may be approximately a third of the first width.

In a second aspect, the present disclosure provides a cold plate cooling system comprising the manifold of any of embodiment or example of the first aspect of this disclosure and a cold plate.

It will be appreciated that a cold plate is a well-known term of the art for a plate which is actively cooled by a coolant system. It will be appreciated that any type of cold plate may be provided.

Optionally, the cold plate comprises a body, an input flow passage configured to interface with the input channel outlet, and a return flow passage configured to interface with the return channel inlet, wherein the input flow passage and the return flow passage each extend longitudinally through the body of the cold plate, and a return manifold coupled to the input flow passage and the return flow passage, such that a fluid flow path extends from the input channel inlet to the return channel outlet.

Optionally, the guide element is shaped and positioned to at least partially deflect coolant fluid towards an inner wall of the cold plate. Thus, a higher ratio of coolant fluid may be directed towards the inner wall which may more effectively cool the cold plate and improve efficiency of the cooling system.

Optionally, the input flow passage comprises at least a first passage and a second passage.

Optionally, the inner wall extends longitudinally through the body of the cold plate and at least partially separates the first passage from the second passage.

Optionally, the second passage is adjacent the first passage.

In some embodiments, the input flow passage comprises three or more passages. The three or more passages may be at least partially separated from each other by a plurality of inner walls. Optionally, a plurality of guide elements may be provided, wherein each guide element at least partially deflects coolant fluid towards a respective one of the plurality of inner walls.

Optionally, the second passage comprises an outer wall and the inner wall, wherein the outer wall forms part of the body of the cold plate. The guide element may be shaped and positioned to deflect flow of the coolant fluid in the second passage away from the outer wall. By directing fluid flow away from an exterior wall of the cold plate this may more effectively cool the cold plate and improve efficiency of the cooling system.

Optionally, the inner wall is aligned with the input channel inlet.

Optionally, the cooling system may comprise a plurality of cold plates.

The manifold may comprise a plurality of input channels and outlet channels to interface with the plurality of cold plates. Optionally, a plurality of manifolds may be provided.

Embodiments of this disclosure will be described hereinafter, by way of example only, with reference to the accompanying drawings in which like reference signs relate to like elements and in which:.

Embodiments of this disclosure are described in the following with reference to the accompanying drawings.

<FIG> shows an example of a cooling system according to the prior art for cooling a plurality of electronic controllers, or electronic components, <NUM>. The cooling system comprises a first cold plate <NUM> and a second cold plate <NUM> positioned between a respective pair of the electronic controllers <NUM>. A thermal interface material (not shown) may be provided between the electronic controllers <NUM> and the cold plates <NUM>, <NUM>.

At least one manifold is provided to circulate coolant fluid through internal channels in the cold plates <NUM>, <NUM> to actively cool the electronic controllers <NUM>. In the example shown in <FIG>, the manifold <NUM> comprises an inlet <NUM> and an outlet <NUM>. The inlet <NUM> is configured to receive input coolant fluid and to output the coolant fluid to the first and second cold plates <NUM>, <NUM>. The inflow stream of coolant fluid from the inlet <NUM> to the first and second cold plates <NUM>, <NUM> is shown by the arrows extending from the inlet <NUM> in <FIG>. The coolant fluid then returns via an outflow stream (as shown by the arrows) to the outlet <NUM>, wherein the coolant fluid is output from the system.

This type of heat exchanger (or cooling system) is compact and therefore useful in automotive design, and other types of system which are typically characterized by tight assembly spaces.

Ideally, the first and second cold plates <NUM>, <NUM> provide the same cooling performance. However, in practice this is often not achieved, as the flow of coolant fluid through the cold plates can be uneven, which can reduce the efficiency and efficacy of the cooling process. The present disclosure seeks to remedy this deficiency.

<FIG> shows an exploded view of a cooling system according to an embodiment of this disclosure. <FIG> shows the cooling system of <FIG> when assembled. The cooling system may be provided in an automotive vehicle.

In this embodiment, the cooling system comprises a first manifold <NUM> and a second manifold <NUM> and two cold plates <NUM>. In some embodiments, the first and second manifold <NUM>, <NUM> may be a single manifold. In some embodiments only a single cold plate <NUM> may be provided.

Each manifold <NUM>, <NUM> comprises an input channel <NUM> and an output channel <NUM>. The first manifold <NUM> comprises an outlet pipe <NUM> and the second manifold <NUM> comprises an inlet pipe <NUM>. In other embodiments, the first manifold <NUM> comprises the inlet pipe <NUM> and the second manifold <NUM> comprises the outlet pipe <NUM>. The inlet pipe <NUM> is configured to receive the input coolant fluid and the outlet pipe <NUM> is configured to output the returned coolant fluid from the system.

In this embodiment, each cold plate <NUM> comprises two internal input passages <NUM> and two internal output passages extending longitudinally through the body of the cold plate <NUM> (see <FIG>). The pair of input passages <NUM> are adjacent to the pair of output passages <NUM>. Each of the input passages <NUM> are separated by a first internal wall <NUM>, and each of the output passages <NUM> are separated by a second internal wall <NUM>. The input passages <NUM> are separated from the output passages by a further internal wall.

The input passages <NUM> in a respective cold plate <NUM> are configured to interface with a respective one of the input channels <NUM> in the manifolds <NUM>, <NUM>, when the system is assembled (as shown in <FIG>). Similarly, the outlet passages <NUM> in a respective cold plate <NUM> are configured to interface with a respective one of the output channels <NUM> in the manifolds <NUM>, <NUM>. Two return manifolds <NUM> are also provided.

When assembled, as shown in <FIG>, each return manifold <NUM> fluidly couples the input passages <NUM> to the output passages <NUM> for a given one of the cold plates. Thus, in use, a fluid flow path for coolant fluid is established from the inlet pipe <NUM>, through the input channel <NUM>, the input passages <NUM>, the return manifold <NUM>, the output passages <NUM>, the output channel <NUM> and out of the output pipe <NUM>.

<FIG> shows a more detailed view of an input channel of a coolant fluid manifold according to an embodiment of this disclosure. Features which are common between <FIG> and <FIG> have been given the same reference numeral.

In <FIG>, the input channel <NUM> comprises an inlet <NUM> and an outlet <NUM>. In this embodiment, the inlet <NUM> is provided in a top wall <NUM> of the input channel <NUM>. In other embodiments, the inlet <NUM> may be, for example, in the bottom wall or base <NUM> of the input channel <NUM>. The inlet <NUM> is in fluid communication with the inlet pipe <NUM> which is configured to receive input coolant fluid. The flow of coolant fluid during use of the manifold is illustrated in <FIG> by the arrows. The outlet <NUM> is the outwards facing aperture of the input channel <NUM>. Thus, during use, coolant fluid flows from the inlet pipe <NUM>, through the inlet <NUM>, along the input channel <NUM> and out through the outlet <NUM> into the cold plate <NUM>.

A guide element <NUM> is provided to guide the flow of coolant fluid from the input channel outlet <NUM>. In <FIG>, the guide element <NUM> projects from the top wall <NUM> of the input channel <NUM>. In other embodiments, the guide element <NUM> may project from the base <NUM>, or a sidewall of the input channel <NUM>.

The guide element <NUM> is (or comprises) a fin or rib shaped projection. In this exemplary embodiment, the guide element <NUM> has a leading contact surface <NUM> and a trailing contact surface <NUM>. The maximum height of the guide element <NUM> is provided by the leading contact surface <NUM>.

As shown in <FIG>, the guide element <NUM> has a maximum height of h<NUM>. The maximum height may be provided by the leading contact surface <NUM>. The input channel has a height of h<NUM>, wherein h<NUM> is greater than h<NUM>. In some embodiments, h<NUM> may be approximately half of h<NUM> Accordingly, the guide element <NUM> does not extend across the entire height of the input channel <NUM> from the top wall <NUM> to the bottom wall <NUM>. Instead, a gap A is provided between the leading contact surface <NUM> and the bottom wall <NUM> of the input channel <NUM>. Thus, some amount of fluid flow is permitted underneath the guide element <NUM>.

Without the guide element <NUM> a high proportion of the coolant fluid output from the outlet <NUM> can flow towards the outer wall <NUM> of the cold plate (see <FIG>). As the fluid flow is not uniform this results in a decrease in the efficiency of the cooling system, as some areas of the cold plate <NUM> are cooled more than others. Thus, the guide element <NUM> is configured to redirect fluid flow towards the center or midpoint of the outlet <NUM> and to reduce the amount of fluid flow output from the portion of the outlet <NUM> proximate the first sidewall <NUM>. Thus, a higher ratio of the coolant fluid is output towards the center or midpoint of the outlet <NUM> and the guide element <NUM> can ensure a more uniform distribution of the coolant flow, thereby improving cooling performance.

In some embodiments, due to the guide element <NUM> the fluid flow output from the outlet <NUM> may not be uniform, but may be skewed towards outputting a higher proportion of fluid proximate the center or midpoint of the outlet <NUM>. A higher portion of the output fluid may flow in a direction substantially perpendicular to the plane of the outlet <NUM>.

It will be appreciated that the flow of coolant fluid from the outlet <NUM> at least partially depends on the operational parameters of the coolant system, such as the pressure and temperature of the coolant fluid. It will also be appreciated that the guide element <NUM> is not limited to the position or configuration shown in these figures. Instead, the guide element <NUM> can be shaped and/or positioned to guide fluid flow from the outlet <NUM> in any desired direction to improve efficiency of the cooling and/or at least partially correct flow abnormalities, depending on the particular requirements of the coolant system.

In this embodiment, the leading contact surface <NUM> is inclined at a steeper angle than the trailing contact surface <NUM> relative to the top wall <NUM> of the input channel. In this non-limiting example, the leading contact surface is orientated at an angle between <NUM>° and <NUM>° from the top wall <NUM> of the input channel, but this angle can vary, for example depending on operational parameters. The trailing contact surface <NUM> tapers or curves from the leading contact surface <NUM> towards a sidewall of the input channel <NUM>. This is shown in more detail in <FIG> and <FIG>.

<FIG> shows a bottom perspective view of a longitudinal cross-section of the input channel <NUM> in <FIG>. The inlet <NUM> is not shown in <FIG>. The input channel <NUM> has a generally v-shaped, or curved v-shaped, longitudinal cross-section. A first sidewall <NUM> and a second sidewall <NUM> of the input channel extend from the outlet <NUM> to a vertex <NUM>. The three-dimensional shaping of the guide element <NUM> is clearly shown in <FIG>. The leading contract surface <NUM> is substantially vertical. The trailing contact surface <NUM> extends from the leading contact surface <NUM> and tapers the guide element <NUM> towards the first sidewall <NUM>.

Again, it will be appreciated that the guide element <NUM> could be used with any size or shape input channel, and is not limited to the v-shaped input channel <NUM> shown in the exemplary arrangements of the accompanying figures.

<FIG> shows a longitudinal cross-section of the input channel <NUM> (e.g. as shown in <FIG>) when viewed from the underside or bottom of the input channel. The leading contact surface <NUM> of the guide element extends from the outlet <NUM> to the first sidewall <NUM>, wherein the leading contact surface <NUM> is approximately perpendicular to the plane of the outlet <NUM>. As shown, the leading contact surface <NUM> is spaced from, or offset from, the inlet <NUM> and the vertex <NUM>.

The width of the input channel <NUM> is defined as the distance between the sidewalls <NUM>, <NUM> in the x-direction in <FIG>. The length of the input channel <NUM> is defined as the distance in the y-direction in <FIG>. The height of the input channel <NUM> (as shown in <FIG>) corresponds to the distance in the z-direction in <FIG>.

The input channel <NUM> has a maximum width W<NUM> (referred to as the first width) at the outlet <NUM>, wherein the width of the v-shaped input channel <NUM> narrows towards the vertex <NUM>. The maximum width of the guide element <NUM>, W<NUM>, (referred to as the second width) is also proximate the outlet <NUM>. As shown, W<NUM> is less than half of W<NUM>. In this embodiment, the second width W<NUM> is approximately a third of the first width W<NUM>.

In this embodiment, the longitudinal cross-section of the guide element <NUM> is shaped approximately like a right-angled triangle, with a portion of the first sidewall <NUM> forming the hypotenuse.

The input channel <NUM> has a maximum length L<NUM> from the outlet <NUM> to the vertex <NUM>. The length of the input channel <NUM> narrows towards the edges of the outlet <NUM>. The maximum length of the guide element <NUM> is at the leading contact surface <NUM>. The leading contact surface <NUM> has a length L<NUM>, wherein L<NUM> is less than L<NUM>.

The flow direction of coolant fluid from the inlet <NUM> towards the outlet <NUM> is represented by the arrows in <FIG>. Accordingly, the guide element <NUM> partially blocks fluid flow from the inlet towards the first sidewall <NUM>, but some fluid flow is permitted underneath the guide element <NUM> (e.g. through gap A in <FIG>). Thus, the coolant fluid is partially redirected by the guide element <NUM> towards the midpoint of the width W<NUM> of the outlet <NUM>.

As shown in <FIG>, in this embodiment the guide element <NUM> therefore functions to direct flow of the coolant fluid towards the inner wall <NUM> between the inlet passages <NUM> of the cold plate. <FIG> shows a longitudinal cross section through the assembled cooling system (e.g. through the top cold plate in <FIG>). The input channel <NUM> interfaces with a first input passage 202a and a second input cooling passage 202b through the cold plate <NUM>. The output passage <NUM> interfaces with a first output passage 204a and a second output passage 204b through the cold plate <NUM>.

The guide element <NUM> is shaped and positioned to direct at least a portion of the input coolant flow from away from an outer (or exterior) wall <NUM> of the cold plate. This is shown in more detail in <FIG>, which is a close up of section B in <FIG>. In <FIG> the dotted lines represent the flow of the coolant fluid from the inlet <NUM> towards the outlet <NUM> of the input channel <NUM>.

In <FIG> an 7B, the inner wall <NUM> which separates the two input passages <NUM> is substantially aligned with the inlet <NUM> and the vertex <NUM> of the input channel <NUM>. The guide element <NUM> interfaces with the second input passage 202b. As described above, the guide element <NUM> may extend from either the top wall or the bottom wall of the input channel <NUM>. In this embodiment, the shape and position of the guide element <NUM> at least partially deflects flow of the coolant fluid from the outlet <NUM> towards the inner wall <NUM>. Some coolant fluid is permitted to flow under or over the guide element <NUM> (as shown by the dotted lines) towards the outer wall <NUM> of the cold plate, but fluid flow in this direction is reduced by the guide element.

The guide element <NUM> may not affect fluid flow from the outlet <NUM> to the first input passage 202a. In some embodiments, the guide element <NUM> may increase the fluid flow to the first input passage 202a.

It is advantageous to have increased flow of coolant fluid towards the inner wall <NUM> of the cold plate <NUM>, as this has been found to cool the cold plate <NUM> more effectively and therefore improve performance of the cooling system.

In other embodiments, the guide element <NUM> may at least partially deflect flow of the coolant fluid in another direction to improve uniformity of flow, or to improve the efficiency of the cooling system, depending on the operational parameters of the system and the construction of the cold plate and the manifold. Thus, the guide element <NUM> is not limited to directing fluid flow towards an inner wall of the cold plate.

The guide element <NUM> can also reduce or eliminate unwanted vortices in the region of the input channel <NUM>, by reducing the fluid flow towards the outer wall <NUM>. These vortices can occur due to the particular inner geometry of the cold plate. Reduction of vortices advantageously makes the coolant flow smoother, improves the heat exchange effect and can lead to lower pressure drop.

It will be appreciated that the present disclosure is not limited to the particular cold plate shown in the exemplary arrangements of the accompanying figures. Instead, the manifold of the present disclosure could be used with any type of cold plate. Accordingly, although the cold plate <NUM> is shown as comprising two input passages 202a 202b and two output passages 204a 204b, any number of input and output passages may be provided. The number of input passages may not be equal to the number of output passages.

In some embodiments the cold plate may comprise a plurality of inner walls that separate a plurality of input passages. Thus, the input channel <NUM> may comprise a plurality of guide elements <NUM>. In some embodiments, the number of guide elements provided may equal the number of inner walls provided in the cold plate.

Accordingly, there has been described a coolant fluid manifold for coupling to a cold plate, wherein the manifold comprises an input channel comprising an inlet (and an outlet, the inlet in fluid communication with an inlet pipe for receiving input coolant fluid, and a return channel comprising an inlet and an outlet, the outlet in fluid communication with an outlet pipe for outputting returned coolant fluid, wherein the input channel comprises a guide element that projects from a wall of the input channel, wherein the guide element is configured to guide fluid flow output from the input channel outlet. The guide element may preferentially direct fluid flow towards an inner wall of the cold plate.

Claim 1:
A coolant fluid manifold (<NUM>, <NUM>) for coupling to a cold plate (<NUM>), wherein the manifold comprises:
an input channel (<NUM>) comprising an inlet (<NUM>) and an outlet (<NUM>), the inlet (<NUM>) configured to receive input coolant fluid;
wherein the input channel (<NUM>) comprises a guide element (<NUM>) that projects from a wall (<NUM>, <NUM>) of the input channel, wherein the guide element (<NUM>) is configured to guide fluid flow from the outlet (<NUM>)
the coolant fluid manifold being characterized in that
the guide element (<NUM>) partially occludes the outlet (<NUM>) and a height of the guide element (<NUM>) varies across a width of the guide element, such that the guide element (<NUM>) is shaped and positioned to at least partially direct fluid flow from the inlet (<NUM>) towards a center or a midpoint of the outlet (<NUM>).