Intra-lid Multi-Core Vapor Chamber Architecture for Heterogeneous Electronic Packages: Technology Concept to Prototype Evaluation

Intra-lid Multi-Core Vapor Chamber Architecture for Heterogeneous Electronic Packages: Technology Concept to Prototype Evaluation

Event Date: December 26, 2022
Authors: S. Bandyopadhyay, A. Yuksel, A.M. Marconnet, and J.A. Weibel
Journal: IEEE Transactions on Components, Packaging and Manufacturing Technology
S. Bandyopadhyay, A. Yuksel, A.M. Marconnet, and J.A. Weibel, IEEE Transactions on Components, Packaging and Manufacturing Technology, vol. 12, no. 12, p. 1932 - 1938, 2022. DOI: 10.1109/TCPMT.2022.3230044
Thermal management of future heterogeneous electronic packages with extreme heat fluxes relies on effective spreading of heat in the package lid. Intra-lid integration of vapor chambers is a promising strategy for simultaneous dissipation of large total heat loads and localized high-flux hotspots. However, conventional vapor chambers comprising a single vapor core require relatively thick evaporator wicks to prevent dry out at high total heat loads, thereby imposing a large temperature drop across the wick at the hotspot location. We recently proposed a cascaded multi-core vapor chamber (CMVC) architecture comprising a single-core vapor chamber stacked on an array of smaller footprint vapor cores having relatively thinner wicks. The multi-core array is designed to spread heat from arbitrarily distributed high-flux hotspots before they enter the top vapor chamber having a thicker wick. Then, the top vapor chamber spreads the high total heat loads to the base of the mounted heat sink. To evaluate the proposed CMVC technology, we make a weighted decision to identify an appropriate minimum viable prototype for subsequent design and testing. A reduced-order model is used to determine the dimensions and properties of the wick and vapor core that minimize the temperature drop across the down-selected multi-core vapor chamber architecture for a given power map, considering manufacturing process constraints. Finite element analysis (FEA) simulations are employed to decide a condenser wall thickness that avoids permanent deformation in the vapor chamber architecture under a mechanical load. A prototype is manufactured by a commercial vendor following these parameters and manufacturing constraints. As predicted by the thermal model, experimental characterization of this first-reported multi-core vapor chamber array prototype offers a notable reduction in temperature drop relative to a benchmark solid copper spreader, owing to attenuation of hotspots at a low temperature difference.