Thermally optimized aluminum heat-rejection block with integrated fluidic dissipation architecture

An aluminum cooling block assembly for heat dissipation, comprising:

• an aluminum bottom plate having (i) a planar thermal interface surface configured for direct thermal contact with a heat-generating component and (ii) a plurality of fins integrally formed with the aluminum bottom plate and extending from an opposite surface of the aluminum bottom plate into an internal fluid volume;
• an aluminum top plate coupled to the aluminum bottom plate, the aluminum top plate and the aluminum bottom plate collectively defining the internal fluid volume;
• an elastomeric gasket positioned between the aluminum top plate and the aluminum bottom plate and defining a sealed perimeter of the internal fluid volume;
• a plurality of distributed mechanical fasteners extending through corresponding openings of the aluminum top plate and the aluminum bottom plate and configured to apply compressive force that seals the elastomeric gasket and maintains continuous thermal coupling at the planar thermal interface surface during thermal cycling;
• and
• a first and second fluid fittings coupled to the aluminum top plate and defining an inlet and an outlet in fluid communication with the internal fluid volume, wherein the plurality of fins are arranged to increase convective heat exchange between circulating coolant and the aluminum bottom plate while controlling coolant pressure drop through the internal fluid volume, and
• wherein the planar thermal interface surface is manufactured to a flatness tolerance and includes a polished finish configured to reduce thermal interface resistance.