Cooling of large semi-conductor devices

Claim 2

A wafer scale semi-conductor module stack comprising at least one wafer scale semi-conductor device mounted on each of the two surfaces of an electrical interconnect substrate, said devices having their active devices facing said substrate with means being provided whereby said substrate and said devices are electrically and mechanically attached, the opposing surface of said devices being the heat exchange surfaces wherein heat is removed by flowing two-phase cooling, and there being multiple substrates positioned parallel to each other and sharing a common axis, each substrate being spaced apart such as to provide a conduit between opposing devices for the flow of coolant and said conduits being fed by an input conduit with coolant discharge through an output conduit, said substrates being attached to common posts, said posts also serving as electrical power sources for said wafers, there further being electrical interconnect means between each of the multiple substrates, and said module stack being enclosed in a sealed housing flooded with coolant, said housing being provided with means for the input and discharge of coolant through said conduits, external power interconnection means for said posts and external electrical interconnect means for said substrate electrical interconnect means.

Claim 3

A wafer scale semi-conductor module stack comprising at least one wafer scale semi-conductor device mounted on each of the two surfaces of an electrical interconnect substrate, said devices having their active devices facing said substrate with means provided whereby said substrate and said devices are electrically and mechanically attached, the opposing surface of said devices being the heat exchange surfaces wherein heat is removed by flowing two-phase cooling, and there being multiple substrates positioned parallel to each other and sharing a common axis, each substrate being spaced apart such as to provide a conduit between opposing devices for the flow of coolant and said conduits being fed by an input conduit with coolant discharge through an output conduit, said substrates being attached to common posts, said posts also serving as electrical power sources for said wafers, there further being electrical interconnect means between each of the multiple substrates, and said module stack being enclosed in a sealed housing flooded with coolant, said housing being provided with means for the input and discharge of coolant through said conduits, external power interconnection means for said posts and external electrical interconnect means for said substrate electrical interconnect means, wherein said device heat exchange surface is concave curved in the direction of coolant flow and there being a septum with a convex curved surface corresponding to said concave surface and being spaced from said heat exchange surface to provide a coolant conduit with substantially constant cross section.

Claim 4

A wafer scale semi-conductor module stack comprising at least one wafer scale semi-conductor device mounted on each of the two surfaces of an electrical interconnect substrate, said devices having their active devices facing said substrate with means provided whereby said substrate and said devices are electrically and mechanically attached, the opposing surface of said devices being the heat exchange surfaces wherein heat is removed by flowing two-phase cooling, and there being multiple substrates positioned parallel to each other and sharing a common axis, each substrate being spaced apart such as to provide a conduit between opposing devices for the flow of coolant and said conduits being fed by an input conduit with coolant discharge through an output conduit, said substrates being attached to common posts, said posts also serving as electrical power sources for said wafers, there further being electrical interconnect means between each of the multiple substrates, and said module stack being enclosed in a sealed housing flooded with coolant, said housing being provided with means for the input and discharge of coolant through said conduits, external power interconnection means for said posts and external electrical interconnect means for said substrate electrical interconnect means, wherein said device heat exchange surface is concave curved in the direction of coolant flow and there being a septum with a convex curved surface corresponding to said concave surface and being spaced from said heat exchange surface to provide a coolant conduit with substantially constant cross section.

Claim 5

In the apparatus of claim 2 wherein said device heat exchange surface is periodic concave curved in the direction of coolant flow and there being a septum with a periodic convex curved surface corresponding to said concave surface and being spaced from said heat exchange surface to provide a coolant conduit with substantially constant cross section.

Claim 6

In the apparatus of claim 1 wherein means are provided whereby said coolant conduit surfaces are maintained substantially smooth and continuous to the flow of coolant throughout the length and breadth of said coolant conduits.

Claim 7

In the apparatus of claim 2 wherein an external cooling loop is connect to said housing comprising coolant pumping means and coolant heat exchanger, and optional coolant expansion and resevior means and optional coolant flow, temperature and pressure sensing means.

Claim 8

In the apparatus of claim 1 wherein said electrical interconnect means and said posts are external to said coolant conduits.

Claim 9

In the apparatus of claim 2 wherein said device curved heat exchange surface is prepared by at least one of grinding or chemical etching.

Claim 10

In the apparatus of claim 3 wherein said device periodic curved heat exchange surface is prepared by at least one of grinding or chemical etching.

Claim 11

In the apparatus of claim 2 wherein heat exchange surfaces have bonded thereto members being at least one of curved and periodically curved heat exchange surfaces and having high thermal conductivity and a good expansion match to said device are bonded to said device.

Claim 12

In apparatus of claim 9 said heat exchange members are at least one of tungsten, Silicon Carbide, Silicon Nitride and Boron Nitride.

Claim 13

In the apparatus of claim 2 wherein said heat exchange surface is provided with elevated reentrant nucleating site cavities, said elevated cavities having a height ranging from 0.001 mm to 0.5 mm above said heat exchange surface and the dimensions of said cavities ranging from 0.002 mm to 0.2 mm and said cavities being spaced apart on said heat exchange surface from 0.03 mm to 3 mm.

Claim 14

In the apparatus of claim 2 wherein said heat exchange surface is caused to undulate in the direction of coolant flow, said undulations ranging from a peak-to-peak height above the heat exchange surface from 0.001 mm to 0.5 mm and the periods of said undulations ranging from 0.005 mm to 5 mm.

Claim 15

In the apparatus of claim 1 wherein said substrate has mounted on one surface only at least one wafer scale semi-conductor device.

Claim 16

In the apparatus of claim 1 wherein said electrical interconnect and mechanical mounting means includes at least one of solder bump (flip chip) and Tape Automated Bonding.

Claim 17

The apparatus of claim 3, wherein said conduits are approximately 0.1 to 5 millimeters in height.

Claim 18

The apparatus of claim 1, wherein said wafer is divided into a first segment and a second segment.

Claim 21

The apparatus of claim 17, further comprising a plurality of elongated posts extending in a direction substantially orthogonal to a plane substantially defined by one of said modules, each of said modules being electrically and mechanically secured to each of said posts, said posts being configured to maintain electrical communication between two or more of said semi-conductor devices.

Claim 22

The apparatus of claim 17, wherein said semi-conductor devices comprise substantially circular wafer scale semi-conductor devices, each of said modules further comprising an extension member secured to each of said first and second surfaces of said substrate, said extension member having a circular void formed therein substantially conforming to the shape of said wafer scale semi-conductor device, such that said wafer scale semi-conductor device and said extension member cooperate to define a substantially smooth coolant flow path surface.

Claim 23

The apparatus of claim 19, wherein said coolant flow paths are approximately 0.1 to 5 millimeters in height.