US20110100603A1 - Microchannel cooling device for small heat sources - Google Patents

Microchannel cooling device for small heat sources Download PDF

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Publication number
US20110100603A1
US20110100603A1 US12/940,295 US94029510A US2011100603A1 US 20110100603 A1 US20110100603 A1 US 20110100603A1 US 94029510 A US94029510 A US 94029510A US 2011100603 A1 US2011100603 A1 US 2011100603A1
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Prior art keywords
passages
fluid
heat
heat transfer
sheets
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Abandoned
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US12/940,295
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Geoffrey O. Campbell
Jack M. Fryer
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Science Research Laboratory Inc
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Science Research Laboratory Inc
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Priority claimed from US11/477,344 external-priority patent/US7836940B2/en
Application filed by Science Research Laboratory Inc filed Critical Science Research Laboratory Inc
Priority to US12/940,295 priority Critical patent/US20110100603A1/en
Assigned to SCIENCE RESEARCH LABORATORY, INC. reassignment SCIENCE RESEARCH LABORATORY, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MICROVECTION, INC.
Publication of US20110100603A1 publication Critical patent/US20110100603A1/en
Abandoned legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L23/00—Details of semiconductor or other solid state devices
    • H01L23/34—Arrangements for cooling, heating, ventilating or temperature compensation ; Temperature sensing arrangements
    • H01L23/46—Arrangements for cooling, heating, ventilating or temperature compensation ; Temperature sensing arrangements involving the transfer of heat by flowing fluids
    • H01L23/473—Arrangements for cooling, heating, ventilating or temperature compensation ; Temperature sensing arrangements involving the transfer of heat by flowing fluids by flowing liquids
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2250/00—Arrangements for modifying the flow of the heat exchange media, e.g. flow guiding means; Particular flow patterns
    • F28F2250/04—Communication passages between channels
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F2260/00—Heat exchangers or heat exchange elements having special size, e.g. microstructures
    • F28F2260/02—Heat exchangers or heat exchange elements having special size, e.g. microstructures having microchannels
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
    • F28F3/02—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
    • F28F3/12—Elements constructed in the shape of a hollow panel, e.g. with channels
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
    • H01L2924/0001—Technical content checked by a classifier
    • H01L2924/0002—Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00

Definitions

  • Various semiconductor devices such as laser diodes, power transistors or central processing unit chips, may dissipate large amounts of waste power over very small areas. This may produce a very high heat flux that can be removed to extend the service life and proper operation of such components. Because these components have relatively low operating temperatures, successful heat removal may necessitate minimal heat flow resistance between the heat source and the heat sink.
  • Some current heat removal techniques for such applications may involve microchannel cooling of individual semiconductor devices. For at least some of these cooling configurations, relatively large microchannel passages may be used. These passages may require high coolant flow rates to provide low thermal resistances, and may be limited in their thermal performance even at such flow rates.
  • an apparatus for transferring heat with a target may include a body, and the body may define a surface, an inlet port, a plurality of inlet manifold passages, a plurality of heat transfer passages, and a plurality of outlet manifold passages, and an outlet port.
  • the surface may be for coupling the target with the body, where heat transfers between the target and the body when the target is coupled with the body.
  • the inlet port may be configured to receive a fluid and direct the fluid into a plurality of inlet manifold passages.
  • the plurality of inlet manifold passages may be configured to receive the fluid from the inlet port and direct the fluid to a plurality of heat transfer passages.
  • the plurality of heat transfer passages may be configured to receive the fluid from the plurality of inlet manifold passages, direct all of the fluid from the inlet manifold passages in one or more directions substantially parallel to the surface and substantially perpendicular to the plurality of input manifold passages, and direct the fluid to a plurality of outlet manifold passages, where heat transfers between the body and the fluid when fluid flows through the plurality of heat transfer passages.
  • a plurality of fins may be located on at least one surface of at least one of the plurality of heat transfer passages.
  • the plurality of outlet manifold passages may be configured to receive the fluid from the plurality of heat transfer passages, and direct the fluid to an outlet port.
  • the outlet port may be configured to receive the fluid from the plurality of outlet manifold passages and output the fluid.
  • an apparatus for transferring heat with a target may include a plurality of sheets, where the plurality of sheets are coupled such that a body is formed by the coupled plurality of sheets.
  • the body may define a surface, an inlet port, a plurality of inlet manifold passages, a plurality of heat transfer passages, a plurality of outlet manifold passages, and an outlet port.
  • the surface may couple the target with the body, and heat may transfers between the target and the body when the target is coupled with the body.
  • the inlet port may be configured to receive a fluid and direct the fluid into a plurality of inlet manifold passages.
  • the plurality of inlet manifold passages may be configured to receive the fluid from the inlet port and direct the fluid to a plurality of heat transfer passages.
  • the plurality of heat transfer passages may be configured to receive the fluid from the plurality of inlet manifold passages, direct all of the fluid received from the inlet manifold passages in one or more directions substantially parallel to the surface and substantially perpendicular to the plurality of input manifold passages, and direct the fluid to a plurality of outlet manifold passages, where heat may transfer between the body and the fluid when fluid flows through the plurality of heat transfer passages.
  • the plurality of outlet manifold passages may be configured to receive the fluid from the plurality of heat transfer passages and direct the fluid to an outlet port.
  • the body may also define a plurality of fins protruding into at least one of the plurality of input manifold passages or the plurality of output manifold passages.
  • the outlet port may be configured to receive the fluid from the plurality of outlet manifold passages and output the fluid.
  • an apparatus for transferring heat with a target may include an upper sheet, a plurality of interior sheets, and a lower sheet.
  • the upper sheet may define a surface for coupling with a target, where heat may transfer between the target and the upper sheet when the target is coupled with the surface.
  • At least one of the upper sheet, the plurality of interior sheets, and the lower sheet may define an inlet port for receiving a fluid.
  • the plurality of interior sheets may be coupled with the upper sheet, where heat may transfer between the upper sheet and the plurality of interior sheets.
  • the plurality of interior sheets may define a plurality of inlet manifold passages for receiving the fluid from the inlet port, a plurality of heat transfer passages for receiving the fluid from the plurality of inlet manifold passages, where heat transfers between the fluid and the plurality of interior sheets, and where the plurality of heat transfer passages may be configured to direct all of the fluid received from the inlet manifold passages in one or more directions substantially parallel to the surface, where one or more of the heat transfer passages are curved, and a plurality of outlet manifold passages for receiving the fluid from the plurality of heat transfer passages.
  • the lower sheet be coupled with at least one of the plurality of interior sheets.
  • the lower sheet may also define an outlet port configured to receive the fluid from the plurality of outlet manifold passages and output the fluid.
  • an apparatus for transferring heat with a target may include an upper sheet, a plurality of interior sheets, and a lower sheet.
  • the upper sheet may define a surface for coupling with a target, where heat may transfer between the target and the upper sheet when the target is coupled with the surface.
  • At least one of the upper sheet, the plurality of interior sheets, and the lower sheet may define an inlet port for receiving a fluid.
  • the plurality of interior sheets may be coupled with the upper sheet, where heat may transfer between the upper sheet and the plurality of interior sheets.
  • the plurality of interior sheets may define a plurality of inlet manifold passages for receiving the fluid from the inlet port, a plurality of heat transfer passages for receiving the fluid from the plurality of inlet manifold passages, where heat transfers between the fluid and the plurality of interior sheets, and where the plurality of heat transfer passages may be configured to direct all of the fluid received from the inlet manifold passages in one or more directions substantially parallel to the surface, where one or more of the heat transfer passages are about a fin strip array, and a plurality of outlet manifold passages for receiving the fluid from the plurality of heat transfer passages.
  • the lower sheet be coupled with at least one of the plurality of interior sheets.
  • the lower sheet may also define an outlet port configured to receive the fluid from the plurality of outlet manifold passages and output the fluid.
  • an apparatus for transferring heat with a target may include an upper sheet, a plurality of interior sheets, and a lower sheet.
  • the upper sheet may define a surface for coupling with a target, where heat may transfer between the target and the upper sheet when the target is coupled with the surface.
  • At least one of the upper sheet, the plurality of interior sheets, and the lower sheet may define an inlet port for receiving a fluid.
  • the plurality of interior sheets may be coupled with the upper sheet, where heat may transfer between the upper sheet and the plurality of interior sheets.
  • the plurality of interior sheets may define a plurality of inlet manifold passages for receiving the fluid from the inlet port, a plurality of heat transfer passages for receiving the fluid from the plurality of inlet manifold passages, where heat transfers between the fluid and the plurality of interior sheets, and where the plurality of heat transfer passages may be configured to direct all of the fluid received from the inlet manifold passages in one or more directions substantially parallel to the surface, where at least one of the plurality of inlet manifold passages or plurality of outlet manifold passages are tapered, and a plurality of outlet manifold passages for receiving the fluid from the plurality of heat transfer passages.
  • the lower sheet be coupled with at least one of the plurality of interior sheets.
  • the lower sheet may also define an outlet port configured to receive the fluid from the plurality of outlet manifold passages and output the fluid.
  • FIG. 1 is an exploded isometric drawing of the components of an apparatus for transferring heat with a target
  • FIG. 2 is an isometric drawing of an interior sheet of the apparatus shown in FIG. 1 ;
  • FIG. 3 is an isometric drawing of a portion of the interior sheet shown in FIG. 2 ;
  • FIG. 4 is an isometric drawing of the same portion of the interior sheet shown in FIG. 2 , except also showing fluid flow patterns through the sheet;
  • FIG. 5 is a plan view of an upper sheet which may form at least a portion of an apparatus for transferring heat with a target;
  • FIG. 6 is a plan view of an interior sheet which may form at least a portion of an apparatus for transferring heat with a target;
  • FIG. 7 is a plan view of another interior sheet which may form at least a portion of an apparatus for transferring heat with a target;
  • FIG. 8 is a plan view of a lower sheet which may form at least a portion of an apparatus for transferring heat with a target;
  • FIG. 9 is an isometric drawing of a portion of a heat transfer passage having heat transfer fins disposed therein;
  • FIG. 10 is an isometric drawing of a portion of an alternative interior sheet having fins disposed in the inlet and outlet manifold passages;
  • FIGS. 11A-11C are plan views of portions of alternative interior sheets having curved heat transfer passages
  • FIGS. 12A-12C shows alternative embodiments of the invention which provide fin strip array configurations
  • FIG. 13A and FIG. 13B show plan views of alternative interior sheets having inlet and outlet manifold passages with one-dimensional tapers.
  • FIG. 14A and FIG. 14B show alternative embodiments of the invention which provide for inlet and outlet manifold passages with two-dimensional tapers.
  • an apparatus for transferring heat with a target may include a body, and the body may define a surface, an inlet port, a plurality of inlet manifold passages; a plurality of heat transfer passages, a plurality of outlet manifold passages, and an output port.
  • the target may, merely by way of example, be a heat source.
  • the surface may couple the target with the body, and heat may transfer between the target and the body when the target is coupled with the body.
  • the inlet port may be configured to receive a fluid and direct the fluid into a plurality of inlet manifold passages.
  • the plurality of inlet manifold passages may be configured to receive the fluid from the inlet port and direct the fluid to a plurality of heat transfer passages.
  • the plurality of inlet manifold passages may be configured to direct the fluid in a direction substantially parallel to the surface.
  • the plurality of heat transfer passages may be configured to: receive the fluid from the plurality of inlet manifold passages; direct the fluid in a direction substantially parallel to the surface and substantially perpendicular to the plurality of input manifold passages; and direct the fluid to a plurality of outlet manifold passages, where heat may transfer between the body and the fluid when fluid flows through the plurality of heat transfer passages.
  • the plurality of outlet manifold passages may be configured to receive the fluid from the plurality of heat transfer passages and direct the fluid to an outlet port.
  • the outlet port may be configured to receive the fluid from the plurality of outlet manifold passages and output the fluid.
  • the plurality of outlet manifold passages may be configured to direct the fluid in a direction substantially parallel to the surface.
  • an apparatus for transferring heat with a target may include a plurality of sheets, where the plurality of sheets are coupled such that a body is formed by the coupled plurality of sheets.
  • the body may define a surface, one or more inlet ports, a plurality of inlet manifold passages, a plurality of heat transfer passages, a plurality of outlet manifold passages, and one or more outlet ports.
  • the plurality of sheets may include an upper sheet, a plurality of interior sheets, and a lower sheet.
  • the upper sheet or the lower sheet may define the surface.
  • At least one of the upper sheet, the plurality of interior sheets, and the lower sheet may define the inlet port.
  • the plurality of interior sheets may define the plurality of inlet manifold passages, the plurality of heat transfer passages, and the plurality of outlet manifold passages.
  • at least one of the upper sheet, the plurality of interior sheets, and the lower sheet may define the outlet port.
  • all of the sheets may define the inlet port as well as the outlet port. In other embodiments, only a portion of the sheets may define either port.
  • the upper sheet and some of the plurality of interior sheets in proximity to the upper sheet may define the inlet port.
  • the outlet port may be defined all of the sheets besides the lower sheet or possibly by the lower sheet and some of the plurality of interior sheets in proximity to the lower sheet.
  • Each of the plurality of sheets may be made from a variety of thermally conductive, low-expansion materials, including, but not limited to, molybdenum, tungsten, nickel, aluminum, stainless steel, silicon, beryllia, aluminum nitride, silicon carbide, chemical vapor deposition diamond, copper-diamond, copper-graphite, copper tungsten, and copper-molybdenum.
  • each of the plurality of sheets may be made from copper or a copper alloy.
  • each of the plurality of sheets may be made from a different material.
  • Each sheet may be a certain shape. Some sheets may have the same shape, while some sheets may have unique shapes. The shape of any one sheet may be formed by photochemical etching or other type of etching. Other manufacturing methods may also be employed, including, but not limited to, laser machining and micro-machining methods.
  • the plurality of sheets may be coupled using various methods, including, but not limited to, soldering, brazing, and diffusion bonding.
  • the plurality of sheets may be coated with a diffusion aid.
  • the diffusion aid may be nickel or other suitable substance.
  • the sheets may be coupled so that they are “stacked,” and corresponding features of each sheet may combine to form features of the body of the apparatus.
  • the upper and lower sheet may be characterized by a thickness, and the upper and lower sheet may be between about 50 microns and about 10,000 microns thick. In some embodiments, the upper and lower sheet may be the same thickness, while in other embodiments, they may be of different thickness. In an exemplary embodiment, both the upper and lower sheet may be about 250 microns thick.
  • each of the plurality of interior sheets may be characterized by a thickness, and each of the plurality of interior sheets may be between about 12.5 microns and about 500 microns thick. In an exemplary embodiment, each of the plurality of interior sheets is about 50 microns thick.
  • the surface may couple the target with the body, and heat may transfer between the target and the body when the target is coupled with the body.
  • the inlet port may be configured to receive a fluid and direct the fluid into a plurality of inlet manifold passages.
  • the plurality of inlet manifold passages may be configured to receive the fluid from the inlet port and direct the fluid to a plurality of heat transfer passages.
  • the fluid may be any heat transfer fluid known in the art, including, but not limited to, distilled water, deionized water, ethylene glycol, diethylene glycol, propylene glycol, acetone, ammonia, dielectric fluids such as the FluorinertTM series, fluids with large operating temperature ranges such as the DowthermTM and CoolanolTM series, and brines and aqueous mixtures.
  • the inlet manifold passages may be characterized by a width, and each of plurality of inlet manifold passages may be in between about 100 microns and about 2000 microns wide. In some embodiments, each of the plurality of inlet manifold passages may be about 200 microns wide.
  • the plurality of heat transfer passages may be configured to receive the fluid from the plurality of inlet manifold passages; direct the fluid in a direction substantially parallel to the surface and substantially perpendicular to the plurality of input manifold passages; and direct the fluid to a plurality of outlet manifold passages, where heat may transfer between the body and the fluid when fluid flows through the plurality of heat transfer passages.
  • Each of the plurality of heat transfer passages may have a height in the range of about 10 microns to about 250 microns, and a width in the range of about 50 microns to about 1250 microns.
  • the heat transfer passages may be microchannels. Microchannels may be any passage with a hydraulic diameter of about 500 microns or less.
  • the dimension may define one or more heat transfer passages between each inlet manifold passage and outlet manifold passage.
  • the interior sheets coupled closer to the upper sheet may define more heat transfer passages than interior sheets coupled closer to the lower sheet define.
  • all of the interior sheets may define the same number of heat transfer passages.
  • the first embodiment may define: three heat transfer passages between each inlet manifold passage and outlet manifold passage in the five sheets closest to the surface; two heat transfer passages between each inlet manifold passage and outlet manifold passage in the next five sheets; and one heat transfer passage between each inlet manifold passage and outlet manifold passage in the five sheets furthest from the surface.
  • every interior sheet may define the same number of heat transfer passages between each inlet manifold passage and outlet manifold passage.
  • each of the sheets may be characterized by a thickness and each of the plurality of heat transfer passages may be characterized by a height.
  • the height of each of the plurality of heat transfer passages may be less than the thickness of at least one of the plurality of sheets. In some embodiments, the height of each of the plurality of heat transfer passages may be substantially half of the thickness of at least one of the plurality of sheets.
  • the plurality of outlet manifold passages may be configured to receive the fluid from the plurality of heat transfer passages and direct the fluid to an outlet port.
  • the outlet port may be configured to receive the fluid from the plurality of outlet manifold passages and output the fluid.
  • the outlet manifold passages may be characterized by a width, and each of plurality of outlet manifold passages may be in between about 100 microns and about 2000 microns wide. In some embodiments, each of the plurality of outlet manifold passages may be about 200 microns wide.
  • the apparatus may also include the target.
  • the target may, merely by way of example, be a laser diode, a power transistor, or a central processor unit chip. If the target is a laser diode, the laser diode may have an average heat flux of about 1000 Watts per square centimeter and a 1 millimeter by 10 millimeter footprint.
  • an apparatus for transferring heat with a target may include an upper sheet, a plurality of interior sheets, and a lower sheet.
  • the upper sheet may define a surface for coupling with a target, where heat may transfer between the target and the upper sheet when the target is coupled with the surface.
  • At least one of the upper sheet, the plurality of interior sheets, and the lower sheet may define at least one inlet port for receiving a fluid.
  • the plurality of interior sheets may be coupled with the upper sheet, where heat may transfer between the upper sheet and the plurality of interior sheets.
  • the plurality of interior sheets may define a plurality of inlet manifold passages for receiving the fluid from the inlet port; a plurality of heat transfer passages for receiving the fluid from the plurality of inlet manifold passages, where heat transfers between the fluid and the plurality of interior sheets, and where the plurality of heat transfer passages may be configured to direct the fluid in a direction substantially parallel to the surface; and a plurality of outlet manifold passages for receiving the fluid from the plurality of heat transfer passages.
  • the heat transfer passages may be any shape between the plurality of inlet manifold passages and the plurality of outlet manifold passages.
  • different heat transfer passages within the same body may be different shapes.
  • the heat transfer passages may be curved, serpentine, or tapered. Other two dimensional patterns are also possible.
  • the lower sheet be coupled with at least one of the plurality of interior sheets.
  • the lower sheet may also define at least one outlet port configured to receive the fluid from the plurality of outlet manifold passages and output the fluid.
  • FIG. 1 an exploded isometric drawing of the components of an apparatus of the invention for transferring heat with a target is shown.
  • the components of a body 100 in this embodiment include an upper sheet 110 , an first interior sheet 120 having three heat transfer passages 180 A between each inlet manifold passage 160 and outlet manifold passage 170 , a second interior sheet 130 having two heat transfer passages 180 B between each inlet manifold passage 160 and outlet manifold passage 170 , a third interior sheet 140 having one heat transfer passage 180 C between each inlet manifold passage 160 and outlet manifold passage 170 , and a lower sheet 150 .
  • the sheets may be coupled together to form body 100 .
  • a portion of the sheets which form an inlet port and an outlet port is not shown in FIG. 1 , but will be shown in greater detail in FIG. 5 , FIG. 6 , FIG. 7 , and FIG. 8 .
  • more or less configurations of interior sheets may be used, with each configuration having different number of heat transfer passages between each inlet manifold passage 160 and outlet manifold passage 170 .
  • the efficiency of the apparatus in transferring heat with a target may be adjusted by varying fluid flow rates, changing the size of apparatus passages and features, and the number of passages and features.
  • the top of upper sheet 110 may define a surface 111 for coupling a target with body 100 .
  • the target may be bonded to surface 111 with another substance, for example, a thermally conductive paste.
  • Interior sheets 120 , 130 , 140 may form multiple inlet manifold passages 160 , and outlet manifold passages 170 . Only inlet manifold passages 160 A, 160 B, 160 C and outlet manifold passages 170 A, 170 B are specifically labeled in FIG. 1 , but the pattern of alternating inlet manifold passages 170 and outlet manifold passages 180 continues down the length of each interior sheets 120 , 130 , 140 .
  • FIG. 3 shows a closer view of a portion of first interior sheet 120 shown in FIG. 1 and FIG. 2 .
  • the width of the inlet manifold passages 160 and outlet manifold passages 170 may be about the same width as each one of the three heat transfer passages 180 A.
  • the interior walls 310 may be a different width. In other embodiments, the dimensions of the various features may be different as described above.
  • the depth of heat transfer passages 180 in this embodiment may be about half the thickness of interior sheet 120 . In other embodiments, the depth of heat transfer passages 180 may be more or less than the thickness of interior sheet 120 .
  • FIG. 4 shows an isometric drawing of the same portion of first interior sheet 120 shown in FIG. 3 , except also showing fluid flow patterns 410 , 420 through the sheet.
  • FIG. 6 shows a plan view of an upper interior sheet 600 which may form at least a portion of the apparatus for transferring heat with a target.
  • a plurality of upper interior sheets may be coupled with upper sheet 500 in one embodiment to form a continuous inlet port 510 , and a body of an apparatus. Fluid may flow from inlet port 510 to inlet manifold passages 160 , be directed through heat transfer passages 180 , and be received by outlet manifold passages 170 .
  • Upper interior sheet 600 may also define a portion of a continuous outlet port 520 .
  • FIG. 7 shows a plan view of a lower interior sheet which may form at least a portion of the apparatus for transferring heat with a target.
  • a plurality of lower interior sheets 700 may be coupled with other sheets to form a continuous outlet port 520 , and the body of the apparatus. Fluid may flow from inlet manifold passages 160 , be directed through heat transfer passages 180 , and be received by outlet manifold passages 170 . Fluid may then flow from outlet manifold passages 170 to outlet port 520 .
  • Lower interior sheet 700 may also define a portion of a continuous inlet port 510 .
  • FIG. 13A and FIG. 13B show another alternative interior sheets 120 F, 120 G.
  • Each of sheet 120 F and 120 G have tapered inlet manifold passages 160 and outlet manifold passages 170 .
  • the taper angle may be constant as shown in interior sheet 120 F, or may be non-constant, and possibly curved as shown in interior sheet 120 G. In other embodiments, non-constant taper linear angles may be used in each inlet manifold passage 160 and/or outlet manifold passage 170 . Merely by way of example, the angle of the taper may increase or decrease deeper into the inlet manifold passage 160 and/or outlet manifold passage.

Abstract

According to the invention, an apparatus for transferring heat with a target is disclosed. The apparatus may include a body which defines a surface, inlet and outlet ports, inlet and outlet manifold passages, and heat transfer passages. The surface may couple the target with the body. The inlet port may be configured to receive and direct a fluid into inlet manifold passages. The outlet port may be configured to receive and output the fluid. The inlet and outlet manifold passages may be configured to receive and direct the fluid to and from the heat transfer passages. The heat transfer passages may be configured to receive and direct all of the fluid from the inlet manifold passages in one or more directions substantially parallel to the surface and substantially perpendicular the input manifold passages. At least one heat transfer passages may have a plurality of fins on at least one surface.

Description

    PRIORITY CLAIM
  • This application is a continuation-in-part of U.S. patent application Ser. No. 11/477,344 filed Jun. 28, 2006, entitled “MICROCHANNEL COOLING DEVICE FOR SMALL HEAT SOURCES,” which claims priority to Provisional U.S. Patent Application No. 60/695,517 filed Jun. 29, 2005, entitled “MICROCHANNEL COOLING DEVICE FOR SMALL HEAT SOURCES,” the entire disclosures of which are hereby incorporated by reference, for all purposes, as if fully set forth herein.
    • STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
  • The United States Government may have certain rights in this invention pursuant to USAF Contract F33615-03-C-2343.
    • BACKGROUND OF THE INVENTION
  • Various semiconductor devices, such as laser diodes, power transistors or central processing unit chips, may dissipate large amounts of waste power over very small areas. This may produce a very high heat flux that can be removed to extend the service life and proper operation of such components. Because these components have relatively low operating temperatures, successful heat removal may necessitate minimal heat flow resistance between the heat source and the heat sink.
  • Some current heat removal techniques for such applications may involve microchannel cooling of individual semiconductor devices. For at least some of these cooling configurations, relatively large microchannel passages may be used. These passages may require high coolant flow rates to provide low thermal resistances, and may be limited in their thermal performance even at such flow rates.
  • Various disadvantages may result from these high flow rates. Higher flow rates may incur larger flow resistance penalties in the system, and associated cooling system components such as pumps, lines, filters, valves, reservoirs, and radiators may require increased flow capacity. Additionally, the high velocities of the coolant flow may lead to erosion of various components, including the walls of the microchannel cooling passages within the cooler itself, and this may cause increased thermal resistance and decreased service life.
    • BRIEF SUMMARY OF THE INVENTION
  • In one embodiment, an apparatus for transferring heat with a target is provided. The apparatus may include a body, and the body may define a surface, an inlet port, a plurality of inlet manifold passages, a plurality of heat transfer passages, and a plurality of outlet manifold passages, and an outlet port. The surface may be for coupling the target with the body, where heat transfers between the target and the body when the target is coupled with the body. The inlet port may be configured to receive a fluid and direct the fluid into a plurality of inlet manifold passages. The plurality of inlet manifold passages may be configured to receive the fluid from the inlet port and direct the fluid to a plurality of heat transfer passages. The plurality of heat transfer passages may be configured to receive the fluid from the plurality of inlet manifold passages, direct all of the fluid from the inlet manifold passages in one or more directions substantially parallel to the surface and substantially perpendicular to the plurality of input manifold passages, and direct the fluid to a plurality of outlet manifold passages, where heat transfers between the body and the fluid when fluid flows through the plurality of heat transfer passages. A plurality of fins may be located on at least one surface of at least one of the plurality of heat transfer passages. The plurality of outlet manifold passages may be configured to receive the fluid from the plurality of heat transfer passages, and direct the fluid to an outlet port. The outlet port may be configured to receive the fluid from the plurality of outlet manifold passages and output the fluid.
  • In another embodiment, an apparatus for transferring heat with a target is provided. The apparatus may include a plurality of sheets, where the plurality of sheets are coupled such that a body is formed by the coupled plurality of sheets. The body may define a surface, an inlet port, a plurality of inlet manifold passages, a plurality of heat transfer passages, a plurality of outlet manifold passages, and an outlet port. The surface may couple the target with the body, and heat may transfers between the target and the body when the target is coupled with the body. The inlet port may be configured to receive a fluid and direct the fluid into a plurality of inlet manifold passages. The plurality of inlet manifold passages may be configured to receive the fluid from the inlet port and direct the fluid to a plurality of heat transfer passages. The plurality of heat transfer passages may be configured to receive the fluid from the plurality of inlet manifold passages, direct all of the fluid received from the inlet manifold passages in one or more directions substantially parallel to the surface and substantially perpendicular to the plurality of input manifold passages, and direct the fluid to a plurality of outlet manifold passages, where heat may transfer between the body and the fluid when fluid flows through the plurality of heat transfer passages. The plurality of outlet manifold passages may be configured to receive the fluid from the plurality of heat transfer passages and direct the fluid to an outlet port. The body may also define a plurality of fins protruding into at least one of the plurality of input manifold passages or the plurality of output manifold passages. The outlet port may be configured to receive the fluid from the plurality of outlet manifold passages and output the fluid.
  • In another embodiment, an apparatus for transferring heat with a target is provided. The apparatus may include an upper sheet, a plurality of interior sheets, and a lower sheet. The upper sheet may define a surface for coupling with a target, where heat may transfer between the target and the upper sheet when the target is coupled with the surface. At least one of the upper sheet, the plurality of interior sheets, and the lower sheet may define an inlet port for receiving a fluid. The plurality of interior sheets may be coupled with the upper sheet, where heat may transfer between the upper sheet and the plurality of interior sheets. The plurality of interior sheets may define a plurality of inlet manifold passages for receiving the fluid from the inlet port, a plurality of heat transfer passages for receiving the fluid from the plurality of inlet manifold passages, where heat transfers between the fluid and the plurality of interior sheets, and where the plurality of heat transfer passages may be configured to direct all of the fluid received from the inlet manifold passages in one or more directions substantially parallel to the surface, where one or more of the heat transfer passages are curved, and a plurality of outlet manifold passages for receiving the fluid from the plurality of heat transfer passages. The lower sheet be coupled with at least one of the plurality of interior sheets. The lower sheet may also define an outlet port configured to receive the fluid from the plurality of outlet manifold passages and output the fluid.
  • In another embodiment, an apparatus for transferring heat with a target is provided. The apparatus may include an upper sheet, a plurality of interior sheets, and a lower sheet. The upper sheet may define a surface for coupling with a target, where heat may transfer between the target and the upper sheet when the target is coupled with the surface. At least one of the upper sheet, the plurality of interior sheets, and the lower sheet may define an inlet port for receiving a fluid. The plurality of interior sheets may be coupled with the upper sheet, where heat may transfer between the upper sheet and the plurality of interior sheets. The plurality of interior sheets may define a plurality of inlet manifold passages for receiving the fluid from the inlet port, a plurality of heat transfer passages for receiving the fluid from the plurality of inlet manifold passages, where heat transfers between the fluid and the plurality of interior sheets, and where the plurality of heat transfer passages may be configured to direct all of the fluid received from the inlet manifold passages in one or more directions substantially parallel to the surface, where one or more of the heat transfer passages are about a fin strip array, and a plurality of outlet manifold passages for receiving the fluid from the plurality of heat transfer passages. The lower sheet be coupled with at least one of the plurality of interior sheets. The lower sheet may also define an outlet port configured to receive the fluid from the plurality of outlet manifold passages and output the fluid.
  • In another embodiment, an apparatus for transferring heat with a target is provided. The apparatus may include an upper sheet, a plurality of interior sheets, and a lower sheet. The upper sheet may define a surface for coupling with a target, where heat may transfer between the target and the upper sheet when the target is coupled with the surface. At least one of the upper sheet, the plurality of interior sheets, and the lower sheet may define an inlet port for receiving a fluid. The plurality of interior sheets may be coupled with the upper sheet, where heat may transfer between the upper sheet and the plurality of interior sheets. The plurality of interior sheets may define a plurality of inlet manifold passages for receiving the fluid from the inlet port, a plurality of heat transfer passages for receiving the fluid from the plurality of inlet manifold passages, where heat transfers between the fluid and the plurality of interior sheets, and where the plurality of heat transfer passages may be configured to direct all of the fluid received from the inlet manifold passages in one or more directions substantially parallel to the surface, where at least one of the plurality of inlet manifold passages or plurality of outlet manifold passages are tapered, and a plurality of outlet manifold passages for receiving the fluid from the plurality of heat transfer passages. The lower sheet be coupled with at least one of the plurality of interior sheets. The lower sheet may also define an outlet port configured to receive the fluid from the plurality of outlet manifold passages and output the fluid.
  • This summary provides only a general outline of some embodiments according to the present invention. Many other objects, features, advantages and other embodiments of the present invention will become more fully apparent from the following detailed description, the appended claims and the accompanying drawings.
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • The present invention is described in conjunction with the appended figures:
  • FIG. 1 is an exploded isometric drawing of the components of an apparatus for transferring heat with a target;
  • FIG. 2 is an isometric drawing of an interior sheet of the apparatus shown in FIG. 1;
  • FIG. 3 is an isometric drawing of a portion of the interior sheet shown in FIG. 2;
  • FIG. 4 is an isometric drawing of the same portion of the interior sheet shown in FIG. 2, except also showing fluid flow patterns through the sheet;
  • FIG. 5 is a plan view of an upper sheet which may form at least a portion of an apparatus for transferring heat with a target;
  • FIG. 6 is a plan view of an interior sheet which may form at least a portion of an apparatus for transferring heat with a target;
  • FIG. 7 is a plan view of another interior sheet which may form at least a portion of an apparatus for transferring heat with a target;
  • FIG. 8 is a plan view of a lower sheet which may form at least a portion of an apparatus for transferring heat with a target;
  • FIG. 9 is an isometric drawing of a portion of a heat transfer passage having heat transfer fins disposed therein;
  • FIG. 10 is an isometric drawing of a portion of an alternative interior sheet having fins disposed in the inlet and outlet manifold passages;
  • FIGS. 11A-11C are plan views of portions of alternative interior sheets having curved heat transfer passages;
  • FIGS. 12A-12C shows alternative embodiments of the invention which provide fin strip array configurations;
  • FIG. 13A and FIG. 13B show plan views of alternative interior sheets having inlet and outlet manifold passages with one-dimensional tapers; and
  • FIG. 14A and FIG. 14B show alternative embodiments of the invention which provide for inlet and outlet manifold passages with two-dimensional tapers.
    •
  • In the appended figures, similar components and/or features may have the same numerical reference label. Further, various components of the same type may be distinguished by following the reference label by a letter that distinguishes among the similar components and/or features. If only the first numerical reference label is used in the specification, the description is applicable to any one of the similar components and/or features having the same first numerical reference label irrespective of the letter suffix.
    • DETAILED DESCRIPTION OF THE INVENTION
  • The ensuing description provides exemplary embodiments only, and is not intended to limit the scope, applicability or configuration of the disclosure. Rather, the ensuing description of the exemplary embodiments will provide those skilled in the art with an enabling description for implementing an exemplary embodiment. It being understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the invention as set forth in the appended claims.
  • Specific details are given in the following description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details.
  • In one embodiment, an apparatus for transferring heat with a target is provided. The apparatus may include a body, and the body may define a surface, an inlet port, a plurality of inlet manifold passages; a plurality of heat transfer passages, a plurality of outlet manifold passages, and an output port. The target may, merely by way of example, be a heat source.
  • The surface may couple the target with the body, and heat may transfer between the target and the body when the target is coupled with the body. The inlet port may be configured to receive a fluid and direct the fluid into a plurality of inlet manifold passages. The plurality of inlet manifold passages may be configured to receive the fluid from the inlet port and direct the fluid to a plurality of heat transfer passages. In some embodiments, the plurality of inlet manifold passages may be configured to direct the fluid in a direction substantially parallel to the surface.
  • The plurality of heat transfer passages may be configured to: receive the fluid from the plurality of inlet manifold passages; direct the fluid in a direction substantially parallel to the surface and substantially perpendicular to the plurality of input manifold passages; and direct the fluid to a plurality of outlet manifold passages, where heat may transfer between the body and the fluid when fluid flows through the plurality of heat transfer passages.
  • The plurality of outlet manifold passages may be configured to receive the fluid from the plurality of heat transfer passages and direct the fluid to an outlet port. The outlet port may be configured to receive the fluid from the plurality of outlet manifold passages and output the fluid. In some embodiments, the plurality of outlet manifold passages may be configured to direct the fluid in a direction substantially parallel to the surface.
  • In another embodiment, an apparatus for transferring heat with a target is provided. The apparatus may include a plurality of sheets, where the plurality of sheets are coupled such that a body is formed by the coupled plurality of sheets. The body may define a surface, one or more inlet ports, a plurality of inlet manifold passages, a plurality of heat transfer passages, a plurality of outlet manifold passages, and one or more outlet ports.
  • In some embodiments, the plurality of sheets may include an upper sheet, a plurality of interior sheets, and a lower sheet. In various embodiments the upper sheet or the lower sheet may define the surface. At least one of the upper sheet, the plurality of interior sheets, and the lower sheet may define the inlet port. The plurality of interior sheets may define the plurality of inlet manifold passages, the plurality of heat transfer passages, and the plurality of outlet manifold passages. In some embodiments, at least one of the upper sheet, the plurality of interior sheets, and the lower sheet may define the outlet port.
  • In an exemplary embodiment, all of the sheets may define the inlet port as well as the outlet port. In other embodiments, only a portion of the sheets may define either port. For example, in some embodiments, the upper sheet and some of the plurality of interior sheets in proximity to the upper sheet may define the inlet port. In these embodiments, the outlet port may be defined all of the sheets besides the lower sheet or possibly by the lower sheet and some of the plurality of interior sheets in proximity to the lower sheet.
  • Each of the plurality of sheets may be made from a variety of thermally conductive, low-expansion materials, including, but not limited to, molybdenum, tungsten, nickel, aluminum, stainless steel, silicon, beryllia, aluminum nitride, silicon carbide, chemical vapor deposition diamond, copper-diamond, copper-graphite, copper tungsten, and copper-molybdenum. In an exemplary embodiment, each of the plurality of sheets may be made from copper or a copper alloy. In some embodiments, each of the plurality of sheets may be made from a different material. Each sheet may be a certain shape. Some sheets may have the same shape, while some sheets may have unique shapes. The shape of any one sheet may be formed by photochemical etching or other type of etching. Other manufacturing methods may also be employed, including, but not limited to, laser machining and micro-machining methods.
  • The plurality of sheets may be coupled using various methods, including, but not limited to, soldering, brazing, and diffusion bonding. In embodiments where diffusion bonding is employed, the plurality of sheets may be coated with a diffusion aid. In some embodiments, the diffusion aid may be nickel or other suitable substance. In some embodiments, the sheets may be coupled so that they are “stacked,” and corresponding features of each sheet may combine to form features of the body of the apparatus.
  • In some embodiments, the upper and lower sheet may be characterized by a thickness, and the upper and lower sheet may be between about 50 microns and about 10,000 microns thick. In some embodiments, the upper and lower sheet may be the same thickness, while in other embodiments, they may be of different thickness. In an exemplary embodiment, both the upper and lower sheet may be about 250 microns thick.
  • In some embodiments, each of the plurality of interior sheets may be characterized by a thickness, and each of the plurality of interior sheets may be between about 12.5 microns and about 500 microns thick. In an exemplary embodiment, each of the plurality of interior sheets is about 50 microns thick.
  • The surface may couple the target with the body, and heat may transfer between the target and the body when the target is coupled with the body. The inlet port may be configured to receive a fluid and direct the fluid into a plurality of inlet manifold passages. The plurality of inlet manifold passages may be configured to receive the fluid from the inlet port and direct the fluid to a plurality of heat transfer passages. The fluid may be any heat transfer fluid known in the art, including, but not limited to, distilled water, deionized water, ethylene glycol, diethylene glycol, propylene glycol, acetone, ammonia, dielectric fluids such as the Fluorinert™ series, fluids with large operating temperature ranges such as the Dowtherm™ and Coolanol™ series, and brines and aqueous mixtures.
  • In some embodiments the inlet manifold passages may be characterized by a width, and each of plurality of inlet manifold passages may be in between about 100 microns and about 2000 microns wide. In some embodiments, each of the plurality of inlet manifold passages may be about 200 microns wide.
  • The plurality of heat transfer passages may be configured to receive the fluid from the plurality of inlet manifold passages; direct the fluid in a direction substantially parallel to the surface and substantially perpendicular to the plurality of input manifold passages; and direct the fluid to a plurality of outlet manifold passages, where heat may transfer between the body and the fluid when fluid flows through the plurality of heat transfer passages. Each of the plurality of heat transfer passages may have a height in the range of about 10 microns to about 250 microns, and a width in the range of about 50 microns to about 1250 microns. In some embodiments, the heat transfer passages may be microchannels. Microchannels may be any passage with a hydraulic diameter of about 500 microns or less.
  • Various embodiments of the dimension may define one or more heat transfer passages between each inlet manifold passage and outlet manifold passage. In some embodiments, the interior sheets coupled closer to the upper sheet may define more heat transfer passages than interior sheets coupled closer to the lower sheet define. In other embodiments, all of the interior sheets may define the same number of heat transfer passages.
  • For example, in two embodiments with 15 interior sheets, the first embodiment may define: three heat transfer passages between each inlet manifold passage and outlet manifold passage in the five sheets closest to the surface; two heat transfer passages between each inlet manifold passage and outlet manifold passage in the next five sheets; and one heat transfer passage between each inlet manifold passage and outlet manifold passage in the five sheets furthest from the surface. In the second example embodiment, every interior sheet may define the same number of heat transfer passages between each inlet manifold passage and outlet manifold passage.
  • In some embodiments, each of the sheets may be characterized by a thickness and each of the plurality of heat transfer passages may be characterized by a height. The height of each of the plurality of heat transfer passages may be less than the thickness of at least one of the plurality of sheets. In some embodiments, the height of each of the plurality of heat transfer passages may be substantially half of the thickness of at least one of the plurality of sheets.
  • The plurality of outlet manifold passages may be configured to receive the fluid from the plurality of heat transfer passages and direct the fluid to an outlet port. The outlet port may be configured to receive the fluid from the plurality of outlet manifold passages and output the fluid.
  • In some embodiments the outlet manifold passages may be characterized by a width, and each of plurality of outlet manifold passages may be in between about 100 microns and about 2000 microns wide. In some embodiments, each of the plurality of outlet manifold passages may be about 200 microns wide.
  • In some embodiments, the apparatus may also include the target. The target may, merely by way of example, be a laser diode, a power transistor, or a central processor unit chip. If the target is a laser diode, the laser diode may have an average heat flux of about 1000 Watts per square centimeter and a 1 millimeter by 10 millimeter footprint.
  • In another embodiment, an apparatus for transferring heat with a target is provided. The apparatus may include an upper sheet, a plurality of interior sheets, and a lower sheet.
  • The upper sheet may define a surface for coupling with a target, where heat may transfer between the target and the upper sheet when the target is coupled with the surface. At least one of the upper sheet, the plurality of interior sheets, and the lower sheet may define at least one inlet port for receiving a fluid.
  • The plurality of interior sheets may be coupled with the upper sheet, where heat may transfer between the upper sheet and the plurality of interior sheets. The plurality of interior sheets may define a plurality of inlet manifold passages for receiving the fluid from the inlet port; a plurality of heat transfer passages for receiving the fluid from the plurality of inlet manifold passages, where heat transfers between the fluid and the plurality of interior sheets, and where the plurality of heat transfer passages may be configured to direct the fluid in a direction substantially parallel to the surface; and a plurality of outlet manifold passages for receiving the fluid from the plurality of heat transfer passages. In this or other embodiments, the heat transfer passages may be any shape between the plurality of inlet manifold passages and the plurality of outlet manifold passages. In some embodiments, different heat transfer passages within the same body may be different shapes. Merely by way of example, the heat transfer passages may be curved, serpentine, or tapered. Other two dimensional patterns are also possible.
  • The lower sheet be coupled with at least one of the plurality of interior sheets. The lower sheet may also define at least one outlet port configured to receive the fluid from the plurality of outlet manifold passages and output the fluid.
  • Turning now to FIG. 1, an exploded isometric drawing of the components of an apparatus of the invention for transferring heat with a target is shown. The components of a body 100 in this embodiment include an upper sheet 110, an first interior sheet 120 having three heat transfer passages 180A between each inlet manifold passage 160 and outlet manifold passage 170, a second interior sheet 130 having two heat transfer passages 180B between each inlet manifold passage 160 and outlet manifold passage 170, a third interior sheet 140 having one heat transfer passage 180C between each inlet manifold passage 160 and outlet manifold passage 170, and a lower sheet 150. The sheets may be coupled together to form body 100. A portion of the sheets which form an inlet port and an outlet port is not shown in FIG. 1, but will be shown in greater detail in FIG. 5, FIG. 6, FIG. 7, and FIG. 8.
  • In some embodiments, a body 100 may be formed of differing numbers and types of upper sheets, interior sheets, and lower sheets. While the embodiment shown in FIG. 1 has three interior foils 120, 130, 140, each having a different number of heat transfer passages between each inlet manifold channel 160 and outlet manifold channel 170, other embodiments may be of different configurations. In some embodiments, all interior sheets may have the same number of heat transfer passages between each inlet manifold channel 160 and outlet manifold channel 170. In other embodiments, the sheet layout may be substantially as shown in FIG. 1, except having multiple first interior sheets 120, multiple second interior sheets 130, and multiple third interior sheets 140. In some embodiments, more or less configurations of interior sheets may be used, with each configuration having different number of heat transfer passages between each inlet manifold passage 160 and outlet manifold passage 170. The efficiency of the apparatus in transferring heat with a target may be adjusted by varying fluid flow rates, changing the size of apparatus passages and features, and the number of passages and features.
  • The top of upper sheet 110 may define a surface 111 for coupling a target with body 100. In some embodiments, the target may be bonded to surface 111 with another substance, for example, a thermally conductive paste. When all sheets 110, 120, 130, 140, 150 are coupled together to form body 100, heat may flow between body 100 and the target. Interior sheets 120, 130, 140 may form multiple inlet manifold passages 160, and outlet manifold passages 170. Only inlet manifold passages 160A, 160B, 160C and outlet manifold passages 170A, 170B are specifically labeled in FIG. 1, but the pattern of alternating inlet manifold passages 170 and outlet manifold passages 180 continues down the length of each interior sheets 120, 130, 140.
  • FIG. 2 shows a closer view isometric drawing of first interior sheet 120 of the apparatus shown in FIG. 1. Inlet manifold passages 160, outlet manifold passages 170, and heat transfer passages 180 can be seen more clearly in FIG. 2. Also note that the portions of interior sheet 120 which form the sidewalls 210, 220 and front wall 230 of body 100. On the side of interior sheet 120 may extend in different configurations in a direction opposite front wall 230 to form inlet and outlet ports which will be shown in greater detail in FIG. 5, FIG. 6, FIG. 7, and FIG. 8.
  • FIG. 3 shows a closer view of a portion of first interior sheet 120 shown in FIG. 1 and FIG. 2. In this embodiment, it may be seen how the width of the inlet manifold passages 160 and outlet manifold passages 170 may be about the same width as each one of the three heat transfer passages 180A. The interior walls 310 may be a different width. In other embodiments, the dimensions of the various features may be different as described above. The depth of heat transfer passages 180 in this embodiment may be about half the thickness of interior sheet 120. In other embodiments, the depth of heat transfer passages 180 may be more or less than the thickness of interior sheet 120.
  • FIG. 4 shows an isometric drawing of the same portion of first interior sheet 120 shown in FIG. 3, except also showing fluid flow patterns 410, 420 through the sheet.
  • Fluid may be received by inlet manifold passages 160 as shown by directional arrows 410, be directed through heat transfer passages 180, and received by outlet manifold passages 170 as shown by direction arrows 420.
  • FIG. 5 shows a plan view of an upper sheet 500, including an inlet port 510 and an outlet port 520 which may form at least a portion of an apparatus for transferring heat with a target. A surface 530, or portion of the top of upper sheet 500, may also be defined for coupling a target to upper sheet 500.
  • FIG. 6 shows a plan view of an upper interior sheet 600 which may form at least a portion of the apparatus for transferring heat with a target. A plurality of upper interior sheets may be coupled with upper sheet 500 in one embodiment to form a continuous inlet port 510, and a body of an apparatus. Fluid may flow from inlet port 510 to inlet manifold passages 160, be directed through heat transfer passages 180, and be received by outlet manifold passages 170. Upper interior sheet 600 may also define a portion of a continuous outlet port 520.
  • FIG. 7 shows a plan view of a lower interior sheet which may form at least a portion of the apparatus for transferring heat with a target. A plurality of lower interior sheets 700 may be coupled with other sheets to form a continuous outlet port 520, and the body of the apparatus. Fluid may flow from inlet manifold passages 160, be directed through heat transfer passages 180, and be received by outlet manifold passages 170. Fluid may then flow from outlet manifold passages 170 to outlet port 520. Lower interior sheet 700 may also define a portion of a continuous inlet port 510.
  • FIG. 8 shows a plan view of a lower sheet 800, including a portion of inlet port 510 and of outlet port 520 which may form at least a portion of the apparatus for transferring heat with a target. In this configuration then, inlet and outlet flows of fluid may be coupled to either side of the body formed by sheets 500, 600, 700, 800.
  • FIG. 9 shows a plurality of heat transfer fins 910 on the bottom surface 920 of a portion of a heat transfer passage 180. In any of the described or other embodiments, any (from none to all) of the heat transfer passages 180 may have heat transfer fins 910 on any one or more of their surfaces (sides, bottom, and top). The heat transfer fins 910 may augment the transfer of heat between the fluid and the body 100. The heat transfer fins 910 may be of any shape as desired to increase heat transfer during fluid flow.
  • FIG. 10 shows an alternative interior sheet 120A which can be used to possibly increase heat transfer with the fluid in the inlet manifold passages 160 and outlet manifold passages 170 just before entry, and exiting from, heat transfer passages 180. Once multiple alternative interior sheets 120A are stacked in an embodiment, fins 1010 will be present between adjacent heat transfer passages 180 (“adjacent” describing a nearby heat transfer passage 180 closer than any other heat transfer passage 180 in that direction). In other embodiments, fins 1010 may be located between horizontally adjacent heat transfer passages 180. In some embodiments, fins 1010 may be disposed vertically between each and every heat transfer passage 180, either vertically (as shown in FIG. 10), horizontally, or both. In other embodiments, fins 1010 may be disposed less often between heat transfer passages, either vertically, horizontally, or both.
  • FIG. 11A shows another alternative interior sheet 120B. Interior sheet 120B has a plurality of curved heat transfer passages 180. These heat transfer passages 180 facilitate the flow from the inlet manifold passages to the outlet manifold passages and improve heat transfer. FIG. 11B and FIG. 11C show two other alternative interior sheets 120C, 120D which provide curved heat transfer passages.
  • FIG. 12A shows another alternative interior sheet 120E. Sheet 120E allows fluid flow as shown by directional arrow 1210 in FIG. 12B. When sheets 120E are stacked, they form a fin stack array and allow fluid flow as shown by directional arrow 1220 in FIG. 12C. The profile of heat transfer passages 180 through sheet 120E may allow for improved heat transfer, as opposed to non fin stack array formations, as fluid passes through the heat transfer passages 180.
  • FIG. 13A and FIG. 13B show another alternative interior sheets 120F, 120G. Each of sheet 120F and 120G have tapered inlet manifold passages 160 and outlet manifold passages 170. The taper angle may be constant as shown in interior sheet 120F, or may be non-constant, and possibly curved as shown in interior sheet 120G. In other embodiments, non-constant taper linear angles may be used in each inlet manifold passage 160 and/or outlet manifold passage 170. Merely by way of example, the angle of the taper may increase or decrease deeper into the inlet manifold passage 160 and/or outlet manifold passage.
  • FIG. 14A shows an alternative interior sheet 120H, similar to interior sheet 120F from FIG. 13A, except also having tapered inlet manifold passages 160 and outlet manifold passages 170 tapered in two dimensions (width and height) as illustrated in FIG. 14B (as opposed to a single dimension, width). FIG. 14B is an illustration of the volume of either of the manifold passages 160, 170. As shown from FIG. 14B, the cross-sectional area of the manifold passage 160, 170 decreases deeper into the manifold passage 160, 170 such that X1 is less than X2, and Y1 is less than Y2. While shown in FIG. 14B as being a linear, the two dimensional taper could also be non-liner, or curved, in some embodiments.
  • A number of variations and modifications of the invention can also be used within the scope of the invention. For example, a different manifold scheme could be used to deliver fluid to and from the heat transfer passages. In another example, various sheets, including the upper sheet and lower sheet, could have channels or features for encouraging flow to spread between all inlet manifold passages, or collect from all outlet manifold passages.
  • The invention has now been described in detail for the purposes of clarity and understanding. However, it will be appreciated that certain changes and modifications may be practiced within the scope of the appended claims.

Claims (26)

1. An apparatus for transferring heat with a target, the apparatus including a body, wherein the body defines:
a surface for coupling the target with the body, wherein heat transfers between the target and the body when the target is coupled with the body;
an inlet port, wherein the inlet port is configured to:
receive a fluid; and
direct the fluid into a plurality of inlet manifold passages;
the plurality of inlet manifold passages, wherein the plurality of inlet manifold passages are configured to:
receive the fluid from the inlet port; and
direct the fluid to a plurality of heat transfer passages;
the plurality of heat transfer passages, wherein the plurality of heat transfer passages are configured to:
receive the fluid from the plurality of inlet manifold passages;
direct all of the fluid from the inlet manifold passages in one or more directions substantially parallel to the surface and substantially perpendicular to the plurality of input manifold passages; and
direct the fluid to a plurality of outlet manifold passages, wherein heat transfers between the body and the fluid when fluid flows through the plurality of heat transfer passages;
a plurality of fins on at least one surface of at least one of the plurality of heat transfer passages;
the plurality of outlet manifold passages, wherein the plurality of outlet manifold passages are configured to:
receive the fluid from the plurality of heat transfer passages; and
direct the fluid to an outlet port; and
an outlet port, wherein the outlet port is configured to:
receive the fluid from the plurality of outlet manifold passages; and
output the fluid.
2. The apparatus for removing heat from a heat source of claim 1, the apparatus further comprising the target.
3. The apparatus for removing heat from a heat source of claim 1, the target comprising a laser diode.
4. The apparatus for removing heat from a heat source of claim 1, wherein each of the plurality of heat transfer passages are characterized by a hydraulic diameter, and each of the plurality of heat transfer passages have a hydraulic diameter of about 500 microns or less.
5. An apparatus for transferring heat with a target, the apparatus comprising:
a plurality of sheets, wherein the plurality of sheets are coupled such that a body is formed by the coupled plurality of sheets, and wherein the body defines:
a surface for coupling the target with the body, wherein heat transfers between the target and the body when the target is coupled with the body;
an inlet port, wherein the inlet port is configured to:
receive a fluid; and
direct the fluid into a plurality of inlet manifold passages;
the plurality of inlet manifold passages, wherein the plurality of inlet manifold passages are configured to:
receive the fluid from the inlet port; and
direct the fluid to a plurality of heat transfer passages;
the plurality of heat transfer passages, wherein the plurality of heat transfer passages are configured to:
receive the fluid from the plurality of inlet manifold passages;
direct all of the fluid received from the inlet manifold passages in one or more directions substantially parallel to the surface and substantially perpendicular to the plurality of input manifold passages; and
direct the fluid to a plurality of outlet manifold passages, wherein heat transfers between the body and the fluid when fluid flows through the plurality of heat transfer passages;
the plurality of outlet manifold passages, wherein the plurality of outlet manifold passages are configured to:
receive the fluid from the plurality of heat transfer passages; and
direct the fluid to an outlet port;
a plurality of fins protruding into at least one of the plurality of input manifold passages or the plurality of output manifold passages; and
the outlet port, wherein the outlet port is configured to:
receive the fluid from the plurality of outlet manifold passages; and
output the fluid.
6. The apparatus for removing heat from a heat source of claim 5, wherein a plurality of fins protruding into at least one of the plurality of input manifold passages or the plurality of output manifold passages comprises at least one fin protruding from between two adjacent heat transfer passages.
7. The apparatus for removing heat from a heat source of claim 5, wherein each of the plurality of sheets is characterized by a thickness and each of the plurality of heat transfer passages is characterized by a height, wherein the height of each of the plurality of heat transfer passages is substantially half of the thickness of at least one of the plurality of sheets.
8. The apparatus for removing heat from a heat source of claim 5, wherein each of the plurality of sheets is comprised of a selection from a group consisting of:
copper;
copper alloy;
molybdenum;
tungsten;
nickel;
aluminum;
stainless steel;
silicon;
beryllia;
aluminum nitride;
silicon carbide;
chemical vapor deposition diamond;
copper-diamond;
copper-graphite;
copper-tungsten; and
copper-molybdenum.
9. The apparatus for removing heat from a heat source of claim 5, the plurality of sheets comprising an upper sheet, a plurality of interior sheets, and a lower sheet, wherein:
at least one of the upper sheet and the lower sheet define the surface;
at least one of the upper sheet, the plurality of interior sheets, and the lower sheet define the inlet port;
the plurality of interior sheets define:
the plurality of inlet manifold passages;
the plurality of heat transfer passages; and
the plurality of outlet manifold passages; and
at least one of the upper sheet, the plurality of interior sheets, and the lower sheet define the outlet port.
10. The apparatus for removing heat from a heat source of claim 9, wherein interior sheets coupled closer to the upper sheet define more heat transfer passages than interior sheets coupled closer to the lower sheet define.
11. The apparatus for removing heat from a heat source of claim 9, wherein at least two interior sheet define more than one heat transfer passages between one inlet manifold passage and one outlet manifold passage.
12. The apparatus for removing heat from a heat source of claim 9, wherein the upper sheet and lower sheet are characterized by a thickness, and the upper sheet and lower sheet are each between about 50 microns and about 10,000 microns thick.
13. The apparatus for removing heat from a heat source of claim 9, wherein the upper sheet and lower sheet are characterized by a thickness, and the upper sheet and lower sheet are each about 250 microns thick.
14. The apparatus for removing heat from a heat source of claim 9, wherein each of the plurality of interior sheets is characterized by a thickness, and each of the plurality of interior sheets is between about 12.5 microns and about 500 microns thick.
15. The apparatus for removing heat from a heat source of claim 9, wherein each of the plurality of interior sheets is characterized by a thickness, and each of the plurality of interior sheets is about 50 microns thick.
16. An apparatus for transferring heat with a target, the apparatus comprising:
an upper sheet;
a plurality of interior sheets; and
a lower sheet, wherein:
the upper sheet defines a surface for coupling with a target, wherein heat transfers between the target and the upper sheet when the target is coupled with the surface;
at least one of the upper sheet, the plurality of interior sheets, and the lower sheet define the inlet port, wherein the inlet port is configured to receive a fluid;
the plurality of interior sheets are coupled with the upper sheet, wherein heat transfers between the upper sheet and the plurality of interior sheets, and wherein the plurality of interior sheets define:
a plurality of inlet manifold passages for receiving the fluid from the inlet port;
a plurality of heat transfer passages for receiving the fluid from the plurality of inlet manifold passages, wherein heat transfers between the fluid and the plurality of interior sheets, and wherein the plurality of heat transfer passages are configured to direct all of the fluid received from the inlet manifold passages in one or more directions substantially parallel to the surface, and wherein one or more of the heat transfer passages are curved; and
a plurality of outlet manifold passages for receiving the fluid from the plurality of heat transfer passages;
the lower sheet is coupled with at least one of the plurality of interior sheets; and
at least one of the upper sheet, the plurality of interior sheets, and the lower sheet define the outlet port, wherein the outlet port is configured to receive the fluid from the plurality of outlet manifold passages and output the fluid.
17. The apparatus for removing heat from a heat source of claim 16, wherein one or more of the heat transfer passages being curved comprises one or more of the heat transfer passages being curved to facilitate flow from the inlet manifold passages to the outlet manifold passages.
18. The apparatus for removing heat from a heat source of claim 16, wherein at least one of the upper sheet, the plurality of interior sheets, and the lower sheet comprise a shape, and the shape is formed by photochemical etching.
19. The apparatus for removing heat from a heat source of claim 16, wherein the plurality of sheets are coupled together by diffusion bonding.
20. The apparatus for removing heat from a heat source of claim 19, wherein the plurality of sheets are coated with a diffusion aid.
21. The apparatus for removing heat from a heat source of claim 20, the diffusion aid comprising nickel.
22. The apparatus for removing heat from a heat source of claim 16, wherein the plurality of sheets are coupled by soldering or brazing.
23. An apparatus for transferring heat with a target, the apparatus comprising:
an upper sheet;
a plurality of interior sheets; and
a lower sheet, wherein:
the upper sheet defines a surface for coupling with a target, wherein heat transfers between the target and the upper sheet when the target is coupled with the surface;
at least one of the upper sheet, the plurality of interior sheets, and the lower sheet define the inlet port, wherein the inlet port is configured to receive a fluid;
the plurality of interior sheets are coupled with the upper sheet, wherein heat transfers between the upper sheet and the plurality of interior sheets, and wherein the plurality of interior sheets define:
a plurality of inlet manifold passages for receiving the fluid from the inlet port;
a plurality of heat transfer passages for receiving the fluid from the plurality of inlet manifold passages, wherein heat transfers between the fluid and the plurality of interior sheets, and wherein the plurality of heat transfer passages are configured to direct all of the fluid received from the inlet manifold passages in one or more directions substantially parallel to the surface, and wherein one or more of the heat transfer passages are about a fin strip array; and
a plurality of outlet manifold passages for receiving the fluid from the plurality of heat transfer passages;
the lower sheet is coupled with at least one of the plurality of interior sheets; and
at least one of the upper sheet, the plurality of interior sheets, and the lower sheet define the outlet port, wherein the outlet port is configured to receive the fluid from the plurality of outlet manifold passages and output the fluid.
24. An apparatus for transferring heat with a target, the apparatus comprising:
an upper sheet;
a plurality of interior sheets; and
a lower sheet, wherein:
the upper sheet defines a surface for coupling with a target, wherein heat transfers between the target and the upper sheet when the target is coupled with the surface;
at least one of the upper sheet, the plurality of interior sheets, and the lower sheet define the inlet port, wherein the inlet port is configured to receive a fluid;
the plurality of interior sheets are coupled with the upper sheet, wherein heat transfers between the upper sheet and the plurality of interior sheets, and wherein the plurality of interior sheets define:
a plurality of inlet manifold passages for receiving the fluid from the inlet port;
a plurality of heat transfer passages for receiving the fluid from the plurality of inlet manifold passages, wherein heat transfers between the fluid and the plurality of interior sheets, and wherein the plurality of heat transfer passages are configured to direct all of the fluid received from the inlet manifold passages in one or more directions substantially parallel to the surface, and wherein at least one of the plurality of inlet manifold passages or plurality of outlet manifold passages are tapered; and
a plurality of outlet manifold passages for receiving the fluid from the plurality of heat transfer passages;
the lower sheet is coupled with at least one of the plurality of interior sheets; and
at least one of the upper sheet, the plurality of interior sheets, and the lower sheet define the outlet port, wherein the outlet port is configured to receive the fluid from the plurality of outlet manifold passages and output the fluid.
25. The apparatus for transferring heat with a target of claim 24, wherein at least one of the plurality of inlet manifold passages or plurality of outlet manifold passages being tapered comprises at least one of the plurality of inlet manifold passages or plurality of outlet manifold passages being tapered in one dimension.
26. The apparatus for transferring heat with a target of claim 24, wherein at least one of the plurality of inlet manifold passages or plurality of outlet manifold passages being tapered comprises at least one of the plurality of inlet manifold passages or plurality of outlet manifold passages being tapered in two dimensions.
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