Structure and apparatus for cooling integrated circuits using cooper microchannels

1. A cooler having a unitary construction comprising:

a channel portion comprising a plurality of fins on a base, the plurality of fins defining a plurality of microchannels therebetween;

a tapered opening formed into a vertical portion of a set of the plurality of fins;

a manifold portion disposed on an edge portion of the base and completely covering the channel portion, the manifold portion comprising an inlet port and an outlet port which are in fluid connection with respective tapered inlet and outlet manifold channels; and

a separator sheet comprising at least two elongated openings disposed between the channel portion and the tapered inlet and outlet manifold channels of the manifold portion where at least one of the elongated openings is aligned with a portion of the at least one tapered opening formed in a set of the plurality of fins, wherein distribution channels of the manifold portion are located above an active cooled portion of the plurality of fins, and wherein inlet and outlet channels of the manifold portion are located above the separator sheet.

2. The cooler of claim 1 , wherein the base is between about 0.5 and 2.0 millimeters thick, the microchannels have a pitch of about 200 microns or less, and the fins have a pitch of about 200 microns or less and a fin height of about 1 mm or greater.

3. The cooler of claim 1 , wherein the manifold portion comprises at least two tapered manifold inlet channels connected by an inlet distribution channel comprising at least two tapered manifold outlet channels connected by an outlet distribution channel, where the inlet port and the outlet port are formed for flowing fluid to respective ones of the tapered manifold channels and the distribution channels, and where the distribution channels are disposed above the fins and respective ones of the at least one tapered opening in the plurality of fins.

4. The cooler of claim 1 , wherein the separator sheet is formed of one of metal, compliant plastic layer, and a combination thereof and seals distribution channels.

5. The cooler of claim 1 , wherein the separator sheet is interior to the manifold portion and the manifold portion is metallurgically joined to the base around the edge of the base.

6. The cooler of claim 1 , wherein the separator sheet is bonded to the manifold portion around the distribution channels at edge portions thereof.

7. The cooler of claim 1 , further comprising at least three heat exchanger zones, wherein each heat exchanger zone is about 3 mm or more long.

8. The cooler of claim 1 , wherein a pressure drop due to the cooler is in the range between about 2 and 7 pounds per square inch.

9. The cooler of claim 1 , wherein a pressure drop due to the cooler is greater than about twice the variation in a pressure drop due to an external loop connected to the inlet port and outlet port of a group of coolers connected in parallel.

10. The cooler of claim 1 , wherein a uniformity of a flow distribution in an external loop connected to the inlet port and outlet port of a group of coolers connected in parallel is substantially dependent on a uniformity of a pressure drop in the cooler.

11. The cooler of claim 1 , wherein the elongated openings are partially offset from one another.

12. The cooler of claim 1 , wherein the tapered opening is formed into the vertical portion of the set of the plurality of fins along a length of the fins.

13. The cooler of claim 1 , wherein the manifold portion is formed as a shell.