PDF 原檔：報告_OCP2026_緯穎_液冷機櫃輕量化與可靠度_20261015_original.pdf
講者公開簡報（OCP 官方 Recorded Content 頁提供下載）。文字以 PyMuPDF 逐頁抽取，
### p<n>為頁碼；圖表內容見原檔。
圖片清單（已驗證 2026-10-19）
| 檔名 | 頁 | 分類 | 親眼所見內容 |
|---|---|---|---|
報告_OCP2026_緯穎_液冷機櫃輕量化與可靠度_20261015_p3.png |
p3 | 真資料圖 | 單寬機櫃重量成長示意：約 800 kg（2022 起）→ >1300 kg → >4000 kg（預測，約 2027～2028），附三種機櫃示意圖，標示樓板荷重限制 |
報告_OCP2026_緯穎_液冷機櫃輕量化與可靠度_20261015_p4.png |
p4 | 真資料圖 | 液冷元件減重潛力表：機櫃歧管（低，受高插拔力限制）、QD（低）、冷板／內部歧管／管路（高，合計占液冷元件重量逾 70%）；附伺服器內冷板、內歧管、管路、QD 位置圖 |
報告_OCP2026_緯穎_液冷機櫃輕量化與可靠度_20261015_p9.png |
p9 | 真資料圖 | PPS 減重實物：冷板（PPS+GF 上蓋＋銅微通道底板）減重 66%；內歧管（PPS+GF 主體＋PPS 塑膠管）減重 52% |
報告_OCP2026_緯穎_液冷機櫃輕量化與可靠度_20261015_p10.png |
p10 | 文字卡 | 塑膠冷板與內歧管可靠度驗證項目（熱循環、2,000 小時加速壽命、MTBF、壓力循環、爆破、儲存、85°C/85%RH）與合格標準；100 psi 無洩漏、上蓋平面度變化 0.0018 mm；附兩件實物照 |
原始內容
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Jeff CA Chen Technical Supervisor, Wiwynn Corporation Shawn Ma Sr. Manager, Wiwynn Corporation Rack-Scale Weight Reduction for Liquid- Cooled Server Systems Using Lightweight Materials COOLING ENVIRONMENTS
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Outline 5 4 3 2 1 AI Rack Weight Growth Driving Lightweighting Identifying Liquid Cooling Component Candidates for Lightweighting Material Selection for Lightweight Liquid Cooling Components PPS+GF Component Design for Liquid Cooling PPS+GF Component Reliability Validation Items
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AI Rack Weight Growth Driving Lightweighting 2022 2024 2026 2028 Single-width Rack Weight ~800 kg
1300 kg 4000 kg (projection) Year • Growing AI rack weight is challenging data center floor-loading limits • Lightweighting helps reduce floor-loading demands, material usage, and deployment costs
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• Cold plates, inner manifolds, and tubing account for over 70% of total liquid cooling component weight in a rack Identifying Liquid Cooling Component Candidates for Lightweighting Rack Manifold Components Weight-Reduction Potential Rack Manifold Low (Constrained by high mating force) QD Low (Limited design flexibility) Cold Plate High Inner Manifold High Tubing High Server Liquid Cooling Components Cold Plate Inner Manifold Tubing Quick Disconnect (QD)
70% of total liquid cooling component weight
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• Material selection requires balancing weight, compatibility, and structural strength • Aluminum reduces weight by ~70% vs. copper while retaining sufficient thermal and structural performance • PPS+GF offers the lowest density with good PG25 compatibility Material Selection for Lightweight Liquid Cooling Components Property Copper Aluminum Plastic (PPS+GF) Density High (~8.9 g/cm³) Moderate (~2.7 g/cm³) Low (~1.66 g/cm³) Compatibility with PG25 Compatible Compatible Compatible Thermal Conductivity High (~400 W/m·K) Moderate (150~200 W/m·K) Low (<1 W/m·K) Structural Strength High Moderate to High Moderate PPS: Polyphenylene Sulfide GF: Glass Fiber
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PPS+GF Maintains Strength and Stiffness from 20°C to 80°C Reference: PPS+GF material property data from the DIC PPS Product Guide 20°C- 80°C Flexural Strength of PPS+GF Flexural Modulus of PPS+GF 20°C- 80°C Both flexural strength and flexural modulus retain at least 80% of their room-temperature values up to 80°C
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• A cold plate typically consists of a top cover and a metal base plate • Replacing the top cover with PPS+GF reduces weight • The metal base plate is retained to preserve heat transfer performance • The base plate can be extended to cool adjacent components simultaneously Lightweight Cold Plate without Compromising Thermal Performance PCB Heat Source Heat Source PPS+GF Top Cover Lightweight Cold Plate Architecture QD Liquid Inlet/Outlet Metal Base Plate Extended Base Plate
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• Multiple joining methods were evaluated for manufacturability, structural strength, and sealing Joining Methods for Plastic-Metal and Plastic-Plastic Interfaces Cold Plate QD to Plastic Main Body • Mechanical Fastening Main Body Plastic to Plastic • Ultrasonic Welding Inner Manifold Plastic Top Cover to Metal Base Plate • Mechanical Fastening • Overmolding • Others
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Inner Manifold Cold Plate PPS-Based Designs Achieve >50% Weight Reduction Plastic (PPS+GF) Top Cover Copper Base Plate With Microchannel Plastic (PPS) Tube Plastic (PPS+GF) Main Body 66% Weight Reduction 52% Weight Reduction • Top Cover Replaced with PPS+GF • Metal Base Retained for Thermal Performance • Metal Main Body Replaced with PPS+GF • Plastic Tubing Implementation
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Pass Criteria: • No Leakage • No Cracks, Deformation, or Bulging • No Change in Thermal Resistance • No Change in Pressure Drop • Full Functionality Retained After Reliability Testing • Plastic Cold Plates and Inner Manifolds are validated against thermal, pressure, and environmental stresses to ensure long-term reliability in liquid-cooling applications • Both the cold plate top cover and inner manifold showed no leakage at 100 psi. The cold plate top cover exhibited only 0.0018 mm of flatness change, within specification Reliability Validation for Plastic Components • Thermal Reliability • Thermal Cycling Test • 2,000-hour Accelerated Life Test • MTBF Verification • Pressure Reliability • Pressure Cycling Test • Burst Pressure Test • Environmental Reliability • Storage Test • High Humidity Test (85°C / 85%RH) Plastic Inner Manifold Plastic Cold Plate
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• Effective lightweighting requires both material selection and structural design, while balancing weight, structural integrity, performance, coolant compatibility, and reliability • PPS+GF enables significant weight reduction without compromising functionality. A PPS+GF top cover with a metal base plate maintains cold plate performance, while reducing inner manifold weight • Comprehensive reliability validation is planned to assess the long-term feasibility of PPS+GF liquid-cooling components, including thermal, pressure, and environmental reliability under representative operating conditions Conclusions
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• Future Work ‒ Validate Long-Term Reliability of PPS+GF: Continue evaluating PPS+GF components through extended reliability testing to confirm their long-term feasibility in liquid- cooling applications ‒ Explore Additional Cold Plate Joining Methods: Continue evaluating alternative joining technologies for cold plate assemblies to improve reliability, manufacturability, and design flexibility ‒ Expand Lightweight Material Applications: Continue investigating alternative lightweight materials and exploring additional liquid-cooling components for implementation, maximizing system-level weight reduction while maintaining performance and reliability • Get involved in Cooling Environments – Cold Plate Sub-project ‒ Every 2nd Wednesday of the Month from 8am-9am PT ‒ https://www.opencompute.org/w/index.php?title=Cooling_Environments/Cold_Plate Call for Action
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Confidential - External Thank You! Jeff CA Chen jeff_ca_chen@wiwynn.com https://www.wiwynn.com Shawn Ma Shawn_Ma@wiwynn.com https://www.wiwynn.com