Modular heat exchanger design

Abstract

A cold plate assembly is provided having a base defining a cooling channel and a heat exchanger friction-stir welded to the base, wherein the heat exchanger is located within a portion of the cooling channel, and the friction-stir welding between the heat exchanger and the base forms a fluid seal.

What is claimed is: 
     
         1 . A cold plate assembly comprising:
 a baseplate defining a cooling channel; and   a heat exchanger friction-stir welded to the baseplate, wherein the heat exchanger is located within a portion of the cooling channel, and the friction-stir welding between the heat exchanger and the baseplate forms a fluid seal.   
     
     
         2 . The cold plate assembly of  claim 1 , further comprising a cover, the cover configured to attach to the baseplate. 
     
     
         3 . The cold plate assembly of  claim 2 , wherein the cover forms a lid over the cooling channel where the heat exchanger is not located. 
     
     
         4 . The cold plate assembly of  claim 2 , wherein the cover is friction-stir welded to a portion of the heat exchanger. 
     
     
         5 . The cold plate assembly of  claim 2 , wherein the cover is friction-stir welded to the baseplate. 
     
     
         6 . The cold plate assembly of  claim 1 , wherein the heat exchanger is integral with a component to be cooled by the heat exchanger. 
     
     
         7 . The cold plate assembly of  claim 1 , wherein the heat exchanger comprises a plurality of fins defining a plurality of fluid channels between the plurality of fins. 
     
     
         8 . The cold plate assembly of  claim 1 , wherein the cooling channel of the baseplate includes a plurality of cooling fins and the heat exchanger includes a plurality of cooling fins configured to interleave with the cooling fins of the baseplate. 
     
     
         9 . The cold plate assembly of  claim 1 , wherein the baseplate includes a second cooling channel, the assembly further comprising a top cold plate friction stir welded on the baseplate over the second cooling channel. 
     
     
         10 . A method of manufacturing a cold plate assembly, the method comprising:
 friction stir welding a heat exchanger to a baseplate, the baseplate defining a cooling channel, the heat exchanger located within a portion of the cooling channel, and the friction-stir welding between the heat exchanger and the baseplate forms a fluid seal.   
     
     
         11 . The method of  claim 10 , further comprising attaching a cover to the baseplate. 
     
     
         12 . The method of  claim 11 , wherein the cover forms a lid over the cooling channel where the heat exchanger is not located. 
     
     
         13 . The method of  claim 11 , further comprising friction-stir welding the cover to a portion of the heat exchanger. 
     
     
         14 . The method of  claim 11 , further comprising friction-stir welding the cover to the baseplate. 
     
     
         15 . The method of  claim 10 , wherein the heat exchanger is integral with a component to be cooled by the heat exchanger. 
     
     
         16 . The method of  claim 10 , wherein the heat exchanger comprises a plurality of fins defining a plurality of fluid channels between the plurality of fins. 
     
     
         17 . The method of  claim 10 , wherein the cooling channel of the baseplate includes a plurality of cooling fins and the heat exchanger includes a plurality of cooling fins, the method comprising interleaving the cooling fins of the baseplate with the cooling fins of the heat exchanger. 
     
     
         18 . The method of  claim 10 , wherein the baseplate includes a second cooling channel, the method comprising friction stir welding a top cold plate on the baseplate over the second cooling channel.