CA3123506C - Efficient cooled channel components - Google Patents

Efficient cooled channel components Download PDF

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Publication number
CA3123506C
CA3123506C CA3123506A CA3123506A CA3123506C CA 3123506 C CA3123506 C CA 3123506C CA 3123506 A CA3123506 A CA 3123506A CA 3123506 A CA3123506 A CA 3123506A CA 3123506 C CA3123506 C CA 3123506C
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component
cooled
channel
cooled channel
internal channels
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CA3123506A1 (en
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Niall T. Davidson
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ADC Technologies Inc
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ADC Technologies Inc
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    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/20—Modifications to facilitate cooling, ventilating, or heating
    • H05K7/20709—Modifications to facilitate cooling, ventilating, or heating for server racks or cabinets; for data centers, e.g. 19-inch computer racks
    • H05K7/20763—Liquid cooling without phase change
    • H05K7/20781—Liquid cooling without phase change within cabinets for removing heat from server blades
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F1/00—Details not covered by groups G06F3/00 - G06F13/00 and G06F21/00
    • G06F1/16—Constructional details or arrangements
    • G06F1/20—Cooling means

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Theoretical Computer Science (AREA)
  • Computer Hardware Design (AREA)
  • Thermal Sciences (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Human Computer Interaction (AREA)
  • General Physics & Mathematics (AREA)
  • Cooling Or The Like Of Electrical Apparatus (AREA)
  • Cooling Or The Like Of Semiconductors Or Solid State Devices (AREA)

Abstract

Disclosed is a cooled channel component for installation as part of a wall of an enclosure assembly of the type which can be used to cool electronic equipment installed in the enclosure assembly. The cooled channel component is configured to support and engage a thermal connector on a respective piece of electronic equipment installed into the enclosure. The cooled channel component is also configured such that when it installed as part of the wall it is mechanically independent of other cooled channel components, so that deformation or deflection of the cooled channel component due to the application of a bearing force to improve thermal contact between a cooled surface of the cooled channel component and the thermal connector of the respective piece of electronic equipment does not hinder performance of the other adjacently mounted cooled channel components.

Description

Efficient Cooled Channel Components CROSS-REFERENCE TO RELATED APPLICATION
[01] This application claims the benefit of United States Provisional Patent Application No.
62/525,535 entitled "Efficient Cooled Channel Components" filed June 27, 2017.
BACKGROUND
[02] Data centers are the backbone of the modern Internet and therefore feature prominently in modern life. Cooling of data center equipment is a foundational part of the modern data center and poor cooling technologies increase the data centers operators costs and risk of failure. Cost-efficiently cooling data centers therefore is of vital importance.
[03] Previous work by this inventor disclosed in patent applications published as WO/2014/030046, WO/2016/004528 and WO/2016/004531 describes computer system apparatus and cooled enclosures that can remove heat from data center equipment by engaging a rail type thermal connector with a cooled channel to transfer heat between server and enclosure.
[04] There is a need for channel type apparatus which can be used to efficiently and cost-effectively transfer heat between a rail thermal connector and cooled channel.
SUMMARY
[05] The present disclosure relates to cooled channel components which can be used to efficiently and cost-effectively transfer heat between a rail thermal connector and a channel.
The cooled channel components are configured for use in an enclosure or enclosure wall to be used in a data center.
[06] According to a first broad aspect, the present disclosure provides a cooled channel component comprising: a channel configured to receive a rail thermal connector within the channel; and a means for cooling a surface of the channel. The cooled channel component is Date Recue/Date Received 2022-07-07 configured to be affixable to one or more supports as part of an enclosure wall such that the cooled channel component is mechanically independent of one or more other cooled channel components adjacently installed as part of the enclosure wall.
[07] In some embodiments of the first aspect, the channel comprises a pair of spaced apart arms having a normalized deflection of less than 0.0375 for a bracing force applied between the arms of the channel which is approximately equivalent to a pressure of at least 69kPa.
[08] In some embodiments of the first aspect, the cooled channel component is configured such that, when the cooled channel component is affixed to the one or more supports at one or more points of attachment, deflection of the arms of the channel for a bracing force applied between the arms of the channel which is approximately equivalent to a pressure of between 69kPa to 690kPa is limited to a range that prevents contact with the one or more adjacently installed cooled channel components and the one or more supports outside of the one or more points of attachment.
[09] In some embodiments of the first aspect, the cooled channel component further comprises a spacing feature configured to space the cooled channel component apart from the one or more supports outside the one or more points of attachment.
[010] In some embodiments of the first aspect, the cooled channel component is configured to have sufficient cooling for at least 0.25kW of power.
[011] In some embodiments of the first aspect, the cooled channel component is configured to cool a heat-flux between 10,000 W/m2 and 200,000 W/m2 when the means for cooling uses a water based coolant.
[012] In some embodiments of the first aspect, the means for cooling comprises a first flow path comprising a first inlet, a first outlet and a first at least one internal channel connecting the first inlet to the first outlet, whereby the surface of the channel is coolable by flowing a coolant through the first flow path.
[013] In some embodiments of the first aspect, the at least one internal channel comprises a spiral or serpentine configuration.
[014] In some embodiments of the first aspect, the at least one internal channel comprises features configured to disrupt the laminar flow of coolant flowing through the first flow path.
[015] In some embodiments of the first aspect, the cooled channel component further comprises a second flow path comprising a second inlet, a second outlet and a second at least one internal channel connecting the second inlet to the second outlet.
[016] In some embodiments of the first aspect, the first and second inlets and the first and second outlets are arranged so that a direction of a coolant flow through the first flow path along a lengthwise direction of the cooled channel component is generally opposite to a direction of a coolant flow through the second flow path along the lengthwise direction of the cooled channel component.
[017] In some embodiments of the first aspect, the first flow path and the second flow path have a substantially equal length thermal path to the surface of the channel.
[018] In some embodiments of the first aspect, the first at least one internal channel comprises a plurality of first internal channels and the second at least one internal channel comprises a plurality of second internal channels, the first internal channels and second internal channels alternating along a widthwise direction of the cooled channel component.
[019] In some embodiments of the first aspect, the cooled channel component comprises a base component defining the channel, and the means for cooling comprises: a flow director affixed to the base component; and at least one lid plate affixed to the flow director. In such embodiments, the flow director and the at least one lid plate may form at least part of a first flow path, whereby the surface of the channel is coolable by flowing a coolant through the first flow path.
[020] In some embodiments of the first aspect, the base component comprises an extrusion and the flow director comprises a casting affixed to a surface of the base component. In such embodiment, the flow director may further comprise features to create internal channels of the first flow path when joined to the base component.
[021] In some embodiments of the first aspect, the base component and the flow director comprise features which when joined together create internal channels of the first flow path.
[022] In some embodiments of the first aspect, the internal channels are rifled.
[023] In some embodiments of the first aspect, the cooled channel component further comprises a second flow director affixed to the base component.
[024] In some embodiments of the first aspect, the cooled channel component comprises a base component defining the channel, and the means for cooling comprises: a seal plate affixed to the base component; and at least one guide component affixed to the seal plate. In such embodiments, the seal plate and the at least one guide component may form at least part of a first flow path when joined to the base component, whereby the surface of the channel is coolable by flowing a coolant through the first flow path. In some implementations, the base component may comprise features to create internal channels of the first flow path when joined to the seal plate.
[025] In some embodiments of the first aspect, the seal plate is manufactured from a plastic material.
[026] In some embodiments of the first aspect, the at least one guide component comprises a first guide component and a second guide component, the seal plate and the first guide component forming at least part of the first flow path, and the seal plate and the second guide component forming at least part of a second flow path when joined to the base component, whereby the surface of the channel is coolable by flowing a coolant through the first and second flow paths. In some implementations, the base component may further comprise features to create internal channels of the second flow path when joined to the seal plate.
[027] In some embodiments of the first aspect, the internal channels of the first flow path and the internal channels of the second flow path are alternating along a widthwise direction of the cooled channel component.
[028] In some embodiments of the first aspect, the cooled channel component further comprises a second flow director affixed to the base component.
[029] In some embodiments of the first aspect, the cooled channel component comprises a base component defining the channel, the base component comprising an extrusion having a plurality of internal channels forming at least part of the means for cooling.
The internal channels may be contained within at least the arm of the channel that includes the cooled surface, whereby the surface of the channel is coolable by flowing a coolant through the internal channels of the extrusion.
[030] In some embodiments of the first aspect, the means for cooling further comprises a first manifold affixed to the extrusion and a second manifold affixed to the extrusion opposite the first manifold. The first manifold may comprise a first inlet and a second outlet, the first inlet being in fluid communication with a first subset of the internal channels of the extrusion, and the second outlet being in fluid communication with a second subset of the internal channels of the extrusion. Similarly, the second manifold may comprise a second inlet and a first outlet, the second inlet being in fluid communication with the second subset of the internal channels of the extrusion, and the first outlet being in fluid communication with the first subset of the internal channels of the extrusion.
[031] In some embodiments of the first aspect, the first subset of the internal channels and the second subset of the internal channels are alternating along a widthwise direction of the cooled channel component.
[032] In some embodiments of the first aspect, the cooled channel component comprises a base component defining the channel, and the means for cooling comprises: a multi-port extrusion (MPE) affixed to the base component. In such embodiments, the MPE
may have a plurality of internal channels forming at least part of a first flow path, whereby the surface of the channel is coolable by flowing a coolant through the first flow path.
[033] In some embodiments of the first aspect, the base component and the MPE
are joined via correspondingly shaped interlocking features on surfaces thereof.
[034] In some embodiments of the first aspect, the base component and the MPE
are joined via fins generally projecting away from a surface of the base component opposite the cooled surface of the channel, and correspondingly shaped features on the MPE, the correspondingly shaped features on the MPE defining, at least in part, the internal channels of the MPE.
[035] In some embodiments of the first aspect, the means for cooling further comprises a first manifold affixed to the MPE and a second manifold affixed to the MPE
opposite the first manifold. The first manifold may comprise a first inlet and a second outlet, the first inlet being in fluid communication with a first subset of the internal channels of the MPE, and the second outlet being in fluid communication with a second subset of the internal channels of the MPE. Similarly, the second manifold may comprise a second inlet and a first outlet, the second inlet being in fluid communication with the second subset of the internal channels of the MPE, and the first outlet being in fluid communication with the first subset of the internal channels of the MPE. The first subset of the internal channels and the second subset of the internal channels may alternate along a widthwise direction of the cooled channel component.
[036] In some embodiments of the first aspect, the channel is generally u-shaped.
[037] In some embodiments of the first aspect, the cooled channel component includes only the single channel.
[038] According to a second broad aspect, the present disclosure provides a wall of a cooled enclosure of a type which cools installed equipment by thermal contact with an elongated thermal connector element on at least one side of the equipment. A wall according to this broad aspect comprises one or more supports and a plurality of cooled channel components affixed to the one or more supports for engaging and supporting respective equipment inserted into the cooled enclosure. Each cooled channel component is mechanically independent of the other cooled channel components installed as part of the wall, comprises an elongated thermal connector element having a cooled surface, and is configured to establish a male-female progressive engagement with the elongated thermal connector element of a respective equipment as the equipment is inserted into the enclosure.
[039] In some embodiments of the second aspect, for each of at least one of the cooled channel components, the elongated thermal connector element of the cooled channel component comprises a channel having two spaced apart arms configured to receive a rail thermal connector of a respective equipment.
[040] In some embodiments of the second aspect, the channel comprises a pair of spaced apart arms, the arms having a normalized deflection of less than 0.0375 for a bracing force applied between the arms of the channel which is approximately equivalent to a pressure of at least 69kPa.
[041] In some embodiments of the second aspect, deflection of the arms of the channel for a bracing force applied between the arms of the channel which is approximately equivalent to a pressure of between 69kPa to 690kPa is limited to a range that prevents contact with the other adjacently installed cooled channel components and the one or more supports outside of points of attachment to the one or more supports.
[042] In some embodiments of the second aspect, for each of at least one of the cooled channel components, the elongated thermal connector element of the cooled channel component comprises a rail thermal connector configured to be received within a channel thermal connector of a respective equipment.
[043] In some embodiments of the second aspect, each cooled channel component is configured to provide sufficient cooling for at least 0.25kW of power.
[044] In some embodiments of the second aspect, each cooled channel component is configured to cool a heat-flux between 10,000 W/m2 and 200,000 W/m2 when using a water based coolant to cool the cooled surface.
[045] In some embodiments of the second aspect, each of at least one of the cooled channel components comprises a first flow path comprising a first inlet, a first outlet and a first at least one internal channel connecting the first inlet to the first outlet, whereby the cooled surface is cooled by flowing a coolant through the first flow path.
[046] In some embodiments of the second aspect, the at least one internal channel comprises a spiral or serpentine configuration.
[047] In some embodiments of the second aspect, the at least one internal channel comprises features configured to disrupt the laminar flow of coolant flowing through the first flow path.
[048] In some embodiments of the second aspect, each of the at least one cooled channel component further comprises a second flow path comprising a second inlet, a second outlet and a second at least one internal channel connecting the second inlet to the second outlet.
[049] In some embodiments of the second aspect, the first and second inlets and the first and second outlets are arranged so that a direction of a coolant flow through the first flow path along a lengthwise direction of the cooled channel component is generally opposite to a direction of a coolant flow through the second flow path along the lengthwise direction of the cooled channel component.
[050] In some embodiments of the second aspect, the first flow path and the second flow path have a substantially equal length thermal path to the cooled surface.
[051] In some embodiments of the second aspect, the first at least one internal channel comprises a plurality of first internal channels and the second at least one internal channel comprises a plurality of second internal channels, the first internal channels and second internal channels alternating along a widthwise direction of the cooled channel component.
DRAWINGS
[052] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Fig. la shows an isometric view of a cooled channel component comprising a base component and a flow director and two lid plates in accordance with one embodiment;
Fig. lb shows an exploded isometric view of the cooled channel component of fig. la;
Fig. 2 shows a side elevation view of the base component of the cooled channel component of figs. la and lb;
Figs. 3a, b and c show respectively top view, side elevation view and bottom view of the flow director of the cooled channel component of figs. la and b;
Fig. 3d shows an enlarged view of an end portion of the flow director of figs.
3a, 3b and 3c;
Fig. 3e shows a cutaway view along the A-A axis of the flow director of fig.
3a, showing the structure of the internal channels of the flow director;
Fig. 4a shows a side elevation view of a rail thermal connector in accordance with one embodiment contacting the cooled channel component of figs. la and b and the space between the cooled channel component and supports;

Fig. 4b shows an exploded side elevation view of the cooled channel component and supports of fig. 4a illustrating how the component is fastened to a supporting structure;
Fig. 4c shows a side elevation view of the cooled channel component of figs.
4a and 4b undergoing deflection;
Fig. 5 shows an exploded isometric view of a cooled channel component in accordance with another embodiment;
Fig. 6 shows a side elevation view of three of the cooled channel component of figs. la and lb installed in an enclosure wall;
Fig. 7a shows an isometric view of a cooled channel component in accordance with another embodiment with a simplified assembly;
Fig. 7b shows an exploded isometric view of the cooled channel component of fig. 7a, the cooled channel component having a base component comprising internal channels and a seal plate;
Fig. 7c shows a cross-sectional view of the cooled channel component of figs.
7a and 7b;
Figs. 8a and 8b show top views of the base component of the cooled channel component of fig. 7b showing the structure of the internal channels of the base component;
Fig. 9 shows a top view of the seal plate of the cooled channel component of figs. 7a and 7b;
Figs. 10a, 10b and 10c show bottom, side elevation and top views of the guide components of the cooled channel components of figs 7a and 7b, respectively;
Fig. 11 shows an exploded side elevation view of the cooled channel component of figs. 7a and 7b attached to a supporting structure;
Fig. 12a shows an isometric view of a cooled channel component with a plastic seal plate in accordance with another embodiment;

Fig. 12b shows an exploded isometric view of the cooled channel component of fig.
12a;
Fig. 12c shows a side elevation view of the cooled channel component of figs.
12a and 12b;
Fig. 12d shows a cross-sectional view of the cooled channel component of figs.
12a, 12b and 12c;
Figs 13a, 13b and 13c show bottom, side elevation and top views of the seal plate of the cooled channel component of figs. 12a, 12b and 12c, respectively;
Fig. 14a shows an isometric view of a cooled channel component with rifled internal channels and comprising a base component and a flow director and two lid plates in accordance with another embodiment;
Fig. 14b shows an exploded isometric view of the cooled channel component of fig.
14a;
Fig. 14c shows a cross-sectional view of the cooled channel component of figs.
14a and 14b;
Fig. 15 shows a bottom view of the base component of the cooled channel component of figs. 14a, 14b and 14c;
Figs. 16a, 16b and 16c show bottom, side elevation and top views of the flow director of the cooled channel component of figs. 14a, 14b and 14c, respectively;
Fig. 17 shows a top view of a guide component of the cooled channel component of figs. 14a, 14b and 14c;
Fig. 18a shows an isometric view off a cooled channel component that comprises a base component comprising an extrusion with integrated channels in accordance with another embodiment;
Fig. 18b shows an exploded isometric view of the cooled channel component of fig.
18a;

Fig. 18c shows a cross-sectional view of the cooled channel component of figs.
18a and 18b;
Figs. 19a, 19b and 19c show top cutaway, side elevation and isometric views of a manifold of the cooled channel component of figs 18a, 18b and 18c in accordance with one embodiment;
Fig. 20 shows a dimensioned profile view of the extrusion of the cooled channel component of figs. 18a, b and c;
Fig. 21a shows an isometric view of a cooled channel component comprising a base component, a multi-port extrusion (MPE), a first manifold and a second manifold in accordance with another embodiment;
Fig. 21b shows an exploded isometric view of the cooled channel component of fig.
21a;
Fig. 22a shows a side elevation view of the MPE of the cooled channel component of figs. 21a and 21b;
Fig. 22b shows a top view of the MPE and manifolds assembly of the cooled channel component of figs. 21a and b;
Fig. 22c shows a side elevation view of the base component of the cooled channel component of figs. 21a and 21b;
Fig. 22d shows an isometric view of the manifold of the cooled channel component of figs. 21a and 21b;
Figs. 23a and b show side elevation views of a cooled channel component in accordance with another embodiment;
Figs. 24a and b show side elevation views of a cooled channel comprising a base component and a MPE in accordance with another embodiment;
Fig. 24c shows top and cutaway views cutaway view along the A-A axis of the base component of figs. 24a and 24b;

Fig. 25a shows an isometric view of a cooled channel component in accordance with another embodiment;
Fig. 25b shows an exploded isometric view of the cooled channel component of fig.
25a;
Fig. 25c and 25d show cross sectional side elevation views of the cooled channel component of figs. 24a and b showing the configuration of the internal channels;
Figs. 26a, 26b and 26c show bottom, side elevation and top views of the middle component of the cooled channel component of figs. 25a, 25b and 25c, respectively;
Figs. 27a and 27b show the cooled channel component of figs. 25a, 25b and 25c in use and being clamped around by a receiving channel in a computer server; and Figs. 28a, 28b, 28c 28d and 28e show cutaway views of alternate channel configurations.
DESCRIPTION
[053] It is intended that the following description and claims should be interpreted in accordance with Webster's Third New International Dictionary, Unabridged unless otherwise indicated.
[054] Previous work by this inventor disclosed in patent cooperation treaty application no.
WO/2016/004528, titled "Robust Redundant-Capable Leak-Resistant Cooled Enclosure Wall", the content of which is incorporated herein by reference in its entirety, describes an enclosure wall comprising a plurality of channels configured to receive a rail of installed equipment, each channel having a corresponding coolant guide arranged on a surface of a face component.
[055] The present disclosure relates to cooled channel components that can be used to build an enclosure wall comprising a plurality of channels configured to receive a rail of installed equipment. Described are cooled channel components that are configured to receive a rail of installed equipment and when installed individually or as part of a group can be used to build an enclosure wall similar to the one described in the WO/2016/004528 patent application.
[056] With reference to Figs. la, lb and 2, a cooled channel component 100 in accordance with a first non-limiting embodiment is shown. The cooled channel component 100 comprises a base component 110, a flow director 130 and two lid plates 160.
[057] In this embodiment, the base component 110 comprises a generally u-shaped channel 112 configured to receive a rail thermal connector. As shown in Fig. la, an external surface 116 of the base component 110 is in direct contact with the flow director 130.
A cooled surface 114 of the generally u-shaped channel 112 may be defined as a surface of the generally u-shaped channel 112 that is in the closest proximity of the external surface 116.
The cooled surface 114 may be any other surface in other embodiments. While the cooled surface 114 is generally planar in this embodiment, the cooled surface 114 may have any other suitable configuration in other embodiments (e.g., non-planar). Also, the generally u-shaped channel 112 may have any other configuration in other embodiments (e.g., the channel 112 may have any other suitable shape). The base component 110 may further comprise a positioning feature 120 configured to receive a portion of the flow director 130 to facilitate positioning of the flow director 130 during assembly. In this embodiment, the positioning feature 120 is a recess in the base component 110 generally extending along a longitudinal direction of the base component 110 and configured to engage a correspondingly shaped portion of the flow director 130. In other embodiments, the positioning feature 120 may be a recess or a protrusion of any shape to facilitate positioning of the flow director 130 during assembly. The base component 110 may further comprise attachment points, such as a threaded hole 106 to attach the cooled channel component 100 to a support, as further described below.
[058] With further reference to Figs. 3a to 3e, in this non-limiting first embodiment, the flow director 130 comprises a first flow path 131 and a second flow path 141, the first flow path 131 comprising a first inlet 132, a first outlet 133 and a plurality of first internal channels 134, the second flow path 141 comprising a second inlet 142, a second outlet 143 and a plurality of second internal channels 144. The first inlet 132 and second inlet 142 are in an upper portion of the flow director 130 (see e.g. fig. 3a) while the plurality of first internal channels 134 and second internal channels 144 are in a lower portion of the flow director 130 (see e.g. fig. 3c).
In this embodiment, the plurality of first and second internal channels 134 and 144 have a serpentine configuration and are substantially parallel to each other along a width of the flow director 130, the plurality of first and second internal channels 134 and 144 being configured such that the plurality of first and second internal channels 134 and 144 alternate along the widthwise direction of the flow director 130. In other embodiments, the first and second internal channels 134 and 144 as well as the first outlet 133 and second outlet 143 may have any other suitable configuration.
[059] In this first embodiment, an approximately equal flow of coolant is being directed along each one of the plurality of first internal channels 134 and each one of the plurality of second internal channels 144. The flow director 130 further comprises a plurality of fins 152 which transport heat from the base component 110 and increase the surface area available to communicate heat into the coolant.
[060] The number of first and second internal channels 134 and 144 is equal such that an approximately equal flow of coolant is being directed along the plurality of first internal channels 134 and along the plurality of second internal channels 144. The number of first and second internal channels 134 and 144 may be different in other non-limiting embodiments.
[061] The lid plates 160 are configured for interfitting engagement with the flow director 130 such that the inlet passages 136 and 146 are sealed save for the first and second inlets 132 and 142 and apertures 138 and 148.
[062] With further reference to Figs. 3a to 3e, when the cooled channel component 100 is assembled, coolant entering the flow director 130 at first inlet 132 is guided along the first inlet passage 136 until it reaches apertures 138 which connect into the lower section of the flow director 130 comprising the plurality of first internal channels 134 and outlet 133. The coolant is then guided along the plurality of first internal channels 134 until exiting the flow director 130 at outlet 133. Coolant entering inlet 142 follows a similar pathway along the second flow path 141, being guided along the second inlet passage 146 until it reaches apertures 148 which connect into the lower section of the flow director 130 comprising the plurality of second internal channels 144 and outlet 143, the coolant being then guided along the plurality of second internal channels 134 until exiting the flow director 130 at outlet 143, flowing in a direction generally opposite to a direction of coolant flowing along the first flow path 131. When assembled, coolant flowing along the first flow path 131 and the second flow path 141 do not mix, that is there is no fluid connection between the first flow path 131 and the second flow path 141.
[063] As a result of the first flow path 131 and second flow path 141 having substantially similar configurations and substantially similar heat paths to the cooled surface 114, each one of the flow paths 131 or 141 exhibits a substantially similar cooling capacity. This may in turn enable an active-active type redundancy of the cooled channel component 100, the cooled channel component 100 configured to cool the cooled surface 114 with only a single one of the first and second flow paths 131, 141 having coolant flow. In other non-limiting embodiments, the cooled channel component 100 may not exhibit an active-active type redundancy and may comprise a single flow path or any other suitable number of flow paths.
For example a cooled channel component 100 may comprise a single flow path comprising a single inlet and a single outlet.
[064] In this first embodiment, enabling an active-active form of redundancy may enable supplying the cooled channel component 100 with two or more distinct cooling systems.
Because the cooled channel component 100 of the present embodiment can provide cooling to an attached rail theinial connector with coolant flowing through only one of the first and second flow paths 131, 141, the cooled channel component may continue cooling during failure of one supplying coolant system or allow a coolant system to be shut down for maintenance without interrupting the cooling of an attached rail thermal connector.
[065] Also, having coolant flow through the first and second flow paths 131 and 141 in an opposite direction may allow heat to be more evenly removed from the cooled channel component 100 when coolant is flowing through both the first and second flow paths 131 and 141.
[066] The serpentine configuration of the first and second internal channels 134 and 144 may disrupt laminar flow through the internal channels 134 or 144 and generally improve heat transfer between coolant flowing through flow path 131 or 141 and the cooled channel component 100.
[067] In this first embodiment, the cooled channel component 100 may be configured to prevent air entrapment. Specifically, when the cooled surface 114 is substantially horizontal and the flow director 130 is positioned below the base component 110, air introduced at either one of inlet 132 or 142 flows naturally through the appropriate flow path 131 or 141 and exits at either one outlet 133 or 143.
[068] The flow director 130 may further comprise other features to facilitate assembly of the cooled channel component 100. This may include a projection 154 at the second outlet 143 (or a projection 155 at the first outlet 133) configured to be received by the positioning feature 120 of the base component 110. Specifically, the projection 154 is configured to engage with the positioning feature 120 which generally facilitates the alignment of the flow director 130 with the base component 110. Additional alignment may be provided by allowing the lip of an outlet, such as the first outlet 133 to rest against the surface 118 of base component 110. In this way accurate assembly may be simplified with minimal additional features.
In other embodiments, any other means to facilitate assembly of the cooled channel component 100 and/or positioning of the flow director 130 relative to the base component 110 may be used.
[069] In this first non-limiting embodiment, the cooled channel component 100 is made of and manufactured from aluminum. For example, the base component 110 may be manufactured as an aluminum extrusion which is then machined or otherwise modified to provide the attachment points 106 and the positioning feature 120. The flow director 130 may be manufactured using a process suitable for brazing or soldering. The flow director 130 may be designed to be suitable for high vacuum diecasting, however other processes may also be used such as but not limited to diecasting, low or high pressure diecasting, vacuum assisted diecasting, rapid-fill vacuum assisted diecasting, investment casting, permanent mold casting, plaster casting, sand casting, graphite mold casting, machining and the likes.
The lid plates 160 may be made of aluminum and manufactured from sheet aluminum by laser, plasma, water-jet cutting, stamping or any another suitable method. The cooled channel component 100 may be assembled and brazed, soldered or welded in such a way that all the joints are sealed leaving openings only at the inlets 132 and 142 and the outlets 133 and 143 while preventing any substantial fluid connection between the first flow path 131 and the second flow path 141. This may be achieved by selecting suitable manufacturing processes and tolerances and ensuring that the mating surfaces (i.e., surfaces of the base component 110, the flow director 130 and the lid plates 160) are substantially planar or otherwise suitably aligned for joining.
[070] In other non-limiting embodiments, the cooled channel component 100 may be made of other materials such as but not limited to thermally conductive metals, themially conductive plastics, plastics and the likes. The cooled channel component 100 may also be manufactured using other suitable manufacturing methods such as but not limited to forging, casting, machining, sintering, additive manufacturing and the likes. With further reference to fig. 5, another embodiment of the cooled channel component 100 where the flow director 130 is machined from aluminum is shown.
[071] In this first embodiment, the external surface 116 of the base component 110 to which the flow director 130 is connected is substantially planar. In other non-limiting embodiments, for example if an alternate manufacturing method other than extrusion is used to manufacture the base component 110 or if an additional material is used, the external surface 116 may be modified with the addition of fins, pins, or other features which generally project inside an inner portion of the first and second internal channels 134 and 144, further increasing the surface area available for heat transfer. Other features such as recesses which receive fins 152 and improve the joining of the flow director 130 and the base component 110 may also be present in other embodiments. In yet further embodiments, the external surface 116 of the base component 110 may be non-planar.
[072] A corrosion resistance of the cooled channel component 100 may be improved by anodizing the assembled cooled channel component 100 and performing a sealing process using, for example, polytetrafluoroethylene (PTFE), boiling water, nickel fluoride, nickel acetate, potassium dichromate and the likes. Alternatively, the sealing process described in U.S. patent No. 4,549,910 or any other suitable sealing process may be used.
[073] Heat transfer between two surfaces may be improved by pressing the two surfaces together with an increased force, with benefits in terms of heat transfer being gained by pressing together the surfaces with forces as small as 69kPa to over 690kPa.
Fig. 4a shows a side elevation view of a rail thermal connector 170 in position to be cooled by the cooled channel component 100 (flow director 130 and lid plates 160 not shown). A
surface 172 of the rail thermal connector 170 is in contact with the cooled surface 114 of the cooled channel componentl 1 100. When installed, a bracing force F acting between the arms of the u-channel 112 may be used to urge the surface 172 of the rail thermal connector 170 against the cooled surface 114 without causing significant structural deflections within the larger structure that the cooled channel component 100 is installed in, preferably with each arm deflecting in such a way that the cooled channel component 100 does not deflect into a space between the support 180 and the base component 110 so far as to come in contact with the support 180 outside of the point of attachment of the cooled channel component 100 to the support 180.
With further reference to fig. 4c, the deflection of each arm of the u-channel 112 is defined to be a distance d measured from the point pi which lies on the extremity of an arm when the respective arm undergoes no deflection to the point p2 when the respective arm of the u-channel 112 undergoes deflection. For u-channels 112 having dimensions similar to the dimensions described below, that may be less than 1.5mm of deflection in each arm, in some cases less than lmm, in some cases less than 0.5mm, in some cases less than 0.25mm, in some cases less than 0.1mm and in some cases even less.
[074] For other u-channels 112 having different dimensions, the deflection in each arm may be normalized by a width d3 of the arms. In this case, the normalized deflection may be less than 0.0375, in some cases less than 0.025, in some cases less than 0.0125, in some cases less than 0.006, in some cases less than 0.003 and in some cases even less.
[075] Alternatively, the deflection may be characterized in terms of an angle 0 of each arm relative to the centerline, each one of the arms of the u-channel 112 being at an angle 0 = 00 when respective arms of the u-channel 112 undergo no deflection. For the u-channel 112, 0 may be less than 2.2 , in some cases less than 1.4 , in some cases less than 0.36 , in some cases less than 0.15 and in some cases even less.
[076] With further reference to fig. 4b, a base component 100 having dimensions: d1=17mm, d2=7.2mm, d3=40mm, d4=7.2mm and a total length of 710mm is shown. Using aluminum 6061 with a T6 temper and having a tensile strength of approximately 262 MPa and a yield strength of approximately 241 MPa as material of the base component 100. FEA
predicted deflections for the base component 100 of fig. 4a show that for a pressure P
equally applied along the length of the extrusion to the u-channel internal arm surfaces 114 and 115 of approximately 355 kPa each arm of the u-channel 112 was shown to deflect by no more than approximately 0.1mm (i.e., 0.2mm total deflection).
[077] The amount of pressure that can be supported by the cooled channel component 100 is dependent at least upon the dimensions and the material of the base component 110.
Therefore, in other non-limiting embodiments, other operable ranges of deflection within a range of operable pressures are possible. As non-limiting examples, the base component 110 being the same, increasing the dimensions of the cooled channel component 100 of Fig. 4b d2 and d4 by 50% and increasing the pressure such that P=710kPa, FEA predicted deflections show an estimated deflection of 0.09mm per arm. Furthermore, increasing the pressure such that P=710kPa, FEA predicted deflections show an estimated deflection of no more than approximately 0.25mm per arm. Therefore by varying dimensions, materials and tolerances, for example substituting steel, titanium or another metal or composite material for aluminum, a large range of pressure (e.g., between 5 kPa and 900 kPa, in some cases between 50kPa and 700 kPA, in some cases between 100kPa and 500 kPa and in some cases between 200kPa and 350 kPa) and deflections may be accommodated by the cooled channel components described in the present disclosure.
[078] In order to prevent the deflection experienced by the arms of the base component 110 from causing significant structural deflections within the larger structure that the cooled channel component 100 is installed in, a gap may be provided between the support 180 and the base component 110. The gap may allow the base component 110 to deform without contacting the support 180 beyond the point of attachment to the support 180, thus reducing the force being transmitted to the support 180. In one non-limiting embodiment, the gap may be created by positioning a washer 182 between the support 180 and the base component 110.
In other embodiments, a boss or any other similar feature may be introduced in the base component 110, as further described below. The base component 110 may be fastened to the support 180 by a fastener such as screw 184 which is fastened to the attachment point 106.
The base component may be connected to the support 180 by any suitable mean in other embodiments.
[079] For a cooled channel component 100 with a base component 110 having dimensions as described above and a flow director 130 having a length of 687mm and with approximate dimensions (see e.g. Fig. 3e): D1=5mm, D2=4.6mm, D3=38mm, D4=1.6mm the table below provides computational fluid dynamics (CFD) estimated performance for a water based coolant flowing separately through both the first flow path 131 and the second flow path 141 with an inlet temperature of 30 C. The cooled surface section is defined to be the full width of the cooled surface 114 that stops 20mm from either longitudinal end of the base component 110, giving a total dimension of 670mm x 40mm and a total cooling surface of 268cm2 or 0.0268m2. Other dimensions of the base component 110 and the flow director 130 are possible in other embodiments. For example, the width d3 of the arms of the u-channel 112 of the base component 110 may be between 90mm and 5mm, in some cases between 80mm and lOmm, in some cases between 70mm and 20mm and in some cases between 60mm and 30mm.
The remaining dimensions of the base component may then be selected to ensure that the cooled channel component provides sufficient cooling for at least 0.25kW of power per cooled channel component, in some cases at least 0.5kW of power per cooled channel component, in some cases at least lkW of power per cooled channel component, in some cases at least 2kW
of power and in some cases even more.
[080] The table headings are as follows:
InVel ¨ Inlet velocity (m/s) of coolant as measured at inlet 132 and 142.
CSurfavg ¨ Average temperature ( C) of cooled surface section as defined above.
Velavg ¨ Average velocity (m/s) of coolant flowing through flow path 131 and 141.
Flux ¨ Heat Flux evenly applied to cooled surface 114 section as defined above.
FluxPer10 ¨ Heat Power applied (W) per 10cm length of cooled surface section.
OutTemp ¨ Max coolant temperature ( C) as measured at outlet 133 or 143.
Drop ¨ Coolant pressure (bulk) drop (kPa) between inlet 132 or 142 and outlet 133 or 143.

InVel CSurfavg Velavg Flux FluxPer10 (W) OutTemp Drop (kPa) (m/s) ( C) (m/s) (W/m2) ( C) 1.25 54 2.8 187,500 750 34 27 1.25 42 2.8 93,750 375 32 27 1 57 2.3 187,500 750 35 19 1 44 2.3 93,750 375 32 19 0.75 61 1.6 187,500 750 36 13 0.75 46 1.6 93,750 375 33 13 0.5 65 1.2 187,500 750 39 9 0,5 49 1.2 93,750 375 35 9 0.5 44 1.2 75,000 300 34 9 0.5 43 1.2 67,500 270 33 9 0.5 41 1.2 60,000 240 33 9
[081] For a water based coolant flowing through each of the first flow path and second flow paths at a rate of 1.25m/s and having an inlet temperature of 30 C, the cooled surface 114 temperature reaches approximately 54 C when cooling 750W of heat applied to the cooled surface 114 per 10 cm length of cooled surface 114 (i.e., a heat flux applied to the cooled surface 114 of 187.5kW/m2), with a coolant outlet temperature of approximately 34 C and a pressure drop of 27kPa. Accordingly, the cooled channel component 100 may provide a heat flux of at least 10,000W/m2, is some cases at least 50,000W/m2, in some cases at least 75,000W/m2, in some cases at least 100,000W/m2, in some cases at least 150,000W/m2, in some cases at least 175,000 W/m2 and in some cases even more for a water based coolant.
[082] The table below provides computational fluid dynamics (CFD) estimated performance for a water based coolant flowing through only the first flow path 131 with an inlet temperature of 30 C.

InVel (m/s) CSurtvg ( C) Velavg (m/s) Flux (W/m2) FluxPeri OutTemp ( C) Drop (kPa) (W) 1.25 67 2.8 187,500 750 38 27 1.25 50 2.8 93,750 375 34 27 1 72 2.3 187,500 750 40 19 1 52 2.3 93,750 375 35 19 0.75 78 1.6 187,500 750 43 13 0.75 55 1.6 93,750 375 36 13 0.5 86 1.2 187,500 750 49 9 , 0,5 58 1.2 93,750 375 40 9 0.5 53 1.2 75,000 300 38 9 0.5 51 1.2 67,500 270 37 9 0.5 48 1.2 60,000 240 36.2 9
[083] While the results above are given for a water-based coolant, non water-based coolants may also be used in other embodiments such as, but not limited to, a glycol-based coolant, glycol, CO2, NH3, a coolant such as sold under the trade names Novec or Fluorinet by 3M, headquartered in Maplewood, Minnesota or any other suitable coolant. For non water-based coolants (e.g., exhibiting phase change), the cooled channel component 100 may provide a heat flux at least 2 times, in some cases at least 5 times, in some cases at least 10 times and in some cases even more that of the heat flux for a water based coolant as shown above.
[084] With further reference to fig. 6, three cooled channel components 100 fixed to supports 180 as might be found in an enclosure wall are shown, the cooled channel components 100 being installed in their operating orientation with the flow director 130 being below the cooled surface 114. As can be observed there are spaces between adjacent cooled channel component 100. These spaces and the gaps between supports 180 and the base component 110 allow each one of the cooled channel component 100 to be mechanically independent of the other cooled channel components 100. That is each cooled channel component 100 being capable of deforming without the deformations significantly affecting other cooled channel components 100 installed in the enclosure wall.
[085] In another non-limiting embodiment, the cooled channel component 100 may comprise two flow directors 130, each flow director 130 being fixed to an arm of the cooled channel component such that each one of the two arm of the u-channel 112 comprises a cooled surface 114.
[086] With further reference to figs. 7a, b and c, a second non-limiting embodiment of the cooled channel component is shown. The cooled channel component 200 comprises a base component 210, a seal plate 290 and two guide components 260. When assembled coolant flows through the cooled channel component 200 in a manner similar to that of the cooled channel component 100.
[087] With further reference to figs. 8a and 8b, the base component 210 comprises a generally u-shaped channel 212 having a cooled surface 214 configured to receive a rail thermal connector and, the arm of the generally u-shaped channel 212 comprising the cooled surface 214 further comprising a plurality of channels, the plurality of channels containing sections of a first flow path 231 and a second flow path 241. A seal plate 290 and two guide components 260 are configured to be fitted onto the base component 210 such that the first flow path 231 comprises a first inlet 232, a first outlet 233 and a plurality of first internal channels 234 and second flow path 241 comprises a second inlet 242, a second outlet 243 and a plurality of second internal channels 244. The first and second internal channels 234 and 244 have a serpentine configuration and are substantially parallel to each other along a width of the base component 210, the plurality of first and second internal channels 234 and 244 being configured such that the plurality of first and second internal channels 234 and 244 channels alternate along the widthwise direction of the base component 210. In other embodiments, the first and second internal channels 234 and 244 may have any other suitable configuration. While the cooled surface 214 is generally planar in this embodiment, the cooled surface 214 may have any other suitable configuration in other embodiments (e.g., non-planar). Also, the generally u-shaped channel 212 may have any other configuration in other embodiments (e.g., the channel 212 may have any other suitable shape).
[088] In this embodiment, an approximately equal flow of coolant is being directed along each one of the plurality of first internal channels 234 and each one of the plurality of second internal channels 244. The number of first and second internal channels 234 and 244 is equal such that an approximately equal flow of coolant is being directed along the plurality of first internal channels 234 and along the plurality of second internal channels 244.
The number of first and second internal channels 234 and 244 may be different in other non-limiting embodiments.
[089] In this embodiment, the plurality of first and second internal channels 234 and 244 are directly integrated into the base component 210 such that there is no need for a separate flow director 130 which simplifies manufacturing by reducing the complexity of the components attached to the base component 210. Also, the flow of coolant occurs closer from the cooled surface 214 when compared to the first embodiment, thereby minimizing the path that heat must travel.
[090] The cooled channel component 200 may be made of and manufactured from aluminum. The base component 210 may be manufactured using a process suitable for brazing, soldering or welding such as a casting or forging and processes such as high-vacuum diecasting or precision forging may produce a component that has a reduced need for subsequent machining or other operations. Other processes such as but not limited to diecasting, low or high pressure diecasting, vacuum assisted diecasting, rapid-fill vacuum assisted diecasting, investment casting, permanent mold casting, plaster casting, sand casting, graphite mold casting, machining, sintering or additive fabrication may also be used.
[091] With further reference to fig. 9, the seal plate 290 may be manufactured from sheet aluminum by laser, plasma or water-jet cutting, stamping or any other suitable fottning or cutting method. Compared to the flow director 130 of the first embodiment, the seal plate 290 is a simpler part. The seal plate 290 fits into a recess 219 within the base component 210. The seal plate 290 may further comprise apertures 292 cut into the seal plate 290 to facilitate alignment of the seal plate 290 with the base component 210 and generally facilitate assembly of the cooled channel component 200. The seal plate 290 may also comprise apertures 238 and 248 which allow coolant flowing within guide components 260 to communicate with the channels located within base component 210.
[092] In some embodiments, the seal plate 290 may also be manufactured from a clad aluminium sheet that has cladding suitable for brazing, reducing or removing the need for additional brazing filler material during joining.
[093] With further reference to figs. 10a, 10b and 10c, the guide components 260 may be made of aluminum and manufactured by using a sheet metal forming process such as stamping, hydro-forming, superplastic forming or another suitable process. The guide components 260 provide the inlets 232 and 242 and guide coolant from each inlet 232 and 242 to the appropriate apertures 238 and 248 in the seal plate 290. The guide components 260 may further comprise keys 262 for interfitting engagement with the apertures 292 cut into the seal plate 290 to provide positional alignment.
[094] The cooled channel component 200 may be assembled and brazed, soldered or welded in such a way that all the joints may be sealed leaving openings only at inlets 232 and 242 and outlets 233 and 243 and preventing any substantial fluid connection between the first flow path 231 and the second flow path 241. This may be achieved by selecting suitable manufacturing processes and tolerances and ensuring that the mating surfaces (i.e, surfaces of the base component 210, the seal plate 290 and the guide components 260) are substantially planar or otherwise suitably aligned for joining.
[095] A corrosion resistance of the cooled channel component 200 may be improved by anodizing the assembled cooled channel component 200 and sealing it using a sealing process using, for example, PTFE, boiling water, nickel fluoride, nickel acetate, potassium dichromate and the likes. Alternatively, the sealing process described in U.S. Patent No.
4,549,910 or any other suitable sealing process may be used.
[096] In other non-limiting embodiments, the cooled channel component 200 may be made of aluminum or other alternative materials such as but not limited to thermally conductive metals, thermally conductive plastics and plastics. The cooled channel component 200 may also be manufactured using methods such as but not limited to forging, casting, machining, sintering or any other suitable manufacturing process.
[097] With further reference to fig. 11, the base component 210 may further comprise a boss 282 which performs the same spacing function as the washer 182 described in connection with the first embodiment above. Any other spacer may be used in other embodiments. In place of the threaded attachment point 106 the base component 210 may also further comprise a threaded shaft 206 or a shaft configured to receive a push nut, a retaining ring and the likes.
In this embodiment, the cooled channel component 200 is connected to the support 280 via the use of a nut 284, a belleville washer 286 and a washer 288. The cooled channel component 200 may be connected to the support 280 in any other suitable manner in other embodiments.
[098] For a cooled channel component 200 as described and with a base component 210 having dimensions d1=17mm, d2=7.2mm, d3=40mm, d4=7.2mm, D1=4.2mm, D2=4mm and a total length of 710mm, the table below provides CFD estimated performance for a water based coolant flowing separately through both the first flow path 231 and second flow path 241 with an inlet temperature of 30 C. As shown below, the cooled channel component 200 may provide a heat flux of at least 10,000W/m2, is some cases at least 50,000W/m2, in some cases at least 75,000W/m2, in some cases at least 100,000W/m2, in some cases at least 150,000W/m2, in some cases at least 175,000 W/m2 and in some cases even more for a water based coolant.

InVel (m/s) CSurfavg ( C) Velavg (m/s) Flux (W/m2) FluxPer10 OutTemp ( C) Drop (kPa) (W) 1.25 40 4.5 187,500 750 32 65 1.25 35 4.5 93,750 375 31 65 1 42 3.3 187,500 750 33 43 1 36 3.3 93,750 375 32 43 0.75 44 2.6 187,500 750 34 25 0.75 37 2.6 93,750 375 32 25 0.5 49 1.8 187,500 750 36 13 0,5 39 1.8 93,750 375 33 13 _ 0.5 37 1.8 75,000 300 33 13 0.5 37 1.8 67,500 270 32 13 0.5 36 1.8 60,000 240 32 13
[099] The table below provides computational fluid dynamics (CFD) estimated performance for a water based coolant flowing through only the first flow path 131 with an inlet temperature of 30 C.

InVel (m/s) CSurfavg ( C) Velavg (m/s) Flux (W/m2) FluxPer10 OutTemp ( C) Drop (kPa) (W) 1.25 45 4.5 187,500 750 35 65 ' 1.25 37 4.5 93,750 375 33 65 1 47 3.3 187,500 750 36 43 1 39 3.3 93,750 375 33 43 0.75 50 2.6 187,500 750 38 25 0.75 40 2.6 93,750 375 34 25 0.5 58 1.8 187,500 750 43 13 0,5 44 1.8 93,750 375 36 13 0.5 41 1.8 75,000 300 35 13 0.5 40 1.8 67,500 270 35 13 0.5 39 1.8 60,000 240 34 13
[0100] With further reference to figs.12a, 12b, 12c and 12d, a third non-limiting embodiment of the cooled channel component is shown. The cooled channel component 300 comprises a base component 310, a seal plate 390 and two guide components 360. When assembled coolant flow through cooled channel component 300 is similar to coolant flow through the cooled channel components 100 and 200.
[0101] The base component 300 may be similar to the base component 200 described above and comprisie a generally u-shaped channel 312 configured to receive a rail thermal connector and having channels located within the at least one of the arms comprising cooled surface 314 of the u-channel 312 containing sections of a first flow path and a second flow path. The seal plate 390 and the two guide components 360 may be configured to be fitted onto the base component 310 such that the first flow path comprises a first inlet 332, a first outlet 333 and a plurality of first internal channels 334 and the second flow path comprises a second inlet 342, a second outlet 343 and a plurality of second internal channels 344. The plurality of first and second internal channels 334 and 344 have a serpentine configuration and are substantially parallel to each other along a width of the base component 310, the plurality of first and second internal channels being configured such that the plurality of first and second internal channels 334 and 344 alternate along the widthwise direction of the base component 310. In other embodiments, the first and second internal channels 334 and 344 may have any other suitable configuration. While the cooled surface 314 is generally planar in this embodiment, the cooled surface 314 may have any other suitable configuration in other embodiments (e.g., non-planar). Also, the generally u-shaped channel 312 may have any other configuration in other embodiments (e.g., the channel 312 may have any other suitable shape).
[0102] In this non-limiting embodiment, the seal plate 390 and guide components 360 may be made of plastic such as but not limited to ABS, PVC, Nylon or any injection moldable or thermoset plastic including filled plastics, composites and the likes. The seal plate 390 and the guide components 360 may be manufactured using injection molding or other any other suitable manufacturing process. The cooled channel component 300 may be assembled by joining the base component 310, the seal plate 390 and the guide components 360 using an adhesive, a brazing process or any other suitable process.
[0103] With further reference to figs. 13a, 13b and 13c, the seal plate 390 may comprise features to improve and/or facilitate the adhesion of the seal plate 390 to the base component 310. The seal plate 390 may comprise a plurality of recesses 394 configured to receive the fins 352 of base component 310. This technique may also be applied to other cooled channel components described herein joined by other means such as brazing or welding.
[0104] As the seal plate 390 may be plastic injection molded, a number of structural features may be implemented on the seal plate 390 to simplify the corresponding structural features of the guide component 360. In a non-limiting example, the guide component 360 may be a sheet of plastic received by a ledge or recess in the walls of the first inlet passage 336 or the second inlet passage 346. Any other suitable configuration of the guide component 360 and the seal plate 390 may be possible in other embodiments.
[0105] The seal plate 390 may be joined to the base component 310 using an adhesive. A
suitable adhesive may be Loctite UK U-05F or any suitable adhesive capable of withstanding immersion within the intended coolant and retaining adequate strength over the life of the component. To improve adhesion, the areas of the base component 310 to be contacted to by the adhesive may be abraded, either mechanically or by an acid etch.
[0106] The aluminum base component 310 may have its corrosion resistance improved by anodization. In some embodiments, the aluminum base component 310 may be anodized prior to joining the seal plate 390 to the base component 310. The areas of the base component 310 to be contacted with the adhesive may then be abraded as disclosed above. The base component 310 and the seal plate 390 may then be joined using adhesive. The assembled cooled channel component 300 may then be sealed using, for example, P1'1-E, boiling water, nickel fluoride, nickel acetate, potassium dichromate and the likes.
Alternatively, the sealing process described in U.S. Patent No. 4,549,910 or any other suitable sealing process may be used. In other embodiments, the cooled channel component 300 may be assembled prior to the anodization step.
[0107] With further reference to figs. 14a, 14b and 14c, a fourth non-limiting embodiment of the cooled channel component is shown. The cooled channel component 400 comprises a base component 410, a flow director 430 and two guide components 460. When assembled coolant flow through cooled channel component 400 is similar to coolant flow through the previously described cooled channel components 100, 200 and 300.
[0108] The base component 410 comprises a generally u-shaped channel 412 configured to receive a rail thennal connector and having channels located within at least one of the arms of the generally u-shaped channel 412 comprising a cooled surface 414. The cooled surface 414 of the u-channel 412 comprises sections of a first flow path 431 and a second flow path 441.
A flow director 430 and two guide components 460 are configured to be fitted onto to the base component 410 such that the first flow path 431 comprises a first inlet 432, a first outlet 433 and a plurality of first internal channels 434 and the second flow path comprises a second inlet 442, a second outlet 443 and a plurality of second internal channels 444. The plurality of first and second internal channels 434 and 444 may be generally cylindrical. In some non-limiting embodiments, the generally cylindrical channels may have a rifling or helical geometry. The plurality of first and second internal channels 434 and 444 are generally parallel to each other along the width of the base component 410, the plurality of first and second internal channels 434 and 144 being configured such that the plurality of first and second internal channels 434 and 444 alternate along the widthwise direction of the flow director 430. In other embodiments, the first and second internal channels 434 and 444 may have any other suitable configuration. While the cooled surface 414 is generally planar in this embodiment, the cooled surface 414 may have any other suitable configuration in other embodiments (e.g., non-planar). Also, the generally u-shaped channel 412 may have any other configuration in other embodiments (e.g., the channel 412 may have any other suitable shape).
[0109] The rifling or helical geometry of the plurality of cylindrical first internal channels 434 and second internal channels 444 may improve the heat transferred between the liquid coolant flowing through the first flow path 431 and second flow path 432 and the base component 410.
[0110] With further reference to fig. 15, the base component 410 may have a recess 419 configured for interfitting engagement with the flow director 430. In this non-limiting embodiment, the base component 410 comprises the features of one-half of the geometry of the internal channels 434 and 444 and the outlets 433 and 443 with the flow director 430 comprising the features of the opposing half of the geometry of the internal channels 434 and 444 and the outlets 433 and 443 such that when the base component 410 and flow director 430 are joined the features of each opposing half align to create the internal channels 434 and 444, and outlets 433 and 433 that comprise the first and second flow paths 431 and 432.
[0111] With further reference to figs. 16a, 16b, 16c and 17, the flow director 430 is shown. In addition to comprising the features of the opposing halves of the internal channels 434 and 444 and outlet 433 and 443 the flow director 430 also comprises half of the first inlet passage 436 and the second inlet passage 446, the opposing half of the first inlet passage 436 and the second inlet passage 446 being a part of the guide components 460, one of which is shown in figure 17. Flow director 430 also contains apertures 438 and 448 which allow coolant to flow from inlet passages 436 and 446 to the internal channels 434 and 444.
[0112] In this embodiment, the base component 410 may be made of and manufactured from aluminum, however other materials such as thermally conductive plastics and other thermally conductive metals and composites may be used. The flow director 430 and guide components may be manufactured from either aluminum or plastic and may be joined to base component 410 via a brazing, soldering or welding step or an adhesive as described above. Subsequently the part may optionally be anodized in a manner similar to that described above. A brazing filler material may be applied via cold gas spraying or any other suitable thermal spray process when the parts are brazed as notably disclosed in "Thermally Sprayed Solder/Braze Filler Alloys for the Joining of Light Metals" by B. Wielage, A. Wank, Th.
Grund.
[0113] In the following example, the cooled surface section is defined to be the full width of the cooled surface that stops 20mm from either end of the base component, in this case giving a total dimension of 560mm x 40mm.
[0114] For a cooled channel component 400 as described and having dimensions d1=17mm, d2=7.5mm, d3=41mm, d4=7.5mm, D1=5mm and a total length of 600mm the table below provides CFD estimated performance for a water based coolant flowing separately through both the first flow path 431 and second flow path 441 with an inlet temperature of 30 C. As shown below, the cooled channel component 400 may provide a heat flux of at least 10,000W/m2, is some cases at least 50,000W/m2, in some cases at least 75,000W/m2, in some cases at least 100,000W/m2, in some cases at least 150,000W/m2, in some cases at least 175,000 W/m2 and in some cases even more for a water based coolant.

InVel (m/s) CSurtvg ( C) Velavg (m/s) Flux (W/m2) FluxPeri OutTemp ( C) Drop (kPa) (W) 1.25 43 2.7 187,500 750 36 52 1.25 37 2.7 93,750 375 33 52 1 45 2.2 187,500 750 37 34 1 37 2.2 93,750 375 34 34 0.75 47 1.7 187,500 750 40 19 0.75 39 1.7 93,750 375 35 19 0.5 52 1.1 187,500 750 45 9 0,5 41 1.1 93,750 375 37 9 0.5 39 1.1 75,000 300 35 9 0.5 38 1.1 67,500 270 35 9 0.5 37 1.1 60,000 240 35 9
[0115] With further reference to figs. 18a, 18b and 18c, a fifth non-limiting embodiment of the cooled channel component is shown. The cooled channel component 500 comprises a base component 510, first manifold 595 and a second manifold (not shown) installed opposite the first manifold 595. The base component 510 comprises a generally u-shaped channel 512 configured to receive a rail thermal connector. The base component 510 further comprises a first plurality of internal channels 534 and a second plurality of internal channels 544 contained in at least the arm containing a cooled surface 514 of the u-channel 512.
[0116] The cooled channel component 500 comprises a first flow path and a second flow path, with the first flow path comprising a first inlet 532, a first outlet (part of the second manifold, not shown) and a plurality of first internal channels 534 and the second flow path comprising a second inlet (part of the second manifold, not shown), a second outlet 543 and a plurality of second internal channels 544. The first and second internal channels 534 and 544 have a generally rectangular geometry and are substantially parallel to each other along the width of the base component 510. The plurality of first and second internal channels 534 and 544 may further comprise fins to increase the surface available for heat exchange. The plurality of first and second internal channels 534 and 544 are configured such that the plurality of first and second internal channels 534 and 544 alternate along a widthwise direction of the base component 510 and an approximately equal flow is directed along each one of the plurality of first internal channels 534 and each one of the plurality of second internal channels 544.
[0117] With further reference to figs. 19a, 19b and 19c, a first manifold 595 is shown containing the first inlet 532 and the second outlet 543. The first manifold 595 is configured to fit at one end of the base component 510 so as to direct a first coolant flow flowing into inlet 532 through a first plurality of internal channels 534 in the base component 510 via apertures 538 and direct a second coolant flow being received through the second plurality of internal channels 544 in the base component to outlet 543 without allowing coolant flowing through inlet 532 and outlet 543 to mix. That is, there is no fluid connection between the first coolant flow and the second coolant flow in the first manifold 595. A second manifold component (not shown) is configured to fit at an opposite end of the base component 510 in a similar manner so as to direct the second coolant flow flowing from the second manifolds inlet through the second plurality of internal channels 544 in the base component 510 and direct the first coolant flow being received through the first plurality of internal channels 534 in the base component 510 to the second manifolds outlet without allowing coolant flowing through the second manifold inlet and second manifold outlet to mix. That is, there is no fluid connection between the first coolant flow and the second coolant flow in the second manifold. The first manifold 595 and the second manifold may have any other suitable configuration in other embodiments.
[0118] The component 510 may be manufactured as an extrusion from aluminum or from another thermally conductive metal such as but not limited to copper, from a thermally conductive plastic or from any other suitable material in other embodiments.
Once extruded each end of the base component 510 may be machined to be configured to receive the manifold described above. The manifolds 595 may be made of aluminum, any other metal, plastic or any other suitable material in other embodiments. In some embodiments, the manifolds 595 may be joined to the base component 510 via a brazing step or by the use of an adhesive as described above. The assembled cooled channel component 500 may then be anodized as described above.
[0119] A base component 510 fabricated from aluminum 6061 with a T6 temper and having a tensile strength of approximately 262 MPa and a yield strength of approximately 241 Mpa with a similar profile as shown in figure 20 with dimensions: d1=17mm, d2=10mm, d3=40mm, d4=12mm, D1=6.4mm, D2=4.5mm, D3=1.8mm and a total length of 710mm yielded the following FEA predicted deflection. For a pressure P equally applied along the length of the extrusion to the u-channel internal aim surfaces of approximately 414 kPa each arm of the u-channel was shown to deflect no more than approximately 0.1mm (0.2mm total).
[0120] With further reference to figs. 21a and 21b, a sixth non-limiting embodiment of the cooled channel component is shown. The cooled channel component 600 comprises a base component 610, a multi-port extrusion (MPE) 630, a first manifold 695 and a second manifold 696.
[0121] With further reference to figs. 22a to 22d, the MPE 630, the manifold 695 and 696 and the base component 610 are shown.
[0122] In this non-limiting embodiment, the base component 610 comprises a generally u-shaped channel 612 configured to receive a rail thennal connector. The base component 610 is further configured to receive the MPE 630 on one of its external surfaces 616, preferably opposite a cooled surface 614 of the base component 610. In some embodiments, the base component 610 may further comprise recesses 619 to facilitate a correct positioning of the MPE 630 and manifolds 695 and 696 relative to the base component 610 while maintaining thermal contact between the MPE 630 and the base component 610. In other non-limiting embodiments, the manifolds 695 and 696 and the MPE 630 may have any other suitable design that does not require recesses to facilitate a positioning of the MPE
630 and manifolds 695 and 696 relative to the base component 610. In some embodiments, the base component 610 may further comprise a spacing feature 682 configured to provide a spacing between the cooled channel component 600 and a support onto which the cooled channel component 600 is connected.
[0123] The first manifold component 695 may be configured for interfitting engagement at one end of the MPE 630. In this non-limiting embodiment, the first manifold component 695 comprises a first inlet 632 and a second outlet 643 and is configured to direct a first coolant flow flowing into the first inlet 632 through a first plurality of internal channels 634 in the MPE 630 and to direct a second coolant flow being received through a second plurality of internal channels 644 of the MPE 630 to the second outlet 643 without allowing coolant flowing through the first inlet 632 and second outlet 643 to mix. That is, there is no fluid connection between the first coolant flow and the second coolant flow in the first manifold 695.
[0124] The second manifold 696 may be configured for interfitting engagement at an opposite end of the MPE 630. In this non-limiting embodiment, the second manifold component 696 comprises a second inlet 642 and a first outlet 633 and is configured to direct the second coolant flow flowing from the second inlet 642 through the second plurality of internal channels 644 in the MPE 630 and to direct the first coolant flow being received through the first plurality of internal channels 634 in the MPE 630 to the second outlet 633 without allowing coolant flowing through the second inlet 642 and the first outlet 633 to mix. That is, there is no fluid connection between the first coolant flow and the second coolant flow in the second manifold 696.
[0125] In this non-limiting embodiment, the first plurality of internal channels 634 and the second plurality of internal channels 644 are generally parallel to each other along a width of the MPE 630, the first plurality of internal channels 634 and second plurality of internal channels 644 being configured such that the first plurality of internal channels 634 and the second plurality of internal channels 644 alternate along the widthwise direction of the MPE
630. In other embodiments, the first plurality of internal channels 634 and the second plurality of internal channels 644 may have any other suitable configuration.
[0126] In this embodiment, an approximately equal flow of coolant is being directed along each one of the plurality of first internal channels 634 and each one of the plurality of second internal channels 644. The plurality of first and second internal channels 634 and 644 may further comprise fins along their respective lengths to increase the surface area available for heat transfer.
[0127] The number of first and second internal channels 634 and 644 may be equal such that an approximately equal flow of coolant is being directed along the plurality of first internal channels 634 and along the plurality of second internal channels 644. The number of first and second internal channels 634 and 644 may be different in other non-limiting embodiments.
[0128] In this embodiment, the base component 610 may be an extrusion manufactured from a thermally conductive metal such as aluminum or any other suitable conductive metal. The MPE 630 may be manufactured from a thermally conductive plastic, a thermally conductive metal such as but not limited to aluminum or from any other suitable material in other embodiments. The manifolds 634 and 644 may be manufactured from a metal suitable for joining to the MPE 630 such as aluminum, plastic and the likes. The material of the manifolds 634 and 644 may be different from the material of the MPE 630 and the base component 610 or may be the same material as either one of the MPE 630 or the base component 610. In some embodiments, the manifolds 695 and 696 may be being cast using dissolvable cores, such as salt cores, or may be designed in a similar fashion as manifold 595 which can be manufactured without requiring cores.
[0129] The base component 610 and MPE 630 may be joined together by brazing, soldering, by the use of a thermally conductive adhesive or in any other suitable manner.
The manifolds 695 and 696 may also be joined to the MPE 630 and the base component 610 by brazing, soldering, by the use of an adhesive or in any other suitable manner.
Anodization may be used to improve corrosion resistance.
[0130] With further reference to figs. 23a and 23b, another embodiment of the cooled channel component having a MPE is shown. The cooled channel component 700 comprises a base component 710 and MPE 730 comprising a plurality of channels 734. These component 710 and MPE 730 are configured to be joined to each other via interlocking features 717 on the base component 710 and correspondingly shaped features 739 on the MPE 730.
This increases the heat transfer surface area between the base component 710 and the MPE 730 and may improve a quality of the joint between the base component 710 and the MPE 730.
The MPE
730 may be manufactured from a thermally conductive plastic or any other suitable material.
The base component 710 may also comprise a spacing feature 782 configured to provide a spacing between the base component 710 and a support onto which the base component 710 is connected. The base component 710 and the MPE 730 may have any other suitable configuration in other embodiments.
[0131] With further reference to figs. 24a, 24b and 24c, another embodiment of the cooled channel component having a MPE is shown. The cooled channel component 800 comprises a base component 810 and MPE 830 comprising a plurality of channels 834. The base component 810 and MPE 830 may be configured to be joined to each other via fins 817 generally projecting away from a surface of the base component 810 and correspondingly shaped features 839 on the MPE 830. This increases the heat transfer surface area between the base component 810 and the MPE 830 and may improve a quality of the joint between the base component 810 and the MPE 830. The fins 817 of the base component 810 may also improve thermal conductivity where the base component 810 is made from aluminum by allowing heat to travel further along the fins 817 before crossing the possibly lower thermal conductivity material of MPE 830. Any other suitable projections that project away from the surface of either the base component 810 or MPE 830 may be used in lieu of the fins 817 in other embodiments. The MPE 830 may be manufactured from a thermally conductive plastic or any other suitable material. The base component 810 may also comprise a spacing feature 882 configured to provide a spacing between the base component 810 and a support onto which the base component 810 is connected. The base component 710 and the MPE
730 may have any other suitable configuration in other embodiments.
[0132] With further reference to fig. 24c, the MPE 830 may also comprise features 858 configured to disrupt laminar flow within the MPE 830 and improve heat transfer. The features 858 may be integrated within the MPE 830 where the MPE 830 is manufactured by a process other than extrusion, for example where the MPE 830 is manufactured by joining two halves together.
[0133] With further reference to figs. 25a, 25b, 25c and 25d, a seventh non-limiting embodiment of the cooled channel component is shown. The cooled channel component 900 comprises an upper component 910, a middle component 930 and a lower component configured to be joined together to form a rectangular rail. The cooled channel component 900 may be used as a rail type thermal connector and may be fixed to a computer server or any other electronic equipment and brought into contact with a channel of a counterpart enclosure.
Alternatively, the cooled channel component 900 may be fixed to an enclosure and brought into contact with a channel of a computer server or other electronic equipment. The cooled channel component 900 may be configured to be clamped around by a channel, or otherwise urged into contact with a surface of a channel, such as a generally u-shaped channel, facilitating heat transfer.
[0134] In this embodiment, the assembled cooled channel component 900 comprises a first flow path and a second flow path, first flow path comprising a first inlet 932, a first outlet 933 and a first plurality of internal channels 934 and is configured such that a coolant flow received by the first inlet 932 is directed through the first plurality of internal channels 934 exiting at the first outlet 933. The second flow path comprises a second inlet 942, a second outlet 943 and a second plurality of internal channels 944 and is configured such that a coolant flow received by the second inlet 942 is directed through the second plurality of internal channels 944 exiting at the second outlet 943. The first flow path and the second flow paths being configured such that coolant flowing throw each flow path does not mix. That is, there is no fluid connection between the first flow path and the second flow path in the cooled channel component 900. The plurality of first and second internal channels 934 and 944 are generally parallel to each other along a width of the cooled channel component 900. In some embodiments, the plurality of first and second internal channels 934 and 944 may have a helical or rifled geometry or any other suitable geometry to improve heat transfer. The plurality of first and second internal channels 934 and 944 may be configured such that the plurality of first internal channels 934 and the plurality of second internal channels 944 alternate between the first and second internal channels 934 and 944 along the widthwise direction of the cooled channel component 900. In other embodiments, the first plurality of internal channels 934 and the second plurality of internal channels 944 may have any other suitable configuration.
[0135] In this embodiment, an approximately equal flow of coolant is being directed along each one of the plurality of first internal channels 934 and each one of the plurality of second internal channels 944.
[0136] The number of first and second internal channels 934 and 944 may be equal such that an approximately equal flow of coolant is being directed along the plurality of first internal channels 934 and along the plurality of second internal channels 944. The number of first and second internal channels 934 and 944 may be different in other non-limiting embodiments.
[0137] In other embodiments, the cooled channel component 900 may comprise only a single inlet and a single outlet. In yet further embodiments, the cooled channel component 900 may only comprise an upper component and a lower component. The cooled channel component 900 may have any other suitable configuration in other embodiments.
[0138] The upper component 910, the middle component 930 and the lower component 950 each contain voids which comprise a portion of the first and second flow paths, that is the first and second flow paths being created when the parts are brought together. With further reference to figs. 26a, 26b and 26c, the middle component 930 is shown with the first flow path (via the plurality of first channels 934) and second flow paths (via the plurality of the second channels 944). Surface 905 is configured to contact the lower component 950 and surface 901 is configured to contact the upper component 910. The middle component may further comprise positioning features 920 such as but not limited to pins to facilitate an alignment of the various components (that is, the upper component 910, the middle component 930 and the lower component 950).
[0139] In this embodiment, the second inlet 942 connecting to one of the plurality of internal channels 944 is connected to an aperture 948 through which coolant passes from the lower 950 and middle 930 components to the middle 930 and upper 910 components, the aperture 948 being connected to another of the plurality of internal channels 944 before connecting to the outlet 943.
[0140] The components of cooled channel 900 may be manufactured from a thermally conductive metal such as but not limited to aluminum or from a thermally conductive plastic or composite or from any other suitable material. In other embodiments, a combination of both thermally conductive components (for the parts that are in contact with a surface for the purpose of facilitating heat transfer) and thermally non-conductive components such as plastic may be used. As non-limiting examples, the components 910, 930 and 950 may be made from aluminum and brazed or soldered together or the upper component 910 and the lower component 950 may be made of aluminum while the middle component 930 is made from a plastic with the parts being joined by an adhesive.
[0141] With further reference to figs. 27a and 27b, the cooled component 900 in use is shown.
The cooled component 900 is clamped around, or otherwise contacted to, a channel 974 of a computer server 970 for the purpose of facilitating heat transfer between the cooled component 900 and the computer server 970. The cooled component 900 may be fixed to a support 980, the support 980 being attached to attachment point 906, a threaded shaft, by a nut 984 and a washer 986. The cooled component 900 may be fixed to the support 980 using any other appropriate mean in other embodiments.
[0142] A variety of cooled channel components have been shown and described herein with many varied and different types of internal channel configurations, it is to be understood that a person having ordinary skill in the art can devise many different internal channel configurations which, amongst other features, may have a different number of channels, ranging from one to many, or a variety of different geometric configurations and profiles without departing from the scope of the disclosure. Figs. 28a through 28e show only a few possible channel profiles and configurations, including profiles which are slightly offset such as are shown in figures 28b and 28e, and profiles which integrate fins such as shown in figures 28c and 28d. Examples of channel profiles include, but is not limited to, geometric shapes such as circles and 2-dimensional polygons such as triangles, squares, pentagons, hexagons as well as profiles that contain a mix of curves and straight lines.
[0143] The cooled channel components described herein are shown as having multiple parts, however it is anticipated that they are well suited to being 3D printed in materials such as aluminum and that the geometries described herein can be improved upon by the application of that technology. Specifically, by being unlimited in geometry similar apparatus can be built based upon the present disclosure that go beyond the limitations of the manufacturing technologies that these parts have been designed for. For example the internal channels for one or two flow paths of 3D printed cooled channel components embodying the principles of the present invention may comprise channels that are shaped like the double helix, which, by copying nature, may result in very high heat transfer rates.
[0144] Certain additional elements that may be needed for the operation of some embodiments have not been described or illustrated as they are assumed to be within the purview of those of ordinary skill in the art. Moreover, certain embodiments may be free of, may lack and/or may function without any element that is not specifically disclosed herein.
[0145] Any feature of any embodiment discussed herein may be combined with any feature of any other embodiment discussed herein in some examples of implementation.
[0146] Although specific embodiments of the invention have been shown and described herein, it is to be understood that these embodiments are merely illustrative of the many possible specific arrangements that can be devised in application of the principles of the invention. Numerous and varied other arrangements can be devised by those of ordinary skill in the art without departing from the scope and spirit of the invention.

Claims (47)

43
1. A cooled channel component comprising:
a channel configured to receive a rail thermal connector within the channel;
a means for cooling a surface of the channel, the cooled channel component configured to be affixable to one or more supports as part of an enclosure wall such that the cooled channel component is mechanically independent of one or more other cooled channel components adjacently installed as part of the enclosure wall.
2. The cooled channel component of claim 1, wherein the channel comprises a pair of spaced apart arms, the arms having a normalized deflection of less than 0.0375 for a bracing force applied between the arms of the channel which is approximately equivalent to a pressure of at least 69kPa.
3. The cooled channel component of claim 1 or 2 configured such that, when the cooled channel component is affixed to the one or more supports at one or more points of attachment, deflection of the arms of the channel for a bracing force applied between the arms of the channel which is approximately equivalent to a pressure of between 69kPa to 690kPa is limited to a range that prevents contact with the one or more adjacently installed cooled channel components and the one or more supports outside of the one or more points of attachment.
4. The cooled channel component of claim 3 further comprising a spacing feature configured to space the cooled channel component apart from the one or more supports outside the one or more points of attachment.
5. The cooled channel component of any one of claims 1 to 4 being configured to have sufficient cooling for at least 0.25kW of power.
Date Recue/Date Received 2022-07-07
6. The cooled channel component of any one of claims 1 to 4 being configured to cool a heat-flux between 10,000 W/m2 and 200,000 W/m2 when the means for cooling uses a water based coolant.
7. The cooled channel component of any one of claims 1 to 6, wherein the means for cooling comprises a first flow path comprising a first inlet, a first outlet and a first at least one internal channel connecting the first inlet to the first outlet, whereby the surface of the channel is coolable by flowing a coolant through the first flow path.
8. The cooled channel component of claim 7, wherein the at least one internal channel comprises a spiral or serpentine configuration.
9. The cooled channel component of claim 7 or 8, wherein the at least one internal channel comprises features configured to disrupt the laminar flow of coolant flowing through the first flow path.
10. The cooled channel component of any one of claims 7 to 9, wherein the cooled channel component further comprises a second flow path comprising a second inlet, a second outlet and a second at least one internal channel connecting the second inlet to the second outlet.
11. The cooled channel component of claim 10, wherein the first and second inlets and the first and second outlets are arranged so that a direction of a coolant flow through the first flow path along a lengthwise direction of the cooled channel component is generally opposite to a direction of a coolant flow through the second flow path along the lengthwise direction of the cooled channel component.
12. The cooled channel component of claim 10 or 11, wherein the first flow path and the second flow path have a substantially equal length thermal path to the surface of the channel.
13. The cooled channel component of any one of claims 10 to 12, wherein the first at least one internal channel comprises a plurality of first internal channels and the second at least one internal channel comprises a plurality of second internal channels, the first internal channels and second internal channels alternating along a widthwise direction of the cooled channel component.
Date Recue/Date Received 2022-07-07
14. The cooled channel component of any one of claims 1 to 6, wherein:
the cooled channel component comprises a base component defining the channel;
and the means for cooling comprises:
a flow director affixed to the base component; and at least one lid plate affixed to the flow director, the flow director and the at least one lid plate forming at least part of a first flow path, whereby the surface of the channel is coolable by flowing a coolant through the first flow path.
15. The cooled channel component of claim 14, wherein the base component comprises an extrusion and the flow director comprises a casting affixed to a surface of the base component, the flow director further comprising features to create internal channels of the first flow path when joined to the base component.
16. The cooled channel component of claim 14, wherein the base component and the flow director comprise features which when joined together create internal channels of the first flow path.
17. The cooled channel component of claim 16, wherein the internal channels are rifled.
18. The cooled channel component of any one of claims 14 to 17, wherein the cooled channel component further comprises a second flow director affixed to the base component
19. The cooled channel component of any one of claims 1 to 6, wherein:
the cooled channel component comprises a base component defining the channel;
and the means for cooling comprises:
a seal plate affixed to the base component; and at least one guide component affixed to the seal plate, Date Recue/Date Received 2022-07-07 the seal plate and the at least one guide component forming at least part of a first flow path when joined to the base component, whereby the surface of the channel is coolable by flowing a coolant through the first flow path, the base component comprising features to create internal channels of the first flow path when joined to the seal plate.
20. The cooled channel component of claim 19, wherein the seal plate is manufactured from a plastic material.
21. The cooled channel component of claim 19 or 20, wherein:
the at least one guide component comprises a first guide component and a second guide component, the seal plate and the first guide component forming at least part of the first flow path, and the seal plate and the second guide component forming at least part of a second flow path when joined to the base component, whereby the surface of the channel is coolable by flowing a coolant through the first and second flow paths;
the base component further comprising features to create internal channels of the second flow path when joined to the seal plate.
22. The cooled channel component of claim 21, wherein the internal channels of the first flow path and the internal channels of the second flow path are alternating along a widthwise direction of the cooled channel component.
23. The cooled channel component of any one of claims 19 to 22, wherein the cooled channel component further comprises a flow director affixed to the base component.
24. The cooled channel component of any one of claims 1 to 6, wherein the cooled channel component comprises a base component defining the channel, the base component comprising an extrusion having a plurality of internal channels forming at least part of the means for cooling, the internal channels being contained within at least the arm of the channel that includes the cooled surface, whereby the surface of the channel is coolable by flowing a coolant through the internal channels of the extrusion.
25. The cooled channel component of claim 24, wherein the means for cooling further comprises:
Date Recue/Date Received 2022-07-07 a first manifold affixed to the extrusion and comprising a first inlet and a second outlet, the first inlet being in fluid communication with a first subset of the internal channels of the extrusion, and the second outlet being in fluid communication with a second subset of the internal channels of the extrusion; and a second manifold affixed to the extrusion opposite the first manifold, the second manifold comprising a second inlet and a first outlet, the second inlet being in fluid communication with the second subset of the internal channels of the extrusion, and the first outlet being in fluid communication with the first subset of the internal channels of the extrusion.
26. The cooled channel component of claim 25, wherein the first subset of the internal channels and the second subset of the internal channels are alternating along a widthwise direction of the cooled channel component.
27. The cooled channel component of any one of claims 1 to 6, wherein:
the cooled channel component comprises a base component defining the channel;
the means for cooling comprises:
a multi-port extrusion (MPE) affixed to the base component, the MPE having a plurality of internal channels forming at least part of a first flow path, whereby the surface of the channel is coolable by flowing a coolant through the first flow path.
28. The cooled channel component of claim 27, wherein the base component and the MPE
are joined via correspondingly shaped interlocking features on surfaces thereof.
29. The cooled channel component of claim 27, wherein the base component and the MPE
are joined via fins generally projecting away from a surface of the base component opposite the cooled surface of the channel, and correspondingly shaped features on the MPE, the correspondingly shaped features on the MPE defining, at least in part, the internal channels of the MPE.
30. The cooled channel component of any one of claims 27 to 29, wherein the means for cooling further comprises:
Date Recue/Date Received 2022-07-07 a first manifold comprising a first inlet and a second outlet, the first inlet being in fluid communication with a first subset of the internal channels of the MPE, and the second outlet being in fluid communication with a second subset of the internal channels of the MPE; and a second manifold arranged at an opposite end of the MPE to the first manifold, the second manifold comprising a second inlet and a first outlet, the second inlet being in fluid communication with the second subset of the internal channels of the MPE, and the first outlet being in fluid communication with the first subset of the internal channels of the MPE.
31. The cooled channel component of claim 30, wherein the first subset of the internal channels and the second subset of the internal channels are alternating along a widthwise direction of the cooled channel component.
32. The cooled channel component of any one of claims 1 to 31 wherein the channel is generally u-shaped.
33. The cooled channel component of any one of claims 1 to 32 wherein the cooled channel component includes only the single channel.
34. A wall of a cooled enclosure of a type which cools installed equipment by thermal contact with an elongated thermal connector element on at least one side of the equipment, the wall comprising:
one or more supports; and a plurality of cooled channel components affixed to the one or more supports for engaging and supporting respective equipment inserted into the cooled enclosure, each cooled channel component:
being mechanically independent of the other cooled channel components installed as part of the wall; and comprising an elongated thermal connector element having a cooled surface and being configured to establish a male-female progressive engagement with the elongated thermal connector element of a respective equipment as the equipment is Date Recue/Date Received 2022-07-07 inserted into the enclosure.
35. The wall of claim 34, wherein, for each of at least one of the cooled channel components, the elongated thermal connector element of the cooled channel component comprises a channel having two spaced apart arms configured to receive a rail thermal connector of a respective equipment.
36. The wall of claim 35, the arms having a normalized deflection of less than 0.0375 for a bracing force applied between the arms of the channel which is approximately equivalent to a pressure of at least 69kPa.
37. The wall of claim 35 or 36, wherein deflection of the arms of the channel for a bracing force applied between the arms of the channel which is approximately equivalent to a pressure of between 69kPa to 690kPa is limited to a range that prevents contact with the other adjacently installed cooled channel components and the one or more supports outside of points of attachment to the one or more supports.
38. The wall of claim 34, wherein, for each of at least one of the cooled channel components, the elongated thermal connector element of the cooled channel component comprises a rail thermal connector configured to be received within a channel thermal connector of a respective equipment.
39. The wall of any one of claims 34 to 38, wherein each cooled channel component is configured to provide sufficient cooling for at least 0.25kW of power.
40. The wall of any one of claims 34 to 38, wherein each cooled channel component is configured to cool a heat-flux between 10,000 W/m2 and 200,000 W/m2 when using a water based coolant to cool the cooled surface.
41. The wall of any one of claims 34 to 40, wherein each of at least one of the cooled channel components comprises a first flow path comprising a first inlet, a first outlet and a first at least one internal channel connecting the first inlet to the first outlet, whereby the cooled surface is cooled by flowing a coolant through the first flow path.
42. The wall of claim 41, wherein the at least one internal channel comprises a spiral or Date Recue/Date Received 2022-07-07 serpentine configuration.
43. The cooled channel component of claim 41 or 42, wherein the at least one internal channel comprises features configured to disrupt the laminar flow of coolant flowing through the first flow path.
44. The wall of any one of claims 41 to 43, wherein each of the at least one cooled channel component further comprises a second flow path comprising a second inlet, a second outlet and a second at least one internal channel connecting the second inlet to the second outlet.
45. The wall of claim 44, wherein the first and second inlets and the first and second outlets are arranged so that a direction of a coolant flow through the first flow path along a lengthwise direction of the cooled channel component is generally opposite to a direction of a coolant flow through the second flow path along the lengthwise direction of the cooled channel component.
46. The wall of claim 44 or 45, wherein the first flow path and the second flow path have a substantially equal length thermal path to the cooled surface.
47. The wall of any one of claims 44 to 46, wherein the first at least one internal channel comprises a plurality of first internal channels and the second at least one internal channel comprises a plurality of second internal channels, the first internal channels and second internal channels alternating along a widthwise direction of the cooled channel component.
Date Recue/Date Received 2022-07-07
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