Cooling system for electronic devices

[0001] This is a continuation-in-part of U.S. Ser. No. 10/761,503, filed Jan. 20, 2004, as a continuation-in-part of application Ser. No. 10/241,118, filed Sep. 11, 2002 now abandoned.

[0002] This invention relates to a cooling system for electronic components utilizing a liquid coolant. More particularly, it relates to such a system comprising a plurality of pouch bodies, each formed of a flexible sheet material making the pouch body deformable, so that the pouch bodies can be moved against and conform in shape to uneven surfaces. Cooling fluid is circulated through the pouch bodies for cooling objects having the uneven surfaces.

[0003] It is well known that computers include components that produce heat. Various types of cooling systems have been proposed for removing heat from the computer components to maintain the computer within acceptable operating temperature limits. The prior art includes cooling systems utilizing a cooling liquid, such as water and a cooling gas, such as air. The conventional liquid coolant systems comprise cooling blocks formed of hard materials such as metal. It is difficult to make these blocks in such a way that they can be put into contact with uneven surfaces. Also, the cooling blocks are difficult to directly install on such electronic devices as hard-disk drives, video cards, memory cards, or a PCB.

[0004] Conventional air-cooling systems deliver air into direct contact with the surfaces that are to be cooled. Heat absorptivity is low, resulting in a pour cooling efficiency.

[0005] The known systems include the systems disclosed by my U.S. Pat. No. 5,731,954, granted Mar. 24, 1998, and entitled Cooling System For Computer, by my U.S. Pat. No. 6,234,240, granted May 22, 2001, and entitled Fanless Cooling System For Computer, by my U.S. Pat. No. 6,313,990, granted Nov. 6, 2001, and entitled Cooling Apparatus For Electronic Devices, and by my U.S. Pat. No. 6,664,627, granted Dec. 19, 2003, and entitled Water Cooling Type Cooling Block For Semiconductor Chip.

[0006] There is a need for a cooling system that uses a liquid coolant and places the coolant into close proximity with the object to be cooled. A principal object of this invention is to provide that need.

[0007] The cooling system of the invention comprises first and second pouch bodies, each formed of sheet material that is deformable. Each pouch body has first and second ends, an inlet for a cooling fluid at its first end and an outlet for the cooling fluid at its second end. Preferably, an elongated support is provided, and the first and second pouch members are connected to the support, and inlet and outlet manifolds are provided. Inlet conduits extend from the inlet manifold to the inlets for the pouches. Outlet conduits extend from the outlets for the pouches to the outlet manifold.

[0008] Preferably, a first presser plate is positioned outside of the first pouch body and a second presser plate is positioned outside of the second pouch body. The presser plates are movable relatively together and apart.

[0009] Preferably also, a first clamp is positioned endwise of first ends of the pouch bodies and a second clamp member is positioned endwise of second ends of the pouch bodies. The clamps have spaced apart jaws which are movable together and apart.

[0010] Other objects, advantages and features of the invention will become apparent from the description of the best in the mode set forth below, from the drawings, from the claims and from the principles that are embodied in the specific structures that are illustrated and described.

[0020] FIG. 1 shows a mounting board 10 for electronic components that are parts of a computer, for example. FIG. 1 shows two side-by-side cooling assemblies 12. FIGS. 2-4 show one of the cooling assemblies 12. The cooling assembly 12 comprises a plurality of pouch bodies formed of sheet material that is deformable. The illustrated embodiment comprises three poach bodies and they are designated 14, 16, 18. These pouch bodies may be constructed in the manner disclosed in U.S. Ser. No. 10/761,503, the contents of which is hereby incorporated herein. Herein, pouch body 14 is sometimes referred to as the first pouch body. Pouch body 16 is sometimes referred to as the second pouch body. Pouch body 18 is sometimes referred to as the third pouch body. The first and second pouch bodies 14, 16 are positioned at the sides of the assembly 12. Pouch body 18 and any additional pouch bodies are positioned between the pouch bodies 14, 16. Pouch bodies 14, 16, 18 are positioned in a side-by-side relationship.

[0021] In preferred form, support plates 19 are provided above the first ends of the pouch bodies 14, 16, 18. Similar support plates 20 (FIG. 4) are positioned above the second ends of the pouch bodies 14, 16, 18. Each plate 19 includes a fitting 22 and each plate 20 includes a fitting 24. One of the fittings 22, 24 is an inlet fitting and the other is an outlet fitting. For example, fittings 22 may be the inlet fittings and fittings 24 may be the outlet fittings.

[0022] The assembly 12 is provided with a manifold block 26. In the illustrated example, manifold block 26 includes an inlet manifold 28 and an outlet manifold 30. Manifold block 26 includes an inlet fitting 32 and an outlet fitting 34. As shown by FIGS. 2 and 4 the inlet fittings 22 are connected to the inlet manifold 28 by inlet passageways 36. The outlet manifold 30 is connected to the outlet fittings 24 by outlet passageways 38. A liquid coolant (e.g. water) is delivered into the inlet manifold 28 via the inlet 32. This coolant flows into the manifold 28 and from the manifold 28 into the inlet passageways 36 to and through the inlet fittings 22 into the inlet end of the pouch bodies 14, 16, 18. The arrows in FIG. 3 show the flow path of the liquid coolant.

[0023] FIG. 4 shows support structure for the assembly of pouch bodies 14, 16, 18. It comprises a first side part 50 comprising a top 52 and a first presser member 54 depending from the top. A second support member 56 has a top 58 and a second side presser member 60 depending from top 58. Member 52 has upwardly extending end portions 62, 64 that fit within slots formed in the inlet and outlet fittings 22, 24. This fit is shown by FIG. 3. The inlet fittings 22 fit within a space 66 and the outlet fittings 24 fit within a space 68. Top 52 extends under the manifold assembly 26. A screw extends upwardly through an opening 70 formed in the top 52 and screws into the bottom of the manifold block 26, at a solid location between the two manifolds 26, 28. Support member 50 includes mounting plates 74, 76 on which base plates 78, 80 fit. Plates 74, 78 are connected together by screws and plates 76, 80 are connected together by screws.

[0024] An ear 82 projects upwardly from plate 78. An ear 84 projects upwardly from plate 80. Ear 82 includes a threaded screw receiving opening 86 and ear 84 includes a threaded screw receiving opening 88. When support member 50 is connected to the manifold block 26, the top 58 of support member 56 slides under the top 52. This positions base 90 on top of base 78 and places base 92 on top of base 80. An ear 94 extends upwardly from base 90. An ear 96 extends upwardly from base 92. Ear 94 includes a sideways slot 98. Ear 96 includes a sideways slot 100. When the bases 90, 92 are on the bases 78, 80, the slots 98, 100 are in registry with the threaded openings 86, 88. The clamp member 102 is located endwise outwardly of one end of the assembly 12. A clamp 104 is located endwise outwardly of the opposite end of the assembly 12. Clamp 102 includes a base 106 that fits on base 90. Clamp member 104 includes a base 108 that fits on base 92. Clamp member 102 includes an ear 110 that is positioned outwardly of ear 82. Clamp 104 includes an ear 112 that is positioned endwise outwardly of the ear 84. Ear 102 includes a vertical slot 114 and ear 112 includes a vertical slot 116. Vertical slot 114 is alignable with threaded opening 86. Vertical slot 116 is alignable with threaded opening 88. A clamp screw 118 includes a threaded portion 120 that extends first through vertical slot 114, then through horizontal slot 98, and then screws into the threaded opening 86. In like fashion, a second clamp screw 122 includes a threaded portion 124 that extends first through vertical slot 116, then through horizontal slot 100 and then screws into the threaded opening 88. The hook 102 has a lower end portion with an inwardly directed lip 126. In like fashion, the hook 104 includes an inwardly directed bottom lip 128 at its lower end. Side plate 54 and side plate 60 have end edges 130, 132 that are adapted to set down onto the upper edges 134, 136 of end members 138, 140. End members 138, 140 include edges 142, 144 that are positioned above the hooks 126, 128. The slots 114, 116 allow the hooks 102, 104 to be adjusted upwardly to place the lips 126, 128 into contact with the edges 142, 144, before the clamp screws 118, 122 are tightened. The two presser plates 54, 56 are movable together and apart by a distance established by the slots 98, 100. As will be later described, the plates 54, 56 are moved relatively together or apart before the clamp screws 118, 122 are tightened.

[0025] Components to be cooled in the form of cards are positioned between the first and third pouch bodies 14, 18 and between the second and third pouch bodies 16, 18. Then, presser plate 54 is moved against pouch body 14 and presser plate 60 is moved against pouch body 16. This imposes a lateral force on the pouch bodies 14, 18 and 16, 18 which clamps the cards between the pouch bodies 14, 18 and 16, 18. The flexible nature of the sidewalls of the pouch bodies 14, 16, 18 causes the pouch bodies to move into tight engagement with the sides of the cards, deforming the bodies to the irregular shape of the surfaces of the cards that are in contact with the pouch bodies 14, 18 and 16,18.

[0026] Preferably, the center pouch body 16 is wider than the two side pouch bodies 14, 16. The larger size of the pouch body 18 allows it to hold sufficient cooling liquid to cool both of the cards that are on its opposite sides. Pouch bodies 14, 16, 18 are formed of a soft sheet material that is deformable to closely contact heat-generating elements having various shapes due to a contact pressure and is capable of smoothly circulating a coolant, and accommodates a filler 11 and a liquid coolant, e.g. water. The external shape and size of the pouch bodies 14, 16, 18 are determined by shapes and installation locations of the heat-generating elements. Preferably, the filler 11 is a porous sponge having a predetermined elasticity. The pouch bodies 14, 16, 18 are constructed to include space enough to allow the coolant to flow into and through the pouch bodies 14, 16, 18. In the illustrated embodiment, cards carrying elements that generate heat are held by holders having end walls such as shown in FIG. 3, on which end portions of the presser plates are supported. As shown by FIG. 3, clamps at the ends of the pouch body assembly function to connect the pouch body assembly to the end walls. In other installations, other structures can be used for connecting the pouch body assemblies to structure on the board.

[0027] Referring to FIGS. 5 and 6, an element to be cooled 130 is positioned between pouch bodies 14, 18 and an element 132 to be cooled is positioned between pouch bodies 16, 18. The side plates 60, 66 are moved relatively together, to press the pouch bodies 14, 16, 18 tightly against the sides of the elements 130, 132. This deforms the sidewalls of the pouches 114, 116, 118, making them deform and conform to the irregular side surfaces of the elements 130, 132.

[0028] The thickness of the filler body 11 can vary depending on the spacing of the elements 130, 132. The coolant entering the inlet 22 will fill the inner space of the pouch body 14, 16, 18 and will become absorbed by the filler body 11. In some installations, the force applied to the sidewalls of the pouch bodies 14, 16, 18 will compress the filler body 11. Water or other coolant flowing into the inlet 22 will flow through the filler body 11 to the outlet 24 where it will flow out from the pouch body 14, 16, 18 and into and through its outlet passageway 38 and into the outlet manifold.

[0029] The illustrated embodiments are only examples of the present invention and, therefore, are non-limitive. It is to be understood that many changes in the particular structure, materials and features of the invention may be made without departing from the spirit and scope of the invention. Therefore, it is my intention that my patent rights not be limited by the particular embodiments illustrated and described herein, but rather are to be determined by the following claims, interpreted according to accepted doctrines of patent claim interpretation, including use of the doctrine of equivalents and reversal of parts.