Heat transfer unit extrusion process

Abstract

An extrusion process for forming heat transfer units or portions thereof for use in a cooling system for cooling heat generating components in an electronic system. Several embodiments of the present invention are presented. In one embodiment, a material is extruded through a die and a housing is formed that can be used as the housing or a portion thereof, for the heat transfer unit.

1 . A method for fabricating a portion of a heat transfer unit used for cooling heat-generating components in an electronic system, the method comprising the step of:
 extruding a first material to form an extruded portion of one or more heat transfer unit housings.   
   
   
       2 . The method as set forth in  claim 1  wherein the step of extruding the first material comprises the steps of:
 adjusting the first material to a malleable state;   forming the malleable first material into the shape of the extruded portion of the heat transfer unit housing; and   hardening the extruded portion of the heat transfer unit housing.   
   
   
       3 . The method as set forth in  claim 2  wherein the step of forming the malleable first material into the shape of the extruded portion of the heat transfer unit housing comprises:
 inserting the malleable first material into and through a die.   
   
   
       4 . The method as set forth in  claim 3  wherein the die is configured such that at least one side of the extruded portion of the heat transfer unit housing has a different thickness than the other sides. 
   
   
       5 . The method as set forth in  claim 2  comprising the additional step of:
 adjusting the extruded portion of the heat transfer unit housing to a desired length.   
   
   
       6 . The method as set forth in  claim 2  wherein the extruded portion of the heat transfer unit housing is a body having a cavity therethrough, the method comprising the additional step of:
 closing one or more ends of the extruded portion shortly after the extrusion exits the die and while the material is still malleable thereby resulting an enclosed cavity.   
   
   
       7 . The method as set forth in  claim 2  wherein the extruded portion of the heat transfer unit housing is a body having a cavity therethrough, the method comprising the additional step of:
 closing one or more ends in a separate process thereby resulting an enclosed cavity.   
   
   
       8 . The method as set forth in  claim 2  wherein the extruded portion of the heat transfer unit housing is a body having a cavity therethrough, the method comprising the additional step of:
 closing one or more ends by applying pressure to change the shape of the extrusion thereby resulting an enclosed cavity.   
   
   
       9 . The method as set forth in  claim 2  wherein the extruded portion of the heat transfer unit housing is a body having a cavity therethrough, the method comprising the additional step of:
 closing one or more ends by applying additional material thereby resulting an enclosed cavity.   
   
   
       10 . The method as set forth in  claim 9  wherein the ends are closed by attaching one or more end plates to the extruded portion of the heat transfer unit housing, the ends having an opening and means coupled to the openings for mating with a coolant pathway. 
   
   
       11 . The method as set forth in  claim 2  wherein the extruded portion of the heat transfer unit housing is a partial housing with at least one open side, the method comprising the additional steps of:
 forming a multi-sided, second portion of the heat transfer unit housing from a second material; and   attaching the second portion to the extruded portion of the heat transfer unit thereby forming an enclosed cavity.   
   
   
       12 . The method as set forth in  claim 11  wherein the second portion of the heat transfer unit housing has one or more openings and means coupled to the openings for mating with a coolant pathway. 
   
   
       13 . The method as set forth in  claim 11  wherein the second material is a different material than the first material. 
   
   
       14 . The method as set forth in  claim 11  wherein the second portion is formed by extrusion. 
   
   
       15 . The method as set forth in  claim 2  wherein the extruded portion of the heat transfer unit housing is a partial housing having an open surface and no ends, the method comprising the additional steps of
 forming ends to the extruded portion of the heat transfer unit housing thereby forming a housing with an open or partially open surface.   
   
   
       16 . The method as set forth in  claim 15  wherein the ends are formed by attaching one or more end plates to the extruded portion of the heat transfer unit housing, the ends having an opening and means coupled to the openings for mating with a coolant pathway. 
   
   
       17 . The method as set forth in  claim 15  comprising the additional step of:
 attaching the heat transfer unit housing to the surface of a heat-generating component such that the open or partially open surface of the heat transfer unit is coupled to such surface of the heat-generating component, whereby, in operation, coolant circulating through the heat transfer unit can directly contact the surface of the heat-generating component to be cooled.   
   
   
       18 . The method as set forth in  claim 15  comprising the additional step of:
 attaching a third material to the ends and the extruded portion of the heat transfer unit housing thereby eliminating the open surface of the heat transfer unit and forming a heat transfer unit with an enclosed cavity.   
   
   
       19 . The method as set forth in  claim 18  wherein one or more ends have an opening and means coupled to the openings for mating with a coolant pathway. 
   
   
       20 . The method as set forth in  claim 18  wherein the third material is fabricated from a different material than the first material.