PATENT DOCUMENT

Publication Number: US-7848105-B2
Application Number: US-69975610-A
Country: US
Kind Code: B2

Title: Apparatus for air cooling of an electronic device

Abstract:
An apparatus for air-cooling an electronic device is disclosed. A contoured panel channels a flow of air within the housing of an electronic device so as to channel the flow of air more directly over heat producing elements such as the microprocessor and peripheral cards. A sensor can also be employed to determine whether the panel is present and properly placed. If not, measures can be taken to reduce the heat generated by the heat producing elements. For example, a warning can be displayed, or the microprocessor can be instructed to enter sleep mode.

Claims:
1. A removable airflow director adapted to facilitate cooling within a computing device having an outer housing, one or more heat producing elements and one or more cooling fans, the removable airflow director comprising:
 a first contoured portion adapted to direct a first airflow from one of said one or more cooling fans in a first specific manner through a first thermal zone within the computing device; and 
 a second contoured portion adapted to direct a second airflow from one of said one or more cooling fans in a second specific manner through a second thermal zone within the computing device, 
 wherein said first and second thermal zones comprise separate and distinct thermal zones within said computing device. 
 
     
     
       2. The removable airflow director of  claim 1 , wherein cooling within said first and second thermal zones occurs at different rates due to differences in the first and second contoured portions of said removable airflow director. 
     
     
       3. The removable airflow director of  claim 1 , wherein said first thermal zone encompasses a processor. 
     
     
       4. The removable airflow director of  claim 1 , wherein said second thermal zone encompasses a peripheral card. 
     
     
       5. The removable airflow director of  claim 1 , further including:
 an associated sensor configured to determine whether said removable airflow director is properly positioned proximate to the computing device, wherein said sensor generates an error signal when said removable airflow director is not properly positioned proximate to the computing device. 
 
     
     
       6. A computing device, comprising:
 a heat producing element; 
 a fan; 
 a contoured member configured to direct airflow from the fan across the heat producing element; and 
 a detection system configured to generate an error signal that results in a corrective action when the contoured member is improperly positioned relative to the computing device, wherein an adverse thermal condition within the computing device results when said contoured member is improperly positioned relative to the computing device. 
 
     
     
       7. The computing device of  claim 6 , wherein said contoured member comprises a removable airflow director, said removable airflow director including
 a first contoured portion adapted to direct a first airflow from said fan in a first specific manner through a first thermal zone within the computing device, and 
 a second contoured portion adapted to direct a second airflow from said fan in a second specific manner through a second thermal zone within the computing device, 
 wherein said first and second thermal zones comprise separate and distinct thermal zones within said computing device. 
 
     
     
       8. The computing device of  claim 7 , wherein said heat producing element is a processor, and further including:
 a peripheral card, 
 wherein said first thermal zone encompasses said processor and wherein said second thermal zone encompasses said peripheral card. 
 
     
     
       9. The computing device of  claim 6 , wherein a proper positioning of said contoured member results in a more efficient cooling of said heat producing element. 
     
     
       10. The computing device of  claim 6 , wherein said detection system includes a proximity sensor or an optical sensor. 
     
     
       11. A method of cooling a computing device having a heat producing element, a cooling fan, an airflow director and a sensor, the method comprising:
 determining with said sensor whether said airflow director is properly positioned proximate to the computing device, wherein a proper positioning of said airflow director results in a more efficient cooling of said heat producing element and an improper positioning of said airflow director results in a less efficient cooling of said heat producing element; and 
 generating an error signal when said airflow director is not properly positioned proximate to the computing device. 
 
     
     
       12. The method of  claim 11 , wherein said airflow director includes a first contoured portion adapted to direct a first airflow from said cooling fan in a first specific manner through a first thermal zone within the computing device, and a second contoured portion adapted to direct a second airflow from said cooling fan in a second specific manner through a second thermal zone within the computing device, wherein said first and second thermal zones comprise separate and distinct thermal zones within said computing device. 
     
     
       13. The method of  claim 11 , wherein an adverse thermal condition within the computing device results when said airflow director is improperly positioned relative to the computing device. 
     
     
       14. The method of  claim 11 , wherein the generation of said error signal results in a corrective action. 
     
     
       15. The method of  claim 11 , wherein said sensor comprises a proximity sensor or an optical sensor. 
     
     
       16. A computer, comprising:
 a heat producing element; 
 a fan configured to generate an airflow; 
 a removable contoured member configured to direct at least a portion of said airflow across said heat producing element; and 
 a sensor configured to determine whether said contoured member is improperly positioned relative to the remainder of said computer. 
 
     
     
       17. The computer of  claim 16 , wherein said removable contoured member includes a first contoured portion adapted to direct a first airflow from said fan in a first specific manner through a first thermal zone within the computing device, and a second contoured portion adapted to direct a second airflow from said fan in a second specific manner through a second thermal zone within the computing device, wherein said first and second thermal zones comprise separate and distinct thermal zones within said computing device. 
     
     
       18. The computer of  claim 16 , wherein an adverse thermal condition within the computer results when said removable contoured member is improperly positioned relative to the remainder of said computer. 
     
     
       19. The computer of  claim 16 , wherein a proper positioning of said airflow director results in a more efficient cooling of said heat producing element and an improper positioning of said airflow director results in a less efficient cooling of said heat producing element. 
     
     
       20. The computer of  claim 16 , wherein said sensor comprises a proximity sensor or an optical sensor.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of commonly owned and co-pending U.S. patent application Ser. No. 12/277,879, entitled “APPARATUS FOR AIR COOLING OF AN ELECTRONIC DEVICE,” filed Nov. 25, 2008, which is a continuation of U.S. Pat. No. 7,466,547, entitled “APPARATUS FOR AIR COOLING OF AN ELECTRONIC DEVICE,” filed Apr. 30, 2007, which is a continuation of U.S. Pat. No. 7,248,476, entitled “APPARATUS FOR AIR COOLING OF AN ELECTRONIC DEVICE,” filed Feb. 17, 2006, which is a divisional of U.S. Pat. No. 7,035,102 entitled “APPARATUS FOR AIR COOLING OF AN ELECTRONIC DEVICE” filed Mar. 31, 2004, which in-turn claims the benefit of U.S. Provisional Application No. 60/535,279 entitled “QUICK RELEASE STRUCTURES FOR A COMPUTER,” filed Jan. 8, 2004, all of which are incorporated herein by reference in their entirety and for all purposes. 
    
    
     BRIEF DESCRIPTION OF THE INVENTION 
     This invention relates to electronic devices. More specifically, this invention relates to the air cooling of electronic devices. 
     BACKGROUND OF THE INVENTION 
     As electronic devices increase in processing power and speed, their processors generate more and more heat, thus exacerbating wear and tear on various components due to thermal cycling and otherwise compromising their performance. Such temperature-related problems only continue to grow as processor speeds continue their steady march upward. The cooling of these processors, and other heat producing elements, has therefore become an important issue affecting the performance of modern electronic devices such as computers. 
     To this end, methods have been applied in the past to reduce the operating temperatures of electronic devices. For example, various liquid cooling systems have been employed to cool processors with water or other liquids. However, liquid cooling systems are typically bulky, expensive, and upon leaking, risk severe damage to the electronic devices in which they are installed. Fans for air cooling are another common solution to the problem of excessive heat generation. Such fans are an inexpensive and relatively reliable solution, and do not suffer from some of the drawback of liquid cooling systems, such as the risk of leaks. Ongoing efforts thus exist to improve the effectiveness and cooling ability of air cooling systems. 
     SUMMARY OF THE INVENTION 
     Broadly speaking, the invention pertains to improving the air cooling of electronic devices. A contoured panel is employed to channel the flow of air from a fan more directly onto an electronic device&#39;s sources of heat. In this manner, the heat dissipation ability of existing air cooling devices is increased without increasing their fan speeds, or any other parameters which may have potentially detrimental effects such as increased power consumption, noise generation, or the like. 
     The invention can be implemented in numerous ways, including as a method, system, device, apparatus, or computer readable medium. Several embodiments of the invention are discussed below. 
     As a contoured panel for directing a flow of air within an electronic device, one embodiment of the invention comprises a panel configured to be removably placed proximate to an electronic device, the electronic device having a heat producing element and a fan, the panel further having a contoured portion configured to be placed proximate to the fan so as to direct a flow of air from the fan across the heat producing element, the flow of air facilitating the cooling of the heat producing element. 
     As an air-cooled electronic device, one embodiment of the invention comprises a housing and a microprocessor and a fan within the housing. The panel is configured to be removably placed proximate to the housing. The panel also has a contoured portion configured to direct a flow of air from the fan across the microprocessor so as to cool the microprocessor. 
     As an electronic device housing, one embodiment of the invention comprises a first portion configured to support a microprocessor, and a second portion configured to support a first fan. A removable, contoured portion configured to direct air from the first fan across the microprocessor, so as to cool the microprocessor. 
     Other aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a better understanding of the invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings, in which: 
         FIG. 1  illustrates a contoured panel constructed in accordance with an embodiment of the invention. 
         FIG. 2  illustrates a computer system with a removable contoured panel constructed in accordance with an embodiment of the invention. 
         FIG. 3  illustrates a cross section of a computer system with discrete thermal zones constructed in accordance with an embodiment of the invention. 
         FIG. 4 . illustrates a top view of a thermal zone and contoured panel constructed in accordance with an embodiment of the invention, in which peripheral cards are more effectively cooled. 
         FIG. 5 . illustrates a top view of a thermal zone and contoured panel constructed in accordance with an embodiment of the invention, in which a microprocessor is more effectively cooled. 
         FIG. 6  illustrates a block diagram of a sensor and feedback system for determining whether a contoured panel is correctly positioned in accordance with an embodiment of the invention. 
     
    
    
     Like reference numerals refer to corresponding parts throughout the drawings. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Fans are commonly used within electronic devices to direct a flow of air over microprocessors and other heat producing elements. In one embodiment, the invention discloses a contoured panel that channels this flow of air more directly over these elements. In this manner, the same fan, run at the same speed, more effectively cools microprocessors and other heat producing elements than if the panel were not present. 
     In some embodiments, it is of additional benefit to employ a sensor to determine whether the contoured panel is present and properly placed. If it is not, measures can then be taken to reduce the heat generated by the heat producing elements. For example, a warning can be displayed, or the microprocessor can be instructed to enter sleep mode. 
       FIG. 1  illustrates isometric front and back views of a contoured panel constructed in accordance with an embodiment of the invention. The contoured panel  10  has a first contoured portion  20  and a second contoured portion  30 , as well as tabs  40 . The panel  10  is also configured with a handle  50  so as to be removable from a computer or other electronic device. In operation, the contoured panel  10  is placed proximate to fans within an electronic device, so that the contoured portions  20 ,  30  channel air from the fans more directly onto heat producing elements such as microprocessors. The handle  50  facilitates placement of the panel  10 , and the panel  10  can be held in place with the aid of the tabs  40 . The tabs  40  can also be employed to determine whether the panel  10  is in place, or missing/ajar. Sensors such as proximity sensors or optical sensors can be employed to determine the presence of the tabs  40 . For example, the tabs  40  can be metallized so as to trigger proximity sensors or reflect light from an optical sensor, which then alerts the system to the presence or absence of the panel  10 . If the panel  10  is absent, the electronic device can be designed to reduce its processing speed or otherwise conserve power so as to reduce its temperature. 
       FIG. 2  illustrates a computer system  110  employing such a contoured panel  10 . Shown is an exploded view illustrating the placement of various components within the housing  100  of the computer system  110 . The computer system  110  contains a number of known components such as fans  120  for cooling, a microprocessor  130  (not seen from this perspective), cooling fins  140  mounted on and configured to cool the microprocessor  130 , and peripheral cards  150 . 
     Commonly, the abovementioned components are placed in the housing  100  according to known techniques, and the panel  10  and door  160  are then affixed to the housing  100 . A shelf  170  within the housing  100  is positioned so as to divide the housing  100  into, in this embodiment, at least two distinct thermal zones. The peripheral card  150  is placed within the first thermal zone  180 , where it is cooled by the leftmost fan  120 A. Similarly, the microprocessor  130  and cooling fins  140  are placed within the second thermal zone  190  where they are cooled by the rightmost fan  120 B. Rear fans  120 C, shown immediately behind the cooling fans  140 , are not necessary to the invention but often aid in cooling by further drawing air across various components within the two thermal zones  180 ,  190 . The fans  120 A-C are shown as individual components, but can be configured as removable assemblies that can be placed at various points within the housing  100  so as to alter the location and properties of various thermal zones. For instance, it may sometimes be desirable to place certain fans closer to the microprocessor  130 , or insert multiple fans into the same thermal zone, during times of heavy operation. One of skill will realize that the invention encompasses any number and type of fans, placed in any configuration within the various thermal zones. 
       FIG. 3  illustrates a cross sectional view of the computer system  110  of  FIG. 2 , more clearly highlighting the two thermal zones  180 ,  190 , and the air flow through each. Recall that the thermal zones  180 ,  190  are divided according to the shelf  170 , which is placed so as to create separate thermal zones for the microprocessor  130  and peripheral cards  150 , as the peripheral cards  150  often generate a different amount of heat than the microprocessor  130 , and often can be cooled at different rates. It should be noted, though, that the shelf  170  can be placed at any location within the housing  100  so as to create thermal zones encompassing any combination or permutation of the microprocessor  130 , peripheral cards  150 , or other heat producing elements or components. For example, additional shelves can be placed above or below the thermal zones  180 ,  190  so as to further isolate various heat producing elements into separate thermal zones. 
     In the first thermal zone  180 , a fan  120  directs a flow of air (shown by the arrows) past the peripheral cards  150 . Often, microprocessors  130  consume more power and thus generate more heat than peripheral cards  150 . Consequently, in the second thermal zone  190 , two fans  120  direct a flow of air through the cooling fins  140  and over the microprocessor  130 . Here, a dual microprocessor  130  configuration is shown containing two processors. Two fans are employed to reflect the extra cooling often required by this configuration. However, any number of cooling fans  120  can be used in any thermal zone. In each thermal zone, air enters and exits through known openings in the front panel  200  and rear panel  210 , respectively. 
     In many computers, fans are already used to cool components such as the microprocessor  130 . However, dividing the interior of the housing  100  into separate thermal zones  180 ,  190  allows for separate components to be cooled at different rates and/or maintained at different temperatures. The maintenance of separate thermal zones is further aided by the contoured panel  10 , which is configured with contoured portions  20 ,  30  that can be specifically shaped for, and placed in, each thermal zone  180 ,  190 .  FIG. 4  illustrates a cutaway top view of the first thermal zone  180  with the panel  10  placed so as to direct the flow of air within. As can be seen, the fan  120  directs a flow of air into the housing  100  and through the first thermal zone  180 . In many housings not containing a contoured portion  20 , some of the air passes over the peripheral cards  150  (which contain heat producing elements such as dedicated processors that are simply another form of microprocessor  130 ), while some does not, often simply passing through the remaining space  220  where it does not help to cool the peripheral cards  150 . However, the contoured portion  20  is designed to protrude into this remaining space  220 , thus channeling the flow of air more directly over the peripheral card  150 . For any constant fan  120  speed, one of skill will observe that air will flow over the peripheral card  150  faster in the presence of the contoured portion  120  than in its absence, as the contoured portion  20  reduces the area through which air may flow. Consequently, the ability of fans  120  to cool heat producing elements such as the peripheral card  150  is increased. As above, air may exit the housing  100  through any opening in the rear panel  210 , and an additional fan  120  may be placed near the rear panel  210  so as to direct more air out of the housing and establish greater airflow through the first thermal zone  180 . 
     Similar to  FIG. 4 ,  FIG. 5  illustrates a cutaway top view of the second thermal zone  190  with the panel  10  placed so that the second contoured portion  30  more effectively directs airflow across the microprocessor  130  and cooling fins  140 . Here, the fan  120  directs a flow of air into the housing  100 . The contoured portion  30  protrudes into the second thermal zone  190  so as to direct more of the airflow across the microprocessor  130  and through the cooling fins  140 , thus better cooling these components. 
     The division of the housing  100  into multiple thermal zones, with contoured portions tailored to each, allows different components to be cooled at different rates if necessary. For example, it is possible for electronic devices to contain multiple microprocessors  130 . In cases where such microprocessors  130  are all placed within a single thermal zone, it is often the case that that thermal zone generates much more heat than the others. The invention thus contemplates a contoured portion tailored to the demands of that thermal zone, configured so as to direct airflow over each microprocessor  130 . In this regard, it should be observed that the invention includes panels having any number of contoured portions, each specifically tailored to direct airflow within any number of thermal zones that each having different cooling needs. 
     It will be apparent to one of skill that the specific geometry and placement of the contoured portions  20 ,  30  acts to more effectively direct air across components such as the peripheral card  150  and microprocessor  130 . For example, the first contoured portion  20  is designed with a length that is as long or longer than many peripheral cards  150  so as to more effectively cool the entire length of the cards  150 . However, it should be understood that the invention is not limited to the specific geometries and placements shown. For example, the invention contemplates contoured portions  20 ,  30  whose geometries are designed according to known principles for optimizing the cooling of heat producing elements within the space constraints of the housing  100 . The invention simply discloses contoured portions of any specific geometry that acts to more directly channel a flow of air across a component of an electronic device. Space constraints, the location of other components, and the like may require that the contoured portions  20 ,  30  look different than shown, and those of skill will realize that such alternate configurations remain within the scope of the invention. 
     A further advantage of the invention can be achieved if the panel  10  is made of a transparent material, such as many commonly-used plastics. Once installed in the housing  100 , such a transparent panel  10  would allow for visual inspection of various components of the computer system  110  without disturbing the flow of air through the various thermal zones, or alerting the system  110  to the absence of the panel  10 . In this manner, visual inspections of the computer system  110  can be performed while still maintaining the added cooling of the panel  10 . 
     Attention now turns to attachment of the panel  10  to the housing  100 . It is beneficial to design the panel  10  to be easily removable so that the various components can be more effectively cooled without impeding access to the interior of the housing  100 . It is also beneficial to determine whether the panel  10  is present and properly positioned, so as to determine the degree to which components such as the microprocessor  130  are cooled. Specifically, when the panel  10  is present, the microprocessor  130  may be operated at higher speeds, thus generating more heat, than if the panel  10  were absent. 
     To that end,  FIG. 6  illustrates a block diagram of a sensor and feedback system for determining whether a contoured panel is correctly positioned. A sensor  240  is located on or in the housing  110 , and placed in electrical communication with a processor  230 . The processor  230  is, in turn, in electronic communication with the microprocessor  130  and fan  120 . The sensor  240  can be configured as a known optical sensor that emits a beam of light and receives a reflected signal back. In this configuration, the tabs  40  of the panel  10  are metallized reflective tabs capable of reflecting light (or another signal) back to the sensor  240  when they are properly positioned within the housing  110 . 
     In operation, the panel  10  is designed so that its tabs  40  can be fitted within corresponding slots in the housing  100 . The sensor  240  is commonly placed within the housing in proximity to these slots, so that when the panel  10  is properly fitted on the housing  100 , the reflective portion  250  of its tabs  40  reflects light back to the sensor  240 . The sensor  240  indicates the presence of a reflected light signal back to the processor  230 . If the panel  10  is properly placed so as to aid in the cooling of components, normal operation of the microprocessor  130 , fan  120 , and other components ensues. However, the processor  230  can be programmed to act in a number of ways upon receiving an indication from the sensor  240  that the panel  10  is not properly placed. For instance, the processor  230  can be programmed to instruct the microprocessor  130  to issue a warning message to users indicating that the panel is missing and/or improperly placed, to enter sleep mode, to reduce its functionality or processing speed, or even to shut down. It can also direct the fan  120  to speed up. Many other variations exist, such as directing the microprocessor  130  to enter sleep mode after the panel  10  has been missing for an amount of time. One of skill will realize that these and other variations fall within the scope of the present invention, which simply discloses the sensing of the panel  10  and resulting control of the electronic device&#39;s functionality. 
     One of skill will also realize that the invention is not limited to the configuration of  FIG. 6 . Rather, other configurations are contemplated by the invention. For example, the microprocessor  130  can receive feedback directly from the sensor  240 , without need for a dedicated processor  230  (in certain embodiments it is, of course, preferable to maintain a dedicated processor  230  to, for example, reduce the demands placed on the microprocessor  130 ). Such a microprocessor  130  configuration can also control the fan  120  directly. Likewise, the sensor  240  need not be an optical sensor, but rather another form of known proximity sensor such as a pressure sensor or capacitative proximity sensor. Finally, while the components and devices shown in  FIG. 6  can often be placed within the housing  100 , the invention does not require such an arrangement. Rather, components such as the sensor  240  may be located outside, or even remote from, the housing  100 . 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the invention. In other instances, well-known circuits and devices are shown in block diagram form in order to avoid unnecessary distraction from the underlying invention. Thus, the foregoing descriptions of specific embodiments of the present invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obviously many modifications and variations are possible in view of the above teachings. For example, the invention contemplates panel contours of any shape suitable for cooling components of any geometry, within any number of thermal zones. The invention also contemplates determining the presence of panels according to signals from any known sensor, optical or otherwise. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents.

Metadata:
Filing Date: 20100203
Publication Date: 20101207
Grant Date: 20101207
Priority Date: 20040108
Inventors: HOLMES STEVEN
HEIRICH DOUGLAS L.
Assignee: APPLE INC
CPC Classifications: [{"code": "G06F1/3203", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/206", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/3203", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y02D10/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/20", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/20", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y02D10/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/206", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 34743063