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2024-10-29
18/210,626
2023-06-15
US 12,133,363 B1
2024-10-29
-
-
Robert J Hoffberg
Mark Protsik | Thomas Schneck
2043-06-26
A heat-activated pump removes waste heat from an electronic chip. An evaporator integrated into the chip packaging receives heat from the chip, converting a working fluid into vapor. Piping from the evaporator to a heat exchanger and back form a fluid circulation system. A pressure-control valve set for a specified electronic operating temperature allows vaporized working fluid to vent into a liquid-piston chamber, where it expands adiabatically, displacing pumped liquid in a pumping stage and expelling it from the chamber through a unidirectional valve to the shared heat exchanger(s). The heat exchanger(s) has a heatsink transferring heat away to a flow of cooler fluid. The pumped liquid returns in a suction cycle to the chamber through another unidirectional valve. An injector valve returns jets of condensed working fluid to the evaporator in successive brief spurts responsive to periodic pressure pulses in the chamber.
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H05K7/20327 » CPC main
Constructional details common to different types of electric apparatus; Modifications to facilitate cooling, ventilating, or heating using a liquid coolant with phase change in electronic enclosures Accessories for moving fluid, for connecting fluid conduits, for distributing fluid or for preventing leakage, e.g. pumps, tanks or manifolds
H05K7/20327 » CPC main
Constructional details common to different types of electric apparatus; Modifications to facilitate cooling, ventilating, or heating using a liquid coolant with phase change in electronic enclosures Accessories for moving fluid, for connecting fluid conduits, for distributing fluid or for preventing leakage, e.g. pumps, tanks or manifolds
F04B19/24 » CPC further
Machines or pumps having pertinent characteristics not provided for in, or of interest apart from, groups  - ; Other positive-displacement pumps Pumping by heat expansion of pumped fluid
F04F1/04 » CPC further
Pumps using positively or negatively pressurised fluid medium acting directly on the liquid to be pumped using both positively and negatively pressurised fluid medium, e.g. alternating generated by vaporising and condensing
F28D15/0266 » CPC further
Heat-exchange apparatus with the intermediate heat-transfer medium in closed tubes passing into or through the conduit walls ; Heat-exchange apparatus employing intermediate heat-transfer medium or bodies in which the medium condenses and evaporates, e.g. heat pipes with separate evaporating and condensing chambers connected by at least one conduit; Loop-type heat pipes; with multiple or common evaporating or condensing chambers
H01L23/427 » CPC further
Details of semiconductor or other solid state devices; Arrangements for cooling, heating, ventilating or temperature compensation ; Temperature sensing arrangements; Fillings or auxiliary members in containers or encapsulations selected or arranged to facilitate heating or cooling Cooling by change of state, e.g. use of heat pipes
H05K7/20309 » CPC further
Constructional details common to different types of electric apparatus; Modifications to facilitate cooling, ventilating, or heating using a liquid coolant with phase change in electronic enclosures Evaporators
H05K7/20309 » CPC further
Constructional details common to different types of electric apparatus; Modifications to facilitate cooling, ventilating, or heating using a liquid coolant with phase change in electronic enclosures Evaporators
H05K7/20827 » CPC further
Constructional details common to different types of electric apparatus; Modifications to facilitate cooling, ventilating, or heating for server racks or cabinets; for data centers, e.g. 19-inch computer racks; Liquid cooling with phase change within rooms for removing heat from cabinets, e.g. air conditioning devices
H05K7/20827 » CPC further
Constructional details common to different types of electric apparatus; Modifications to facilitate cooling, ventilating, or heating for server racks or cabinets; for data centers, e.g. 19-inch computer racks; Liquid cooling with phase change within rooms for removing heat from cabinets, e.g. air conditioning devices
H05K7/20818 » CPC further
Constructional details common to different types of electric apparatus; Modifications to facilitate cooling, ventilating, or heating for server racks or cabinets; for data centers, e.g. 19-inch computer racks; Liquid cooling with phase change within cabinets for removing heat from server blades
H05K7/20818 » CPC further
Constructional details common to different types of electric apparatus; Modifications to facilitate cooling, ventilating, or heating for server racks or cabinets; for data centers, e.g. 19-inch computer racks; Liquid cooling with phase change within cabinets for removing heat from server blades
H05K7/20 IPC
Constructional details common to different types of electric apparatus Modifications to facilitate cooling, ventilating, or heating
H05K7/20 IPC
Constructional details common to different types of electric apparatus Modifications to facilitate cooling, ventilating, or heating
F28D15/02 IPC
Heat-exchange apparatus with the intermediate heat-transfer medium in closed tubes passing into or through the conduit walls ; Heat-exchange apparatus employing intermediate heat-transfer medium or bodies in which the medium condenses and evaporates, e.g. heat pipes
The present application is a divisional of prior U.S. application Ser. No. 17/471,618, filed Sep. 10, 2021, which claims priority under 35 U.S.C. 119(e) from U.S. Provisional Application 63/076,546, filed Sep. 10, 2020.
The present invention relates to fluid-operated heat activated pumping devices for the transport of heat, and especially those adapted for the removal of the waste heat generated by electronic devices, at the chip, board, rack, or datacenter level.
Electronics, microelectronics, and opto-electronic devices convert most of the power they consume into waste heat. The devices need to be maintained within a narrow operating temperature to ensure optimal performance and long-term reliability. If they run too hot, they will degrade faster. If they are cooled excessively, the amount of cooling infrastructure required can be prohibitively expensive.
Electronics cooling can be classified by the amount of heat being dissipated. For instance, data center level cooling is performed on the order of tens to thousands of kilowatts. Printed Circuit Board (PCBA) level cooling is on the order of tens to thousands of watts. Chip level cooling can be order of milliwatts to tens or hundreds of watts. Different cooling solutions are deployed at each level depending on the amount of heat dissipated and the geometric space available.
Going deeper from the PCBA to the silicon chips, the closer the cooling solutions get to the heat source itself, the more efficient they can be. At the chip level, electronics cooling is facing several challenges:
Conventional chip level cooling solutions vary depending on the amount of heat to be dissipated. Pumped direct liquid cooling through chip microchannels, two phase jet impingement cooling or immersion-cooling are used in applications where the heat dissipation is on the order of hundreds to thousands of watts. These solutions rely on connectivity to the larger system to enable the circulation of fluid in and out of the chip and off-chip fluid cooling.
Low wattage devices (on the order of 0.1 milliwatts to tens or a few hundreds of watts) require specific cooling solutions especially if they are in a constrained space. Smartphones are becoming more sophisticated and power hungry. Smartphone capability is limited by power consumption and heat loss. More computation capability means more power consumption, which means more heat generation and larger battery size.
Heat from smartphones is dissipated by conductive heat transfer from the transistors through the phone body to the surrounding atmosphere, human skin etc. Due to space limitations, there are no active cooling devices like fans or pumps to remove the heat faster. In some advanced smartphones, miniature heat pipes/vapor chambers are used to speed up the heat transfer from the transistors to the smartphone chassis. Heat pipe fluid return capability is limited by the amount of pumping power the capillary wicks can provide. This capillary return capability is both space and material limited. A miniature wick structure can only pump so much fluid even in best case conditions. While heat pipes are somewhat more effective than thermal interface materials, there is still a need for better heat dissipation without consuming too much space. There is a need to use active cooling techniques (like pumped liquid cooling) to speed up the heat transfer without significantly changing the size, thickness, cost, or reliability of the smartphone device.
Wearable devices (fitness monitors, watches etc.) have the same, if not even more critical, challenges of power consumption, size, cost, and battery power as smartphones. With such limited space and close contact with human skin, there is even greater need for better cooling of electronics in a small space. A typical smartwatch is expected to last at least 15 hours with a 2200 mAh battery. Operating at 1.1V, that translates to 2.42 Wh. This energy is mostly converted into heat and dissipated from the battery chassis to ambient air and human skin. Human skin is very sensitive to high temperature and a typical chip in the smartwatch can run as high at 40° C. This limits the capability of the wearable device. Current efforts are focused on using advanced thermal interface materials (graphite etc.), heat pipes, vapor chambers etc. to enhance heat transfer. These techniques are passive solutions which have limited effectiveness for temperature control and heat transfer.
Due to limited power availability, there is also a need to recapture the heat lost so it can be used to power the device rather than being dissipated/wasted into the environment. Even a small amount of energy recapture can help prolong the operating time of the device or reduce the size or cost of the battery. Efforts have been made in the past to use thermoelectric generators that utilize the difference in temperature between the device and human skin to generate electricity. However, this approach has been shown to be insufficient to generate enough useful energy to justify the space consumed by the thermoelectric generator and the cost involved.
There is a need for a scalable solution that can be deployed at the system level (e.g., datacenter), PCBA and chip level to address several of these issues and be cost effective and reliable.
A heat activated pump is provided for the removal of waste heat from an electronic chip. An evaporator integrated into the electronic chip package contains a working fluid and is directly coupled against the chip to receive external heat therefrom to convert the working fluid into vapor. A pressure-control valve is coupled to an exit port of the evaporator, maintains the working fluid in the evaporator at a set target pressure and allows vaporized working fluid to escape through the exit port whenever the target pressure is exceeded. A liquid-piston chamber coupled to the pressure-control valve receives the vaporized working fluid from the evaporator at the target pressure. The vaporized working fluid expands adiabatically and displaces liquid within the liquid-piston chamber, expelling it therefrom in a pumping stage of a thermodynamic cycle. A unidirectional pump-exit check valve is coupled to an exit port of the liquid-piston chamber to allow the displaced liquid to exit the liquid-piston chamber. A unidirectional liquid suction-entry check valve is coupled to a return port of the liquid-piston chamber. A heat exchanger with a heatsink is coupled to the pump-exit and suction-entry check valves to receive displaced liquid and allow it to return to the liquid-piston chamber in a suction stage of the thermodynamic cycle. The heatsink radiates heat away to a flow of cooler air. Finally, a unidirectional vapor-injector return check valve is coupled to both an exit port of the liquid-piston chamber and to an input port of the evaporator. Periodic pressure pulses from the liquid-piston chamber that temporarily exceed the pressure in the evaporator facilitate jets of condensed working fluid to return to the evaporator in successive brief spurts.
The solution presented with this heat-activated multiphase fluid-operated pump technique for electronic chip cooling provides all the benefits of liquid cooling without some of the challenges of conventional pumps, piping and connectors involved in liquid cooling:
In terms of operating conditions, the present heat activated pump solution sits between the two extremes of active and passive cooling solutions. It uses vapor, not liquid, pressure to drive the pumping.
FIG. 1 is a schematic plan view of a heat-driven fluid-operated pump in accord with the present invention for providing a heat activated pump for electronics cooling.
FIG. 2 is a schematic view of a datacenter cooling arrangement using fluid-operated heat activated pumps in accord with the present invention.
FIG. 3 is a perspective view of a heat activated pump as in FIG. 1 for cooling of individual electronic chip components.
FIG. 4 is a close-up of the evaporator portion of the heat activated pump of FIG. 3.
FIGS. 5 and 6 are respective exploded and assembled side sectional views of the heat activated pump body and pressure control valve assembly of the heat activated pump of FIG. 3.
FIGS. 7A-7C are respective perspective, top exterior, and side sectional views of the heat activated pump body of the heat activated pump of FIG. 3 with special focus upon the various pump valves of the piston-suction chamber.
FIGS. 8 and 9 are perspective views of two embodiments of heat activated pump cooling constructions for use with multi-chip circuit boards.
FIG. 10 is an exploded perspective view of a heat activated pump as in FIG. 1 for cooling of space-constrained electronics (as in a smartphone or wearable) FIG. 11 is a top view of the pressure control valve, piston chamber, and heat exchanger portion of the heat activated pump of FIG. 10.
FIG. 12 is a close-up view of piston chamber valves of FIG. 11.
Nomenclature
Working Fluid: The fluid whose change in phase is utilized to performing the pumping operation. The working fluid could be selected from a variety of fluid options: water, as well as commonly used or new refrigerants (e.g., R-130, R-245fa, R-407c, R-410a, R-454b, R-1234yf, etc.). In addition to performance and desired temperature range, safety (flammability and exposure limits) will be factors in the choice of working fluid.
Pumped Fluid: The fluid which needs to be pumped from one location to another. This could be the same as the working fluid or it could be a different fluid material altogether. If the pumped fluid is different, it would need to be immiscible with the working fluid. In that case, a separator 113 may be provided (as seen in FIG. 1) at the return port 110 of the liquid-piston chamber 104 to direct only the working fluid material, and not the pumped fluid material, back to the evaporator(s) 101.
Ambient Temperature: The temperature in the general environment around the region or device in focus.
The Heat-Activated Multiphase Fluid-Operated Pump
The HAMFOP pump utilizes heat to pump a fluid. The heat is used to convert a working fluid from liquid to vapor. The vapor is then used to displace the fluid that needs to be pumped.
The principle of operation is as follows, as referenced by the numbered elements in FIG. 1, assuming that both the working fluid and the pumped fluid are the same:
In the case where the pumped fluid 114 (and 106) is composed of a different material from the working fluid 102 (and 110), and not merely a different liquid-vapor phase of the same material, a difference in density between the working and pumped fluids can be leveraged to separate them. The elements of such an embodiment are largely identical to structure and operation to those in FIG. 1, except for the addition of a separator, in which the pumped fluid and the working fluid are separated. The pumped fluid 114 and 106 being of lower density would float to the top while the working fluid 102 and 110 would sink to the bottom. Accurate tuning (balancing the precise quantity of working and pumped fluid) would need to be performed to ensure that the separator chamber never ends up without any working fluid at all. If that were to happen, then some of the pumped fluid could enter the hot chamber 101, thus interrupting the cycle.
Heat Activated Pump for Cooling of Large Systems such as racks of PCBAs, Datacenters and other such large electronic systems A heat activated pump system can be used to move fluid around a datacenter as illustrated in FIG. 2, in which multiple heat activated pump units are interconnected together.
Heat activated pumps on devices attached to PCBAs in a rack pump the cooling fluid around in piping running throughout the data center. The datacenter-level heat activated pump system uses this hot pumped fluid from each individual heat activated pump to pump the fluid to the heat exchanger and return the fluid back to the PCBA level devices at a cool temperature to close the circuit as shown in FIG. 2. Individual heat activated pumps 152 are mounted on circuit boards 151 positioned in racks 150. Details of the individual heat activated pumps 152 are as referenced in FIG. 3. Evaporator lines 154 from groups of chips, boards, and racks connect through one or more pressure control valves 155 to one or more associated piston-suction chambers 156. Groupings may encompass an entire datacenter or various subsets of a data center, each grouping having a heat exchanger 159. The piston-suction chamber(s) 156 have a corresponding working fluid return valve 157 coupled to working fluid return lines 153 leading back to the grouping of chips, boards, and racks. Each piston-suction chamber 156 also has a pump valve 161 coupled to a heat exchanger 159, with a suction return line 160 back to the chamber 156 via a suction valve 158. Each grouping operates as described above with reference to FIG. 1.
Heat Activated Pump for Cooling of Electronic Devices Mounted on PCBAs
As seen especially in FIG. 3, key heat activated pump elements for device cooling on PCBAs are:
| Material | ||
| Element | Options | Description |
| Printed Circuit | Standard | The board on which |
| Board 200 | Industry | different electrical |
| Materials | devices are mounted | |
| Chip 201 | Standard | Generic designator for the |
| Industry | device that needs to be | |
| Materials | cooled. It could be a | |
| logic chip, memory, | ||
| optical device etc. It could | ||
| be a single monolith | ||
| or a heterogeneous | ||
| multichip device. | ||
| Thermal | Standard | A thin material used to |
| Interface | Industry | contact two heat |
| Material | Materials | transferring surfaces. The |
| (TIM) 202 | fluid-operated heat | |
| activated pump could be | ||
| bonded directly to the | ||
| chip or contacted via the | ||
| TIM material | ||
| Evaporator | High Thermal | The outer body of the |
| Enclosure 203 | Conductivity: | evaporator. This could be |
| Copper, | standalone if a metal foam | |
| Aluminum, | is inserted into the | |
| High Temp | enclosure. It could be | |
| Ceramic etc. | integrated with the core | |
| Evaporator | High Thermal | The core is where the |
| Core 204 | Conductivity: | working vapor is created. |
| Copper, | It is designed to have the | |
| Aluminum, | highest surface area | |
| High Temp | possible for max heat | |
| Ceramic, | transfer. Core examples: | |
| Metal Foam | metal foam, serpentine | |
| etc. | grooved trenches, or | |
| bonded fins | ||
| Evaporator Top | High Thermal | Plate to allow vapor to |
| Cover 205 | Conductivity: | exit the evaporator and |
| Copper, | return to it. Comprised | |
| Aluminum, | of holes strategically | |
| High Temp | located to allow vapor | |
| Ceramic etc. | exit and liquid return | |
| Could be | ||
| bolted, | ||
| soldered, or | ||
| welded to | ||
| evaporator | ||
| and pump | ||
| Pump 206 | Insulating | Vapor from evaporator |
| material: | enters the pump, flows | |
| PTFE, Nylon, | through the channel | |
| Plastic, or | displacing existing fluid. | |
| other | Vapor condenses in the | |
| material | channel while displacing | |
| coated with | the fluid and evacuating | |
| insulation | the channel, thus creating | |
| a low-pressure cavity for | ||
| fresh fluid to be sucked | ||
| in. Contains three valves | ||
| integrated into it: pump | ||
| fluid out, return some | ||
| fluid back to evaporator | ||
| and suck fresh fluid in | ||
| Valve Balls 207 | Plastic, | Balls (could also be thin |
| Metal (Steel, | discs) designed to allow | |
| Tungsten | only unidirectional flow | |
| etc.), | as desired. O-rings | |
| Rubber, | could also be used with | |
| Ceramic | the balls to ensure | |
| tight seals | ||
| Pressure Valve | High Temp, | Thin, flexible gasket |
| Gasket 208 | Fluid Vapor | designed to seal the |
| Resistant | vapor entry into pump | |
| (e.g., | ||
| Silicone) | ||
| Pressure Valve | Copper, | Shaft designed to apply |
| Seat 209 | Aluminum, | solid pressure on valve |
| High Temp | gasket, so the vapor does | |
| Ceramic, or | not enter the pump | |
| high temp | chamber until the | |
| plastic etc. | pressure exceeds | |
| target load value. | ||
| Diaphragm 210 | Silicone, | Diaphragm designed to |
| Rubber, or | flex to allow vapor to | |
| other | escape into second chamber | |
| flexible | when pressure exceeds | |
| material that | target load. Diaphragm can | |
| can withstand | be replaced with O-rings | |
| working vapor | or metal bellows in other | |
| pressure, | embodiments as needed | |
| chemical and | ||
| temperature | ||
| conditions | ||
| Heat | High Thermal | Pumped hot liquid flows |
| exchanger 211 | Conductivity: | from the pump to the heat |
| Copper, | exchanger. Heat exchanger | |
| Aluminum, | has serpentine channels to | |
| High Temp | move fluid and exchange | |
| Ceramic etc. | heat with heatsink | |
| Could be | attached on top of it. | |
| bolted, | Condensed fluid then | |
| soldered, or | returns to the pump | |
| welded to | chamber through the | |
| pump | suction valve. Heat | |
| exchanger could also send | ||
| fluid to another secondary | ||
| heat exchanger for more | ||
| cooling | ||
| Heatsink 211 | High Thermal | Heat from the heat |
| (combined with | Conductivity: | exchanger is transferred |
| heat exchanger) | Copper, | to the heatsink by |
| Aluminum, | conduction. Fins on the | |
| High Temp | heatsink accelerate heat | |
| Ceramic etc. | transfer to flowing air. | |
| In another embodiment, | ||
| the heatsink could be | ||
| more tightly integrated | ||
| into the heat exchanger | ||
| like a conventional | ||
| radiator. Different | ||
| heatsink fins could be | ||
| used: wavy, elliptical, | ||
| slotted etc. The heatsink | ||
| can be mechanically | ||
| clamped/bolted down to | ||
| the PCB to ensure it | ||
| remains firmly in place | ||
| over the chip. A backing | ||
| plate underneath the PCB | ||
| ensures the board remains | ||
| supported and the chip is | ||
| not excessively loaded | ||
| in-situ or during assembly. | ||
| Whenever needed, the | ||
| entire assembly can simply | ||
| be removed and replaced | ||
| Load Seat 212 | Metal or | The seat applies a |
| plastic- | mechanical advantage by | |
| high rigidity | balancing the force of the | |
| load on top of it with the | ||
| vapor counter-pressure | ||
| from the valve seat. | ||
| Grooves on the top | ||
| surface keep the load | ||
| centered on the load seat. | ||
| Load 213 | High density | The target weight that the |
| material: | vapor needs to overcome | |
| Tungsten, | to open the valve. The load | |
| Liquid | could be a dead weight or | |
| Gallium etc. | a compression spring that | |
| could be deflected to | ||
| impart the same target | ||
| load resistance. | ||
| Load | Rigid sheet | Designed to hold the load |
| Cover 214 | metal or | in place and prevent it |
| plastic, | from falling off. Also | |
| preferably | designed to provide a | |
| heat | “back-stop” to ensure that | |
| insulating. | the load does not displace | |
| Could be | excessively due to vapor | |
| bolted, | pressure in case the | |
| welded, or | diaphragm fails. | |
| soldered on | ||
| to the | ||
| heatsink body | ||
This specific embodiment is for a chip and board horizontally oriented with the heat activated pump mounted on top of the chip. This design can easily be modified to operate with a chip and board vertically oriented as well. In situations where multiple chips are mounted close together (as in chiplets on a single substrate) and some of the chips have lower operating temperature requirements as compared to others (as in memories and logic devices); then their heat paths can be completely separated into two distinct pumps operating independently. The vapor pressure of each pump can be tuned to match the target operating temperature of each chip to be cooled. This way, cross heating is mitigated, and each chip operates close to its own target temperature.
Evaporator
The details of the evaporator are outlined in FIG. 4. It is comprised of three key elements:
The details of the pressure control valve are outlined in FIGS. 5 and 6. It is comprised of these key elements:
The details of the piston are outlined in FIGS. 7A-7C. It is comprised of these key elements:
The details of the valves 207a-207c are outlined in FIG. 7C. For compactness, the valves are embedded in the body 206 of the piston pump chamber. This is just one example of the implementation of the valves, they could be implemented in infinite possible geometries and commercially available check valves could also be used. While the image shows the valves only actuated with balls 207e, the balls could be augmented with O-rings, discs, or gaskets depending on the quality of the metrological finish. The valves are actuated by the differential pressure across them.
Heat Exchanger
The details of the heat exchanger and heatsink 211 are outlined in FIG. 3. In this embodiment, the heat exchanger and heatsink 211 are shown as bonded to each other horizontally. Alternatively, the heat exchanger and heatsink could also be in the form of a radiator/heat exchanger, placed remotely from the pump depending on the space available and the access to cooling air. The fluid channels in the heat exchanger could also be structured in infinite possible geometries similar to the piston-suction chamber 207d in FIGS. 7A-7C.
Multiple Chips on PCBA Implementation
The aforementioned implementations are for cooling only one individual electronics device on a PCBA 200. When multiple devices 217 are mounted on a PCBA 200, an example arrangement is shown in FIG. 8.
The fluid-operated heat activated pumps 218 of multiple devices can be joined together to a common heat exchanger 219, as seen in FIG. 9. This ensures that if any one device is running hotter than the others, the cooler device's thermal budget can be consumed by the device requiring more cooling. Thus, the overall thermal performance of the PCBA is optimized. If all the devices are running hotter than target, the heat activated pumps on all the devices will run faster (higher flowrate) while maintaining the devices at their target operating temperature.
The heat exchanger 219 can also be placed in front of the target device so the heat exchanger receives the coolest incoming air and the hot air it releases downstream can be directed at the device to ensure it runs hot.
The heat activated pumps on each device interconnected, convert part of the collective heat dissipated by the devices into useful work to pump the cooling fluid around the devices, to maintain them at a constant target temperature.
Heat Activated Pump for Cooling of Low Wattage Electronics (Smartphones, Wearables, Flat Panels, Etc.)
A fluid-operated heat activated pump for space-constrained devices (smartphones, wearables, etc.) is shown in FIGS. 10-12. Details of each constituent are:
| Material | ||
| Element | Options | Description |
| Chip 201 | Standard | Generic designator for the |
| Industry | device that needs to be | |
| Materials | cooled. It could be a logic | |
| chip, memory, optical device | ||
| etc. It could be a single | ||
| monolith or a heterogeneous | ||
| device complex. The silicon | ||
| chip could have microchannels | ||
| fabricated on the back side, | ||
| using a standard Deep Reactive | ||
| Ion Etching (DRIE) process, | ||
| typically 50 microns deep. The | ||
| purpose of the microchannels | ||
| is to increase the surface | ||
| area, to enhance boiling. | ||
| Conventional silicon | ||
| microchannels have the | ||
| challenge of restricting the | ||
| flow of fluid (due to their | ||
| small dimensions and thus | ||
| increased resistance to fluid | ||
| flow). However, this | ||
| application of silicon | ||
| microchannels is different | ||
| because fluid is not pushed | ||
| through them. Instead, they | ||
| serve as “fins” to enable | ||
| faster heat transfer for | ||
| boiling. | ||
| Evaporator | Thermal | The side facing the chip has |
| Plate 220 | insulator | 2 holes: one for vapor egress |
| (combined | material: | 233f and another for liquid |
| with the chip) | plastic, | ingress 233e. The edges of the |
| polymer, | evaporator plate 220 are | |
| ceramic etc. | bonded to the chip using any | |
| industry standard technique: | ||
| solder, brazing, non-outgassing | ||
| adhesive, welding etc. | ||
| Pressure | Thermal | The load disc 223 transfers |
| Control | insulator | pressure from the deadweight |
| Valve-Load | material: | to the evaporator hole to |
| Disc 223 | plastic, | prevent vapor from exiting |
| polymer, | before the deadweight pressure | |
| ceramic etc. | is reached. The disc could be | |
| used standalone or with a | ||
| gasket/O-ring to achieve leak | ||
| free contact. The disc could | ||
| also be a sphere. | ||
| Pressure | Silicone, | Diaphragm 224 is designed to |
| Control | Rubber, or | flex to allow vapor to escape |
| Valve- | other flexible | into second chamber when |
| Diaphragm 224 | material that | pressure exceeds target load. |
| can withstand | If there is no space for a | |
| working vapor | deadweight, the diaphragm | |
| pressure, | itself can be stiffened to act | |
| chemical and | as the deadweight by tuning | |
| temperature | its thickness. The diaphragm | |
| conditions. It | can be replaced with O-rings | |
| could also be | or metal bellows in other | |
| fabricated | embodiments as needed. The | |
| from silicon | diaphragm material is extended | |
| or silicon | to cover above the piston area | |
| carbide using | as well, where it serves as a | |
| standard wafer | thermal insulator preventing | |
| lithography | heat from leaving the piston | |
| techniques | 234 through the top high | |
| thermal conductivity metal | ||
| heat spreader. | ||
| Pressure | Metal or | The seat 226 applies a |
| Control | plastic-high | mechanical advantage by |
| Valve-Load | rigidity. | balancing the force of the |
| Seat 226 | load 223 on top of it with the | |
| vapor counter-pressure from | ||
| the valve seat. Grooves on the | ||
| top surface keep the load 223 | ||
| centered on the load seat 226. | ||
| Pressure | High Temp, | Thin, flexible gasket 227 is |
| Control | Fluid Vapor | designed to seal a liquid load |
| Valve- | Resistant | on top of the load seat 226. |
| Gasket 227 | (e.g., Silicone) | |
| Single Plate | Any insulating | This accommodates the piston |
| Housing 232 | and rigid | chamber 221, heat exchanger |
| material | 230 with channels 231, and the | |
| valves 233a, c and d, 235 in | ||
| a single plate with small | ||
| form factor. | ||
| Piston | NA | This is a cavity with input |
| Chamber 221 | port 215 and built into the | |
| evaporator plate 220, towards | ||
| the heat spreader side. The | ||
| groove can be a single | ||
| channel, or it can be a | ||
| serpentine channel depending | ||
| on how much volume needs to | ||
| be displaced. Backstops 234a-b | ||
| are embedded in the piston | ||
| groove 234 (in current | ||
| generating applications only) | ||
| to ensure that magnetic | ||
| material suspended in the | ||
| liquid does not leave the | ||
| piston-chamber. | ||
| Heat | NA | This is a cavity 230 built |
| Exchanger | into the evaporator plate 220. | |
| 230 | It could be a single channel, | |
| or a series of channels 231 | ||
| connected together in | ||
| parallel. The heat exchanger | ||
| could also be completely off- | ||
| the-chip depending on the | ||
| amount of heat loss required. | ||
| Inductive | Copper | This interacts with magnetic |
| electrical | winding and | material between the backstops |
| generator 236 | ferro-magnetic | 234a-b to induce a current in |
| material | the windings 236. | |
| Valves 233a, c | NA | These are cavities with |
| and d, 235 | specific obstructions built | |
| into the chambers to allow | ||
| fluid to flow uni-directionally. | ||
| 233a is the injector return | ||
| check valve with small hole | ||
| 233f returning; 233c | ||
| is the pump-exit check valve | ||
| with a groove 233b forming | ||
| a first exit port of the | ||
| liquid-piston chamber; 233d | ||
| is the suction-entry check | ||
| valve coupled to a groove | ||
| 233e forming the return port | ||
| of the liquid-piston chamber. | ||
| Piston Cover | High Thermal | This plate closes the pump |
| and Heat | Conductivity | and isolates it to protect it. It |
| Spreader 225 | Material: | also transfers heat from the |
| Copper, | heat exchanger 230 to the | |
| Aluminum etc. | ambient environment. It could | |
| be attached with thermal | ||
| adhesive to the chassis of a | ||
| smartphone, watch etc. A | ||
| finned heatsink could also be | ||
| attached to the top if there | ||
| is convective air cooling | ||
| available. | ||
| Valve Balls | Plastic, Metal | Balls 222 (could also be thin |
| 222 | (Steel, | discs) designed to allow only |
| Tungsten etc.), | unidirectional flow as | |
| Rubber, | desired. O-rings could also be | |
| Ceramic | used with the balls to ensure | |
| tight seals | ||
| Pressure Valve | High Temp, | Thin, flexible gasket 227 |
| Gasket 227 | Fluid Vapor | designed to seal the vapor |
| Resistant | entry into the pump | |
| (e.g., Silicone) | ||
| Load | Rigid sheet | Designed to hold the load 223 |
| Cover 228 | metal or plastic, | (solid or liquid) in place and |
| preferably | prevent it from falling off. | |
| heat insulating. | Also designed to provide a | |
| If liquid is | “back-stop” to ensure that the | |
| used, could be | load does not displace | |
| made of rubber | excessively due to vapor | |
| or other flexible | pressure in case the | |
| material. Could | diaphragm fails. | |
| be bolted, | ||
| welded, or | ||
| soldered on to | ||
| the heatsink | ||
| body | ||
| Load Cover | Metal or | This is needed when a liquid |
| Top 229 | Plastic, Rigid | load is used. The liquid load |
| is poured into the load cover | ||
| to the desired height and then | ||
| the top is used to seal the | ||
| cover to prevent spillage. | ||
In vertical space constrained applications, a deadweight load cannot be used, especially if the operating temperature is high. In such situations, the diaphragm itself could be stiffened to act as the load by selecting the appropriate thickness, material, and diameter. In situations where a diaphragm cannot be used, a spring or a liquid dead weight (like Gallium) can be used. The operating principle is Pascal's law: the pressure in a fluid is always the same and the pressure is a function of the height of the fluid.
Taller columns produce higher counterweight. In some situations, the counterweight load may need to be dynamically changed (increased or decreased) while the unit is operating. For instance: the ambient temperature temporarily increases beyond nominal values. A higher ambient temperature means a higher flowrate is required through the heat exchanger to transfer the same amount of heat. If the duty load on the chip is low, the temperature of the chip can be raised slightly, so the pump does more work and increases the flowrate through the heat exchanger. This increase in chip temperature can be accomplished by raising the deadweight value: by increasing the height of the liquid column. This can be achieved by using a bimetallic strip which contracts in diameter, thus raising the height of the liquid column.
In applications where the ambient temperature is too high (e.g., a smartphone left on a car dashboard or an electronic device in a higher than specified ambient environment), the pump will act as a “thermal switch” where heat from outside the device will not be conducted back into the device. It accomplishes this because the pump is designed to transfer heat from the evaporator to the heat exchanger. If the heat exchanger temperature exceeds the evaporator temperature, the pump will cease to function until the heat exchanger temperature drops below the evaporator temperature.
1. A heat-activated pump for removal of waste heat from an electronic chip, comprising:
the electronic chip generating the waste heat;
an evaporator containing a working fluid, the evaporator built into and integrated with a packaging of the electronic chip to receive the waste heat from the electronic chip to convert a liquid phase of the working fluid into a vapor of the working fluid;
a pressure-control safety valve coupled to an exit port of the evaporator and maintaining the working fluid in the evaporator at a set target pressure and allowing the vaporized working fluid to escape through the exit port whenever the set target pressure is exceeded;
a liquid-piston chamber coupled to the pressure-control valve to receive the vaporized working fluid from the evaporator at the set target pressure, the vaporized working fluid expanding adiabatically and displacing a liquid within the liquid-piston chamber, the liquid comprising the liquid phase of the working fluid, expelling the liquid from the liquid-piston chamber in a pumping stage of a thermodynamic cycle;
a unidirectional pump-exit check valve coupled to a first exit port of the liquid-piston chamber to allow the working fluid and/or the displaced liquid to exit the liquid-piston chamber;
a unidirectional liquid suction-entry check valve coupled to a return port of the liquid-piston chamber to allow the displaced liquid to enter the liquid-piston chamber;
a heat exchanger with a heatsink, the heat exchanger coupled to the unidirectional pump-exit check valve to receive the displaced liquid into the heat exchanger, and the unidirectional liquid suction-entry check valve to allow the displaced liquid to return to the liquid-piston chamber in a suction stage of the thermodynamic cycle, the heatsink radiating the waste heat away to a flow of cooler fluid; and
a unidirectional injector return check valve coupled to both a second exit port of the liquid-piston chamber and an input port of the evaporator, wherein periodic pressure pulses of the liquid phase of the working fluid from the liquid-piston chamber that temporarily exceed the set target pressure in the evaporator facilitate jets of the liquid phase of the working fluid to replenish the evaporator in successive brief spurts.
2. The heat-activated pump as in claim 1, wherein the evaporator is in the form of microchannels built into the packaging of the electronic chip.
3. The heat-activated pump as in claim 1, wherein the evaporator is a thermally insulative plate with edges bonded to a face of the electronic chip and with a hole for vapor egress and another hole for liquid ingress.
4. The heat-activated pump as in claim 3, wherein the pressure-control safety valve is in the form of a load disc applying deadweight upon the hole for the vapor egress to permit the vapor egress only when the specified target pressure that corresponds to the deadweight is reached.
5. The heat-activated pump as in claim 3, wherein the pressure-control safety valve is in the form of a flexible diaphragm covering the hole for the vapor egress and with a specified thickness and stiffness that flexes open to permit the vapor egress only when the specified target pressure is reached.
6. The heat-activated pump as in claim 1, wherein the liquid-piston chamber and the heat exchanger are in a form of at least one fluid channel accommodated in a single plate housing.
7. The heat-activated pump as in claim 6, wherein the unidirectional pump-exit check valve, the unidirectional liquid suction-entry check valve, and the unidirectional injector return check valve are in a form of balls confined within the at least one fluid channel, the at least one fluid channel having narrow backstops to limit a positional range of the balls.
8. The heat-activated pump as in claim 7, wherein the narrow backstops include O-ring gaskets to seal the at least one fluid channel whenever engaged by a respective one of the balls against a corresponding one of the O-ring gaskets.
9. The heat-activated pump as in claim 6, wherein the at least one fluid channel defining the liquid-piston chamber has a length that accommodates a specified volume of the vaporized working fluid and the displaced liquid.
10. The heat-activated pump as in claim 9, wherein at least one fluid channel defining the liquid-piston chamber has a serpentine arrangement within the single plate housing.
11. The heat-activated pump as in claim 6, wherein the single plate housing with the at least one fluid channel therein has a heat spreader cover in thermal transfer relation to an ambient environment having the flow of the cooler fluid.
12. The heat-activated pump as in claim 11, wherein the heat spreader cover further includes the heatsink attached thereto.
13. The heat-activated pump as in claim 1, further comprising a permanent magnetic material within the displaced liquid in the liquid-piston chamber, and an induction electrical generator surrounding the liquid-piston chamber for generating electrical current.
14. The heat-activated pump as in claim 13, wherein the permanent magnetic material is confined between backstops embedded in a groove defining the liquid-piston chamber, and the induction electrical generator comprises copper windings adjacent to the groove.