The field of the invention generally relates to high temperature superconducting (HTS) front-end filter systems for use in, for example, wireless applications. The present invention has particular usefulness for wireless PCS carriers but is generally applicable to all wireless front-end applications requiring high sensitivity and high selectivity.
It is known that cryogenically cooled front-end receivers can be used to provide increased sensitivity and selectivity for expanding coverage and reducing interference in noise-limited and interference-limited cell sites. In the context of wireless voice services, cryogenically cooled front-ends provide significant enhancements in network performance including, for example, greater call capacity, fewer coverage gaps both outside and inside buildings, as well as an overall improvement in voice quality.
Cryogenically cooled front-ends include one or more HTS radio frequency RF filters that, because of their near-zero resistance, provide high selectivity with low loss. In order for the HTS filters to function properly, however, the HTS filters must be cooled to cryogenic temperatures. In order to cool the filters in the front-end, a cryocooler such as a Stirling cycle cryocooler is used to maintain the filters (as well as other associated electronics) at cryogenic temperatures.
Because of the cryogenic temperatures needed to function properly, cryogenic front-ends must deal with a whole host of thermal management issues. For example, for a cryocooler to function properly, the heat of compression must be efficiently and reliably rejected to the ambient environment. If the heat generated in the compression cycle of the cryocooler cannot be readily rejected, it will result in inefficient cryocooler operation and even crycooler shut down or failure. Still other components of the front-end device can radiate heat that needs to be transferred to ambient.
Various methods and devices have been employed to produce cryogenically cooled front-ends. U.S. Pat. No. 6,263,215 discloses a cryoelectronically cooled receiver front-end for mobile radio systems. The receiver front-end consists of a mast mounted portion of the receiver front-end, a compressor located off the mast, and a conduit for delivering cooling fluid from the compressor to the mast-mounted receiver front-end. This system suffers from the limitation that large amounts of energy are wasted by having to pump cooling fluid from the compressor to the mast-mounted receiver front-end (which may be as high as 200 feet above the ground.)
U.S. Pat. No. 6,112,526 discloses a HTSC filter system that contains a cryocooler and dewar assembly, a heat dissipation assembly, and at least one heat pipe providing thermal coupling between the heat dissipation assembly and the cryocooler and dewar assembly. In certain embodiments of the system of the '526 patent, one or more fan units may be needed to provide forced air over the heat dissipation assembly.
It is also known to mount cryogenically cooled front-ends in a structure such as a shed at the bottom of a wireless base station. In this system, the cryogenically cooled front-end is mounted in a rack or cable tray mount. In both options, however, forced convection cooling using a fan unit is required to ensure proper thermal management.
There thus is a need for a integrated cryogenic receiver front-end that can be located in or adjacent to a wireless base station that does not require a fan unit (either internal or external). There is a further need for a weatherized integrated cryogenic receiver front-end that can be mounted adjacent to a base station in an outdoor environment. There is a further need for an integrated cryogenic receiver front-end that can more efficiently transfer heat generated by power amplifiers, multiplexers, and electronics to ambient.
In a first aspect of the invention, a cryogenic receiver front-end includes a heat sink, the heat sink having a mounting surface and a plurality of fins. A cryocooler is mounted to the mounting surface of the heat sink. A heat rejector surrounds the cryocooler and includes a plurality of c-shaped recesses therein. The cryogenic receiver front-end further includes a plurality of heat pipes having a working fluid disposed therein, each heat pipe having first and second ends, the first ends of the plurality of heat pipes disposed in respective c-shaped recesses of the heat rejector, the second ends of the plurality of heat pipes being thermally coupled to the heat sink. An enclosure unit is mounted to the heat sink.
In a second separate aspect of the invention, a method of dissipating heat from a heat generating component in or adjacent to a base station includes the steps of providing a heat sink, the heat sink being located in or adjacent to a base station. At least one heat generating component is provided. A heat pipe is provided for the at least one heat generating component, the heat pipe having a first end and a second end and a working fluid contained therein, the first end of the heat pipe being thermally coupled to the at least one heat generating component, the second end of the heat pipe being thermally coupled to the heat sink.
In a third aspect of the invention, a thermally conductive interface between a heat source and a heat sink is provided and includes a heat rejector being thermally coupled with a heat source, the heat rejector including a c-shaped recess therein for receiving one end of a heat pipe having a working fluid therein, the heat sink being thermally coupled to an opposing end of the heat pipe.
It is an object of the invention to provide a cryogenic receiver front-end that can be located in or adjacent to a base station that does not require the use of an external fan or similar device to aid in expelling heat to ambient. The cryogenic receiver front-end has a small size and can be mounted either indoors or outdoors. The cryogenic receiver front-end is weather resistant (NEMA-4X compliant) and can be mounted, for example, on a pad, wall, shelf, or pole.
It is a further object of the invention to provide a thermally conductive interface between a heat source and a heat sink that uses a heat pipe mounted to a novel heat rejector.
It is yet another object of the invention to provide a method of dissipating heat from heat generating components located in or adjacent to a wireless base station.
These and further objects of the invention are described in more detail below.
For outdoor use, the enclosure provides a reasonable degree of protection against falling dirt, rain, sleet, snow, windblown dust, splashing water, hose-directed water, and ice. The enclosure 4 is preferably made from a corrosion resistant metal.
With reference now to
Referring to
The cryogenic receiver front-end 2 includes both a dual duplexed RF path shown in
In accordance with the invention, the cryogenic receiver front-end 2 uses a unique heat rejection system that is able to passively reject heat to the outside environment without the aid of a fan or other similar device that would enhance convection on or around the device. Preferably, the cryogenic receiver front-end 2 is able to maintain a temperature difference of less than about 20° C. between the temperature of the heat rejector of the cryocooler 22 and the ambient temperature.
As seen in
FIGS. 6(a) and 6(b) show a detailed view of the cryocooler 24 and the heat rejection system used to transfer heat to ambient. The heat rejection system includes a heat sink 26 having a mounting surface 34 and plurality of fins 36. The cryocooler 24 is mounted to the mounting surface 34 of the heat sink 26 by the carriage assembly 28. Preferably, the heat sink 26 is made from a thermally conductive material such as aluminum. One preferred material for the heat sink 26 and fins 36 is aluminum alloy 6063. The fins 36 are preferably swaged to optimize heat transfer for natural heat convection.
Additional electronic components of the cryogenic receiver front-end 2 are also directly mounted to the mounting surface 34 of the heat sink 26. These components include the power supply 38, power converter 40, diode 42 (for power system protection), DSP board 44, and one or more RF components such as amplifiers 46 (six amplifiers in total are shown). The additional RF components may comprise additional amplification, such as second stage amplification, mixing devices for frequency conversion and/or IF signal processing and analogue to digital converter (A to D converter). The electronic components are advantageously mounted directly to the heat sink 26 in order to more efficiently transfer heat generated thereby to ambient. Heat generated by the various electronic components is transferred to the plate portion of the heat sink 26 and then to the fins 36.
A thermally conductive interface is provided between the heat rejector 32 of the cryocooler 24 and the heat sink 26. In the preferred embodiment, a plurality of heat pipes 48 are used to efficiently transfer heat from the heat rejector 32 to the heat sink 26. As seen in
Referring to
FIGS. 8(a)illustrates one side of the heat rejector 32 used to transfer heat from the cryocooler 24. The heat rejector 32 is formed from a thermally conductive metal such as, for example, copper. Preferably, the thermally conductive metal is annealed OFHC copper. In a preferred method of forming the heat rejector 32 half hard or full hard OFHC copper is annealed (softened) by brazing the copper to at least 450° C. The annealed copper that results is particularly pliable and can form an excellent thermal contact with the heat pipes 48.
The heat rejector 32 includes a c-shaped recess 58 that receives an end of the heat pipe 48. The heat rejector 32 also includes a plurality of holes 60 that can accept bolts 62 (
Referring now to
Also located inside the evaporator section of the heat pipe 48 (the section of heat pipe 48 secured within the heat rejector 32) is a wire mesh or screen 68. The evaporator section is retained in the c-shaped recess 58 when the heat pipe 48 is secured to the heat rejector 32. A working fluid 70 is located inside the heat pipe 48 and is used to transfer heat from the evaporator portion to the cooler condenser portion secured to the heat sink 26. In a preferred aspect of the invention, the working fluid 70 is methanol. However, other working fluids such as ammonia, water, nitrogen, neon, and ethane can be used. A pinch 72 (see also FIGS. 8(b) and 8(c)) is formed at the end of the heat pipe 48 opposite the end having the plug 66. The pinch 72 is formed after filing the heat pipe 48 with the working fluid 70. An epoxy (not shown) is preferably placed over the pinch 72 to protect the pinched zone from damage that might cause working fluid 70 to leak out.
The use of one or more heat pipes 48 in the cryogenic receiver front-end 2 provides a thermal management system that is able to passively reject heat to ambient without the aid of a fan. Moreover, the heat pipes 48 are fully contained within the enclosure 4 (i.e., the heat pipes 48 do not pass through the walls of the enclosure 4) and therefore do not jeopardize the environmental protection quality of the cryogenic receiver front-end 2.
While the preferred embodiment of the invention uses a plurality of heat pipes 48 to transfer the heat of compression generated from a cryocooler 24, it should be understood that the heat rejector 32 and heat pipe(s) 48 may be used to dissipate heat from any number of heat generating components that are in a cryogenic receiver front-end 2 located in or adjacent to a base station 6. In addition, it may be the case that a single heat pipe 48 provides sufficient heat transfer from a heat generating component to a heat sink.
The heat source 82 is preferably thermally coupled to a heat rejector 86 having at least one c-shaped recess 88 of the type described in detail above. A heat pipe 90 (or multiple heat pipes 90 if more than one c-shaped recess 88 is present) is disposed inside the c-shaped recess 88 in a clamped arrangement thereby thermally coupling the heat pipe 90 to the heat rejector 86. The heat pipe 90 is thermally coupled at the other end to the heat sink 84. The heat pipe 90 may be thermally coupled to the heat sink 84 using heat pipe covers 50 as described above (not shown in
The heat pipe 90 may include a plug 92 at one end and a pinch 94 at the other end to retain a working fluid therein (not shown). In
While the invention is susceptible to various modifications, and alternative forms, specific examples thereof have been shown in the drawings and are herein described in detail. It should be understood, however, that the invention is not to be limited to the particular forms or methods disclosed, but to the contrary, the invention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the appended claims.
The U.S. Government may have a paid-up license in this invention and a right in limited circumstances to require the patent owner to license others on reasonable terms as provided for by the terms of Contract No. DMEA90-03-C-0302 awarded by the Defense MicroElectronics Activity (DMEA) established by the Department of Defense.