COLD PLATE WITH PLASTIC BODY

1 . A cold plate for cooling electronics, the cold plate comprising:

a first wall having a plurality of apertures formed therein;

a second wall;

a plastic body positioned between the first and second walls and having at least one channel formed therein configured to pass a cooling fluid therethrough and wherein each aperture of the plurality of apertures is aligned with a respective portion of the at least one channel;

a first gasket positioned between the first wall and a first side of the plastic body;

a second gasket positioned between the second wall and a second side of the plastic body; and

a port coupled with the first wall and comprising an input channel and an output channel respectively coupled with the apertures of the plurality of apertures.

2 . The cold plate of claim 1 , wherein the first and second gaskets comprise a form-in-place gasket material.

3 . The cold plate of claim 1 , wherein the at least one channel of the plastic body comprises a first channel formed in the first side of the plastic body and having a first portion aligned with a first aperture of the plurality of apertures and having a second portion aligned with a second aperture of the plurality of apertures.

4 . The cold plate of claim 3 , wherein the at least one channel of the plastic body comprises a second channel formed in the second side of the plastic body;

wherein the second channel is fluidly coupled with the first channel.

5 . The cold plate of claim 4 , wherein the plastic body comprises:

a first channel aperture formed in the plastic body configured to fluidly couple the first portion of the first channel with a first portion of the second channel; and

a second channel aperture formed in the plastic body configured to fluidly couple the second portion of the first channel with a second portion of the second channel.

6 . The cold plate of claim 5 , wherein a first portion of the cooling fluid is configured to flow from the input channel through the first channel toward the output channel; and

wherein a remaining portion of the cooling fluid is configured to flow from the input channel through the first aperture and through the second channel toward the second aperture and the output channel.

7 . The cold plate of claim 5 , wherein the first channel aperture is aligned with the first aperture; and

wherein the second channel aperture is aligned with the second aperture.

8 . The cold plate of claim 1 , wherein the port is welded to the first wall.

9 . The cold plate of claim 1 , wherein the port is brazed to the first wall.

10 . The cold plate of claim 1 , wherein the plastic body comprises one or more flow directors formed within the at least one channel configured to divide the cooling fluid into a plurality of flow streams; and

wherein a first flow stream of the plurality of flow streams is directed toward a predetermined location of the first wall.

11 . The cold plate of claim 1 further comprising a plurality of fasteners inserted through fastener openings formed in the first wall, the second wall, and the plastic body to couple the first wall, the second wall, and the plastic body together.

12 . The cold plate of claim 1 , wherein each of the first and second walls comprises a plate of thermally conductive material.

13 . A method of manufacturing a cold plate, the method comprising:

aligning a first plate with a synthetic form, wherein a first gasket material is positioned between the first plate and the synthetic form;

aligning a second plate with the synthetic form, wherein a second gasket material positioned between the second plate and the synthetic form;

coupling the first plate, the second plate, and the synthetic form together;

coupling a fluid port to the first plate;

wherein the fluid port comprises an input channel fluidly coupled with an input aperture formed in the first plate and comprises an output channel coupled with an output aperture formed in the first plate;

wherein the synthetic form has at least one channel formed therein to allow a cooling fluid to flow therethrough from the input channel to the output channel.

14 . The method of claim 13 further comprising:

forming a first gasket via the first gasket material, wherein the first gasket material comprises a form-in-place gasket material; and

forming a second gasket material via the second gasket material, wherein the second gasket material comprises the form-in-place gasket material.

15 . The method of claim 13 further comprising:

forming a first channel of the at least one channel in a first side of the synthetic form; and

forming, within the first channel, one or more flow directors configured to divide the cooling fluid into a plurality of flow streams within the first channel.

16 . The method of claim 15 further comprising:

forming a second channel of the at least one channel in a second side of the synthetic form; and

forming a pair of apertures through a center portion of the synthetic form to fluidly couple the first channel with the second channel.

17 . The method of claim 16 further comprising forming, within the second channel, at least one additional flow director configured to divide the cooling fluid into a plurality of flow streams within the second channel.

18 . The method of claim 13 , wherein coupling the fluid port to the first plate comprises one of brazing the fluid port to the first plate and welding the fluid port to the first plate.

19 . The method of claim 13 , wherein forming the first channel comprises forming a serpentine channel configured to direct the flow of the cooling fluid toward a first end of the synthetic form and toward a second end of the synthetic form multiple times.

20 . The method of claim 13 , wherein the synthetic form comprises plastic.