Abstract: The subject invention provides a method of manufacturing an all-metal cold plate heat exchanger assembly for removing excess heat from a heat generating electronic component. The cold plate assembly includes a base plate having micro-channels and associated micro-fins, a manifold plate having alternating channels, and a manifold cover, wherein the manifold plate cooperates with the micro-channels to form an engineered pathway for coolant flow. This method assures a tight interface sealing between the contact surfaces of the alternating channels of the manifold plate and the coplanar surfaces of the micro-fins that would prevent coolant by-pass flow, but without clogging or jeopardizing the flow through the micro-channels. This method utilizes a layer of recast metallic particulates, which is a natural by-product of laser machining, as a compliant gasket material between the coplanar edges of the alternating channels and the coplanar edges of the micro-fins.

Abstract: The invention relates to a method of making a brazed micro-channel cold plate assembly for cooling a heat producing electronic component. The primary components of a cold plate assembly are a base plate, a manifold cover, and inlet/outlet pipes; wherein the individual components are assembled and brazed into an integral unit. The joining surfaces of the individual components have novel features that provide for permanent bonding of the joints by brazing and a hermetic seal along the joint seams. The novel features also forestall excess braze alloy from contaminating the interior surfaces of the assembled cold plate and obstructing the engineered flow channels.