Additively manufactured cooling assemblies for thermal and/or mechanical systems, and methods for manufacturing the assemblies

A multi-domain cooling assembly configured to be coupled with one or more heat sources, the cooling assembly comprising:

• a body comprising an outer surface;
• a cooling channel disposed inside the body, the cooling channel being defined by channel walls that extend through the body from a first side to a second side of the body and fluidly couple the cooling channel with a passageway that is configured to carry cooling fluid into and out of the cooling channel, wherein at least a portion of the cooling fluid is configured to be a liquid phase, a gas phase, or a liquid-gas mix phase, the cooling channel extending in at least two orthogonal dimensions, and the cooling channel further including at least one conduit extension that extends away from the channel walls of the cooling channel and toward the one or more heat sources, the at least one conduit extension being configured (i) to direct the cooling fluid from the cooling channel and toward the one or more heat sources and (ii) to direct the cooling fluid away from the one or more heat sources and toward the cooling channel;
• one or more of (i) a conformal vapor chamber that is disposed within the body and configured to hold a first working fluid inside the conformal vapor chamber, the conformal vapor chamber comprising walls that are disposed inside the body and extend around and enclose the conformal vapor chamber entirely within the body;
• and (ii) a thermal energy storage reservoir that is disposed within the body and includes a second working fluid, the thermal energy storage reservoir comprising walls that are disposed inside the body and extend around and enclose the thermal energy storage reservoir entirely within the body,
• wherein the one or more of the conformal vapor chamber and the thermal energy storage reservoir is configured to be thermally coupled with the cooling channel such that the one or more of the conformal vapor chamber and the thermal energy storage reservoir directs thermal energy from the one or more heat sources to the cooling channel.

An additively manufactured body comprising:

• one or more cooling chambers disposed inside the body, the one or more cooling chambers comprising walls that are disposed inside the body and extend around and enclose the one or more cooling chambers entirely within the body, the one or more cooling chambers including one or more of a liquid phase, a gas phase, or a liquid-gas phase mixture of a working fluid inside the one or more cooling chambers, the one or more cooling chambers extending in at least two orthogonal dimensions;
• and
• a cooling channel disposed within the body, the cooling channel being defined by channel walls that extend through the body from a first side to a second side of the body and fluidly couple the cooling channel with a passageway that is configured to carry cooling fluid into and out of the cooling channel, wherein at least a portion of the cooling fluid is configured to be a liquid phase, a gas phase, or a liquid-gas mix phase, the cooling channel extending in at least two orthogonal dimensions, and the cooling channel further including at least one conduit extension that extends away from the channel walls of the cooling channel and toward one or more heat sources, the at least one conduit extension being configured (i) to direct the cooling fluid from the cooling channel and toward the one or more heat sources and (ii) to direct the cooling fluid away from the one or more heat sources and toward the cooling channel, wherein the cooling channel is thermally coupled with the one or more cooling chambers,
• wherein one or more of the cooling channel or the one or more cooling chambers are configured to extract thermal energy from a heat source coupled with the additively manufactured body,
• wherein the cooling channel and each of the one or more cooling chambers are fluidly separate from each other, and
• wherein the one or more cooling chambers and the cooling channel are configured to be additively manufactured within the body.