Advanced liquid cooling seal structure

Abstract

A multi-layer seal formed from a first layer that visually detects a leak by incorporating a water-soluble colorant, a second layer that electrically detects a leak by incorporating a dispersible agent that disperses into water and causes a change in the chemical and / or electrical properties of the water upon contact with water, and a third layer made of a water-activated material that swells upon contact with water. The orientation of the three layers can be arranged so that a leak first reaches the first layer, then the second layer, and finally the swelling layer. The seal layer arrangement can be relative to the direction of fluid flow. The layers can be formed as separate components placed side-by-side or can be incorporated into a single seal ring.

Description

TECHNICAL FIELD

[0001] Embodiments of the present invention relate generally to electronic equipment cooling within servers and data centers. More specifically, embodiments of the present invention relate to sealing structures for detecting and preventing cooling liquid leaks. BACKGROUND

[0002] Cooling is an important factor in computer system and data center design. The number of high performance electronic components, such as high performance processors packaged within servers, is constantly increasing, increasing the amount of heat generated and dissipated during normal operation of the servers. If the temperature of the operating environment is allowed to increase over time, the reliability of the servers used within the data center can decrease. Maintaining a proper thermal environment is critical to the normal operation of servers in a data center, as well as to server performance and longevity. More effective and efficient cooling solutions are therefore needed, especially in the case of cooling high performance servers.

[0003] Electronic equipment cooling is very important for computing hardware and other electronic equipment such as CPU servers, GPU servers, storage servers, network equipment, edge and mobile systems, in-vehicle computing boxes, etc. All of these devices and computers are used for critical business and are the foundation of a company’s daily business operations. The design of hardware components and electronic packages needs to be improved to continuously support performance requirements. The cooling of these electronic equipment is becoming increasingly challenging to ensure their normal operation by constantly providing a properly designed and reliable thermal environment.

[0004] Many advanced chips, especially high power density chips, require liquid cooling. These chips are very expensive, so it is necessary to ensure their proper heat dissipation. In addition, liquid cooling equipment must be highly reliable, as any liquid leakage can potentially damage these chips, for example, by short-circuiting the electrical circuit, causing hardware loss, loss of available processing time during replacement operations, and even potential impact on service level agreements for processing during a leak.

[0005] Although liquid cooling solutions must provide the required thermal performance and reliability because a data center can have thousands of chips that require liquid cooling, the cost of a liquid cooling system must be kept within an acceptable range. The cost of a liquid cooling system can include the cost of proper testing during the manufacture of cooling elements and the incorporation of cooling elements into a server, as well as the cost of related sensors and leak detectors that can be required to ensure the safe operation of the server.

[0006] During manufacturing, liquid cooling equipment can be tested by filling with a gas, such as nitrogen, to a pre-set pressure level, and then monitoring for any pressure drop over a set time period. However, this test does not detect internal defects that have not manifested as external leaks. Furthermore, this test is relatively easy to perform for individual pieces of equipment, but when many pieces of equipment are incorporated into a server system, the test is difficult to perform. SUMMARY

[0007] Some aspects of the present application provide a seal for a cooling system installed in a server rack, the seal can include a visual leak detection layer including a water-soluble colorant, an electrical leak detection layer including a moisture-dispersible electrical detection agent, and an expansion layer including a water-activated expansion material.

[0008] Some aspects of the present application provide a cooling deck, the cooling deck can include a first block and a second block attached to the first block at a mating surface, a chamber defined between the first block and the second block, and a channel formed in the mating surface; a water inlet barb forming a fluid supply to the chamber; a water outlet barb forming a fluid return from the chamber; and a seal disposed in the channel, the seal including a first layer for visual detection of a leak by incorporating a water-soluble colorant, a second layer for electrical detection of a leak by a sensor, and a third layer made of a water-activated expansion material that expands upon contact with water.

[0009] Some aspects of the present application provide a method of manufacturing a seal for a cooling system and cooling equipment, the method can include forming a core layer from a water-activated expansion material; forming an electrical leak detection layer on the core layer from a moisture-dispersible agent that disperses into water and causes a change in a chemical, optical, and / or electrical property of the water upon contact with the water; and forming a visual leak detection layer on the electrical leak detection layer from a water-soluble colorant. BRIEF DESCRIPTION OF DRAWINGS

[0010] Embodiments of the present application are illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings in which like reference numerals refer to similar elements.

[0011] Figure 1 is a block diagram illustrating an example of a data center facility according to one embodiment.

[0012] Figure 2 is a block diagram illustrating an example of an electronic rack according to one embodiment.

[0013] Figure 3 is a block diagram illustrating an example of a cooling deck configuration according to one embodiment.

[0014] Figure 4 is a conceptual diagram illustrating a concept of leak detection and prevention according to an embodiment.

[0015] Figure 5 is a general diagram of elements of a cooling system in which a device according to an embodiment of the present disclosure can be used to detect and prevent leaks.

[0016] Figure 6 illustrates a bonded device according to an embodiment.

[0017] Figure 7 illustrates a non-bonded device according to an embodiment.

[0018] Figures 8A to 1 IB illustrates operation of a device according to an embodiment of the present disclosure in response to different degrees of leaks.

[0019] Figure 12 illustrates an embodiment of a server cooling module including a leak detection and prevention device according to an embodiment.

[0020] Figure 13 is a conceptual diagram of a method for configuring a leak detection and prevention device according to an embodiment.

[0021] Figure 14 is a flowchart illustrating a process for manufacturing a seal according to an embodiment. DETAILED DESCRIPTION

[0022] Various embodiments and aspects of the application will be described in relation to the details discussed below, and the accompanying drawings will illustrate various embodiments. The following description and drawings are illustrative of the application and are not to be construed as limiting the application. Numerous specific details are described to provide a thorough understanding of various embodiments of the present application. However, in certain instances, well-known or conventional details are not described in order to provide a concise discussion of embodiments of the present application.

[0023] Reference throughout the specification to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the application. The appearances of the phrase "in one embodiment" in various places in the specification are not necessarily referring to the same embodiment.

[0024] Embodiments of the present disclosure provide mechanisms for detecting potential leaks and preventing potential leaks from developing into actual leaks. As such, one feature can be referred to as a pre-leak detection mechanism. Embodiments of the present disclosure are capable of pre-leak detection both during manufacturing of a cooling device and during operation of the cooling device in a server.

[0025] In embodiments of the present disclosure, three levels of security are included in addition to or in lieu of standard sealing. The three levels can be incorporated into a single security device or provided to three separate devices. While use of all three levels is not mandatory, the combination of all three levels provides synergistic advantages and can actually reduce the number of leak detectors required due to the increased reliability of the system, reducing the cost of the system.

[0026] Background information regarding the application of embodiments of the present disclosure will first be provided below, followed by disclosure of specific embodiments.

[0027] Figure 1 is a block diagram illustrating an example of a data center or data center unit according to one embodiment. In this example, Figure 1 A top view of at least a portion of a data center is shown. Referring to Figure 1 , according to one embodiment, a data center system 100 includes an electronic rack of one or more rows of information technology (IT) components, equipment, or instruments 101 and 102 (e.g., computer servers or computing nodes that provide data services to various clients over a network such as the Internet). In this embodiment, each row includes an array of electronic racks such as electronic racks 110A to 110N. However, more or fewer rows of electronic racks can be implemented. Typically, the rows 101 and 102 are aligned in parallel with their front ends facing each other and their back ends facing away from each other, forming an aisle 103 therebetween to allow a manager to walk therein. However, other configurations or arrangements can also be applied. For example, the back ends of two rows of electronic racks can face each other and no aisle is formed therebetween, while the front ends of the two rows of electronic racks face away from each other. The back ends of the electronic racks can be coupled to a room cooling liquid manifold.

[0028] In one embodiment, each of the electronic racks (e.g., electronic racks 110A to 110N) includes a housing to house a plurality of IT components arranged in a stacked form running therein. The electronic rack can include a cooling liquid manifold, a plurality of server slots (e.g., configured with standard racks or chassis of the same or similar form factor), and a plurality of server chassis (also referred to as server blades or server racks) capable of being inserted into and detached from the server slots. Each server chassis represents a computing node having one or more processors, memory, and / or persistent storage devices (e.g., hard disks), where the computing node can include one or more servers running therein. At least one processor is attached to a liquid cooling deck (also referred to as a cooling deck assembly) for receiving cooling liquid. In addition, one or more optional cooling fans are associated with the server chassis to provide air cooling to the computing node included therein. It is noted that the cooling system 120 can be coupled to a plurality of data center systems such as the data center system 100.

[0029] In one embodiment, the cooling system 120 includes an external liquid loop connected to a dry cooler or cooling tower outside the building / housing container. The cooling system 120 can include, but is not limited to, evaporative cooling, free air, large thermal mass discharge, and waste heat recovery designs. The cooling system 120 can include or be coupled to a source of cooling liquid that provides the cooling liquid.

[0030] In one embodiment, each server chassis is modularly coupled to the cooling liquid manifold such that the server chassis can be removed from the electronic rack without affecting the operation of the remaining server chassis and cooling liquid manifold in the electronic rack. In another embodiment, each server chassis is coupled to the cooling liquid manifold by a quick release coupling assembly having a server liquid inlet connector and a server liquid outlet connector, the server liquid outlet connector being coupled to a flexible hose to distribute cooling liquid to the processors. The server liquid inlet connector receives cooling liquid from the cooling liquid manifold mounted at the back end of the electronic rack through a rack liquid inlet connector. The server liquid outlet connector discharges warm / hot liquid carrying heat exchanged with the processors to the cooling liquid manifold through a rack liquid outlet connector and then back to a chiller distribution unit (CDU) within the electronic rack.

[0031] In one embodiment, the cooling liquid manifold disposed on the back end of each electronic rack is coupled to a liquid feed line 132 (also referred to as a room feed manifold) to receive cooling liquid from the cooling system 120. The cooling liquid is distributed through a liquid distribution circuit attached to the cooling bench assembly on which the processors are mounted to remove heat from the processors. The cooling bench is configured to be similar to a heat sink with a liquid distribution tube attached or embedded therein. The resulting warm or hot liquid carrying heat exchanged with the processors is conveyed back to the cooling system 120 via a liquid return line 131 (also referred to as a room return manifold).

[0032] The liquid feed / return lines 131 and 132 are referred to as data center or room liquid feed / return lines (e.g., global liquid feed / return lines) that feed cooling liquid to all electronic racks of the rows 101 and 102. The liquid feed line 132 and the liquid return line 131 are coupled to heat exchangers of the CDUs located within each electronic rack, forming a primary loop. A secondary loop of the heat exchangers is coupled to each server chassis in the electronic rack to deliver cooling liquid to the cooling benches of the processors.

[0033] In one embodiment, the data center system 100 further includes an optional air flow delivery system 135 for generating an air flow to pass through the air spaces of the server enclosures of the electronic racks to exchange heat generated by the compute nodes (e.g., servers) due to the operation of the compute nodes and to exhaust the exchanged air flow to an external environment or a cooling system (e.g., an air-to-liquid heat exchanger) to reduce the temperature of the air flow. For example, the air supply system 135 generates a cool / cold air flow to circulate through the electronic racks 110A to 110N from the aisle 103 to carry away the exchanged heat.

[0034] The cool air flow enters the electronic rack through the front end of the electronic rack and the warm / hot air flow exits the electronic rack from the back end of the electronic rack. The exchanged warm / hot air is exhausted from the room / building or cooled using a separate cooling system, such as an air-to-liquid heat exchanger. Thus, the cooling system is a hybrid liquid air cooling system in which a portion of the heat generated by the processors is removed by the cooling liquid through the respective cooling stations while the remaining portion of the heat generated by the processors (or other electronic devices or processing devices) is removed by the air flow cooling. Further, the liquid cooling can be a multiphase system in which the fluid flows in a liquid phase or a gas phase.

[0035] Figure 2 is a block diagram illustrating an electronic rack according to one embodiment. The electronic rack 200 can represent any one of the electronic racks (e.g., electronic racks 110A to 110N) as shown in Figure 1 FIG. 1, for example. With reference to Figure 2 , according to one embodiment, the electronic rack 200 includes, but is not limited to, a CDU 201, a rack management unit (RMU) 202, and one or more server enclosures 203A to 203E (collectively, server enclosures 203). The server enclosures 203 can be plugged into an array of server slots (e.g., standard racks) from either the front end 204 or the back end 205 of the electronic rack 200, respectively. It should be noted that although five server enclosures 203A to 203E are shown herein, more or less server enclosures can be housed within the electronic rack 200. It should also be noted that the specific locations of the CDU 201, the RMU 202, and / or the server enclosures 203 are shown for illustration purposes only, and other arrangements or configurations of the CDU 201, the RMU 202, and / or the server enclosures 203 can also be implemented. In one embodiment, the electronic rack 200 can be open to the environment or partially contained by a rack container, as long as the cooling fans can generate an air flow from the front end to the back end.

[0036] In addition, for at least some of the server enclosures 203, optional fan modules (not shown) are associated with the server enclosures. Each fan module includes one or more cooling fans. The fan modules can be mounted on the back end of the server enclosures 203 or on the electronic rack to create an airflow that flows from the front end 204, through the air space of the server enclosures 203, and out at the back end 205 of the electronic rack 200.

[0037] In one embodiment, the CDU 201 mainly includes a heat exchanger 211, a liquid pump 212 and a pump controller (not shown), and some other components such as a reservoir, a power supply, monitoring sensors, etc. The heat exchanger 211 can be a liquid-to-liquid or a multi-phase heat exchanger. The heat exchanger 211 includes a first circuit having an inlet port and an outlet port with a first pair of liquid connectors coupled to external liquid supply / return lines 131 and 132 to form a primary circuit. The connectors coupled to the external liquid supply / return lines 131 and 132 can be provided or mounted on the back end 205 of the electronic rack 200. As mentioned above, the liquid supply / return lines 131 and 132 (also referred to as room liquid supply / return lines) can be coupled to the cooling system 120.

[0038] In addition, the heat exchanger 211 also includes a second circuit having two ports with a second pair of liquid connectors coupled to a liquid manifold 225 (also referred to as a rack manifold) to form a secondary circuit, which can include a supply manifold (also referred to as a rack liquid supply line or a rack supply manifold) that supplies cooling liquid to the server enclosures 203 and a return manifold (also referred to as a rack liquid return line or a rack return manifold) that sends the warm liquid back to the CDU 201. It should be noted that the CDU 201 can be any type of commercially available or custom-made CDU. Therefore, the details of the CDU 201 will not be described herein.

[0039] Each of the server chassis 203 can include one or more IT components (e.g., central processing units or CPUs, general purpose / graphics processing units (GPUs), memory, and / or storage devices). Each IT component can perform data processing tasks, where the IT component can include software installed in a storage device, loaded into memory, and executed by one or more processors to perform the data processing tasks. The server chassis 203 can include a host server (referred to as a host node) coupled to one or more compute servers (also referred to as compute nodes), such as CPU servers and GPU servers. The host server (with one or more CPUs) generally interfaces with clients over a network (e.g., the Internet) to receive requests for a particular service, such as a storage service (e.g., a cloud-based storage service, such as backup and / or recovery), execution of an application to perform a particular operation (e.g., image processing, deep data learning algorithms or modeling, etc., as part of a software as a service or SaaS platform). In response to the request, the host server allocates the task to one or more compute nodes or compute servers (with one or more GPUs) managed by the host server. The compute servers perform the actual task, which generates heat during runtime.

[0040] The electronic rack 200 also includes an optional RMU 202 configured to provide and manage power provided to the servers 203 and the CDU 201. The RMU 202 can be coupled to a power supply unit (not shown) to manage power consumption of the power supply unit. The power supply unit can include necessary circuitry (e.g., alternating current (AC) to direct current (DC) or DC to DC power converters, batteries, transformers, or regulators, etc.) to provide power to the remaining components of the electronic rack 200.

[0041] In one implementation, the RMU 202 includes an optimization module 221 and a rack management controller (RMC) 222. The RMC 222 can include a monitor to monitor the operational status of various components within the electronic rack 200 (e.g., the compute nodes 203, the CDU 201, and the fan modules). Specifically, the monitor receives operational data from various sensors representative of the operating environment of the electronic rack 200. For example, the monitor can receive operational data representative of the temperature of the processors, the cooling liquid, and the airflow, which can be captured and collected by various temperature sensors. The monitor can also receive data representative of the fan power and the pump power generated by the fan modules and the liquid pump 212, which can be proportional to their respective speeds. These operational data are referred to as real-time operational data. It should be noted that the monitor can be implemented as a separate module within the RMU 202.

[0042] Based on the operational data, the optimization module 221 performs optimization using a predetermined optimization function or optimization model to arrive at a set of optimal fan speeds for the fan modules and an optimal pump speed for the liquid pump 212 such that the total power of the liquid pump 212 and the cooling fans of the fan modules is minimized while the operational data associated with the liquid pump 212 and the cooling fans of the fan modules are within their respective design specifications. Once the optimal pump speed and the optimal fan speeds are determined, the RMC 222 configures the liquid pump 212 and the cooling fans of the fan modules based on the optimal pump speed and the optimal fan speeds.

[0043] As an example, based on the optimal pump speed, the RMC 222 communicates with the pump controller of the CDU 201 to control the speed of the liquid pump 212, which in turn controls the liquid flow rate of the cooling liquid supplied to the liquid manifold 225 for distribution to at least some of the server enclosures 203. Similarly, based on the optimal fan speeds, the RMC 222 communicates with each of the fan modules to control the speed of each of the cooling fans of the fan modules, which in turn controls the airflow rate of the fan modules. It is noted that each of the fan modules can be controlled individually with its particular optimal fan speed, and different fan modules and / or different cooling fans within the same fan module can have different optimal fan speeds.

[0044] It is noted that the illustrated and described Figure 2 The illustrated rack configuration is for illustration purposes only, and other configurations or arrangements can also be applied. For example, the CDU 201 can be an optional unit. The cooling bays of the server enclosures 203 can be coupled to a rack manifold, which can be coupled directly to the room manifolds 131 and 132 without using the CDU. Although not shown, a power supply unit can be provided within the electronic rack 200. The power supply unit can be implemented as a standard enclosure identical or similar to the server enclosures, where the power supply enclosure can be plugged into any standard rack in place of any server enclosure 203. In addition, the power supply rack can also include a battery backup unit (BBU) to provide battery power to the server enclosures 203 when the main power supply is not available. The BBU can include one or more battery packs, and each battery pack includes one or more battery cells and the necessary charging and discharging circuitry for charging and discharging the battery cells.

[0045] Figure 3 is a block diagram illustrating a processor cooling bay configuration according to one embodiment. The processor / cooling bay assembly 300 can represent any one of the processor / cooling bay structures of the server enclosures 203 as Figure 2 illustrated. Reference is made to Figure 3The processor 301 is inserted into a processor socket mounted on a printed circuit board (PCB) or motherboard 302 that is coupled to other electronic components or circuitry of a data processing system or server. The processor 301 also includes a cooling block 303 attached thereto that is coupled to a rack manifold that is coupled to the liquid supply line 132 and / or the liquid return line 131, for example, via a blind mate connector. A portion of the heat generated by the processor 301 is removed by the cooling liquid through the cooling block 303. The remaining portion of the heat enters the air space below or above and can be removed by the airflow generated by the cooling fan 304.

[0046] Figure 4 is a conceptual representation of the layers that can be used in a combined or non-combined solution to provide leak detection and protection. These layers can be considered as different safety layers, but they can be formed as a combined single device or multiple devices. Here, the visual detection layer 400 should be oriented towards the liquid containment space of the cooling device, while the traditional sealing layer 415 should be the last layer between the containment of the device and the outside of the device. The order of the leak prevention layer and the electrical detection layer can be changed. It is recommended to design the conventional sealing layer as the last sealing layer.

[0047] The visual detection layer is made of a colored material that dissolves in the cooling liquid (e.g., purified water or deionized water). Once the cooling liquid contacts the visual detection layer, the material dissolves and colors the cooling liquid. This feature is particularly advantageous during manufacturing and assembly testing, as the hose is transparent, so it is very easy to identify the color change of the cooling liquid flowing in the hose. In addition, it will also be easy to identify the location of the origin of the color change, thereby identifying the device that caused the color change due to an internal leak. One simple method of manufacturing the visual detection layer is to compress a dry edible coloring powder to form a solid that dissolves easily when in contact with water. In addition, the edible coloring agent does not react with the wetting material used for the cooling device and does not corrode or cause other chemical reactions with the cooling device. In embodiments, other types of materials that meet the proposed functionality can be used.

[0048] Once the liquid cooling system is incorporated into the computing system, the visual detection layer is no longer useful because the tubing will be covered by the insulation. Even when the tubing remains transparent and the color of the fluid flowing within the hose is visible, it is not possible to identify a leak due to the rapid flow of the fluid within the hose and the absence of personnel on site to observe thousands of operating devices in real time. Therefore, an electrical detection layer 410 for pre-detection of leaks is added during normal operation. The electrical detection layer can be implemented using, for example, nanoparticles or chemical agents that change the optical, chemical, and / or electrical properties of the cooling liquid once added to the cooling liquid. For example, when the nanoparticles are made of an electrically conductive material (e.g., copper nanoparticles), the electrical conductivity of the cooling liquid will change once the nanoparticles enter the cooling liquid flow, and can be detected using an electrical sensor. Additionally, the nanoparticles can change the optical properties of the water by diffracting light, which can be detected by an optical sensor that produces a corresponding electrical signal. Nanoparticles or ultrafine particles are generally defined as particles of matter with a diameter between 1 nanometer (nm) and 100 nanometers (nm). These particles are too small to significantly disturb the cooling fluid flow when introduced into the cooling fluid flow. In embodiments, the nanoparticles can enhance thermal performance according to their thermal conductivity and heat retention.

[0049] It should be noted that, as disclosed herein, the term electrical sensor refers to a sensor that provides an electrical signal indicative of a leak. The detection mechanism of the sensor can be electrical, chemical, optical, etc. That is, the term "electrical" does not refer to the way in which the sensor detects a leak, but rather the way in which the sensor communicates a leak. Notably, the communication link can include an optical fiber that transmits an optical signal, but that signal is generated from an electrical output of the sensor and is therefore included within the term electrical leak detection or electrical sensor.

[0050] As will be explained in detail below, the visual detection layer 400 and the electrical detection layer 410 are capable of detecting a potential leak before the potential leak destroys the cooling equipment and causes damage to the server circuitry. Therefore, a leak prevention layer 405 is added to further prevent the cooling liquid from leaking and to provide sufficient time for detecting the leak and replacing the faulty part before damage is caused. This is a great advantage of embodiments of the present disclosure because the faulty cooling component can be replaced before the cooling liquid leaks and causes damage to the operating server, thereby saving the cost of server replacement, shortening or avoiding server downtime, and potentially preventing data loss.

[0051] In embodiments of the present disclosure, the leak prevention layer can be made of a water swellable material (WSM). The leak prevention layer combines with or abates the leak detection layer such that when water reaches the leak detection layer and triggers an alarm, it also reaches the leak prevention layer, which in response will swell and thus prevent the leak from breaking through. The water swellable material can be manufactured, for example, by mixing a superabsorbent polymer, a filler and a solvent with a synthetic resin elastomer as a base material. Another example of a WSM is a water swellable rubber (hydrophilic rubber), which can be based on polychloroprene, polychloroprene and EPDM rubber, polyurethane or semi-vulcanized butyl rubber. According to yet another example, a cellulose component, such as carboxymethyl cellulose, can be used together with an acrylic copolymer to increase the swelling capacity of nitrile rubber in the presence of a cooling liquid, e.g. water.

[0052] As Figure 3 indicated, the liquid cooling system can comprise a cooling table 303 as well as liquid supply and return lines. Figure 5 A liquid cooling arrangement indicating areas susceptible to leaks is shown, where embodiments of the present disclosure can be used to detect and prevent leaks. Figure 5 A cooling table 503 is shown, which is generally comprised of two components 503a and 503b, which when assembled have a direct contact surface 505. When the two components 503a and 503b are assembled, they define a chamber 504 (e.g. microchannel fin area) in which cooling liquid is circulated from a supply line 510 to a return line 512. The lines 510 and 512 are attached to the cooling table 503 by barbs 518 and to the cooling manifold by quick disconnects 516. As shown, a leak detection and prevention device 500 according to embodiments of the present disclosure can be placed in all locations susceptible to leaks, such as the joint surface 505 of the cooling table, the barb connectors and the quick disconnects.

[0053] Figure 5 An electrical detection sensor 520 is also shown arranged at the return line 512 of the cooling table 503, such that if a change in the chemical, optical or electrical properties of the return liquid is detected, it indicates that the leak originated upstream of the location of the sensor 520, thus aiding in locating the source of the leak. It is noted that the addition of sensors to the fluid downstream of the equipment is suggested.

[0054] The present disclosure will now describe a specific example for implementing a leak detection and prevention device according to embodiments of the present disclosure. Figure 6 A top view of the component 503b of the cooling table 503 is shown, with the top component 503a removed. As according to Figure 5As illustrated, component 503b includes a mating surface 505 surrounding a liquid chamber 504. The liquid chamber 504 may include cooling microchannels or any other heat exchange mechanism known in the art. Furthermore, a standard sealing ring 630 may be installed between the two mating surfaces 505. It should be understood that, regardless of the presence or absence of the sealing ring 630, coolant should not be present anywhere on the mating surface 505 when properly machined and assembled. In this document, the presence of liquid on any part of surface 505 is referred to as an internal leak. It should be noted that such an internal leak may be contained within the sealing ring 630; however, once the liquid exceeds the seal 630, the leak will rupture and may be referred to as an external leak. External leaks can cause catastrophic damage to the electronic equipment they contact. Therefore, embodiments of this disclosure are intended to detect internal leaks as a warning of a potential impending external leak and are intended to prevent external leaks at least long enough in advance to allow for the replacement of internally leaking components. This is what is referred to herein as pre-leak detection.

[0055] Figure 6 The illustration shows a cross-section of a leak detection and prevention device 600 according to an embodiment. In this example, device 600 provides a combined solution in which a visual detection layer, an electrical detection layer, and a leak prevention layer are combined into a single device 600. Specifically, in this embodiment, device 600 is a rectangular seal formed as a closed loop, which is mounted inside a standard sealing ring 630. As shown in the illustration, in this embodiment, the core 650 of seal 600 is made of a water-swellable material. A first coating 652 is disposed on the core 650 and is made of nanoparticles of a chemically altering agent. A second coating 654 is disposed on the first coating 652 and is made of a coloring material.

[0056] Use such as Figure 6 The illustration shows a configuration of seal 600 where, if the mating surfaces 505 are improperly manufactured or undergo expansion and contraction deformation, cooling water will be positioned between the mating surfaces 505 and reach the second coating 654. The second coating 654 will dissolve and color the cooling liquid. This can be detected during manufacturing testing before the cooling platform is integrated into the electronic circuitry and before the insulator is applied to the transparent supply and return lines.

[0057] If the initial test is successfully performed, but during normal operation, water begins to appear between the mating surfaces due to thermal cycling, corrosion, or other long-term factors, the coloration can not be detected because the transparent tubing is covered by an opaque insulator. Furthermore, as mentioned above, in a data center, the color change can quickly disappear due to the high flow rate within the hose. However, once the second coating 654 has dissolved, the first coating 652 will begin to dissolve, releasing the nanoparticles into the water flow, if water remains between the mating surfaces 505. This will be detected by the electrical sensor, alerting of a potential failure of the chiller before a water breach.

[0058] Furthermore, if water continues to leak, it will activate the swelling properties of the core 650, which will swell and act to prevent a water breach and cause an external leak. Thus, in addition to enhancing the reliability of the chiller, the water swelling core 650 provides engineers with enough time to replace the chiller before a water breach.

[0059] In the main illustration of the inset, the core and the two detection layers are shown as distinct elements. However, in alternative embodiments, some elements can be combined into a single element. For example, the core 650 can be made of a water swelling material that includes nanoparticles or chemical agents. This case is shown in the left hand side of the inset. Thus, when the core begins to swell, it will release the nanoparticles or chemical agents, enabling the detection of an internal leak. Conversely, the first and second detection layers can be combined into a single layer with both the coloration material and the nanoparticles / chemical agents. This case is shown in the right hand side of the inset. If the device fails during manufacturing testing, the single layer will dissolve and water will be colored. Thus, the device will be discarded or repaired, in which case a new device 600 will be installed, or the entire set of modules of assembly 600 will be replaced. Conversely, if the device passes manufacturing testing and is put into service, when water begins to leak, the single layer will dissolve and the nanoparticles / chemical agents will activate the electrical detection of an internal leak.

[0060] Figure 7 Another embodiment is shown in which each of the leak detection and prevention layers is formed independently. For ease of illustration, this embodiment omits the standard seal ring, but it can include the same seal ring as the embodiment of Figure 6 As shown in the inset, the joint surface 505 includes a channel into which the leak detection and prevention layers are inserted. The top component 503a can have a matching channel or be machined flat to press on the layers. Here, a first rectangular insert 754 is made of a coloration material and serves as a visual leak detector, a second rectangular insert 752 is made of nanoparticles or chemical agents and serves as an electrical leak detector, and a final rectangular insert 750, which serves as a seal, is made of a water swelling material.

[0061] Because this leak detection and prevention device can be manufactured in various shapes, it can be used in any location within a system susceptible to leaks. Therefore, for cooling platforms, such as... Figure 6 and Figure 7 As shown, the device can be formed as a rectangular ring. Alternatively, by forming the device as an O-ring, it can be used in quick-release devices and barbed connectors (such as...). Figure 5 (as shown). In this regard, the term "ring" as used herein is intended to cover a closed shape or loop, and is not limited to a circular shape, as in "boxing ring," where "ring" is actually a square.

[0062] Figures 8A to 1 IB The apparatus according to embodiments of the present disclosure is shown to operate in response to varying degrees of leakage, and these leakages can occur at different times and under different testing or operating conditions. For example, Figure 8A A cooling platform in normal operation is shown, featuring a dry mating surface 805 and a conventional sealing ring 830. Furthermore, in this example, the cooling platform includes a visual leak detection layer 854, an electrical leak detection layer 852, and a water-swellable layer 850. A water supply line 810 delivers cooling water, which circulates within the chamber 804, for example, through cooling fins, and returns via a return line 812 to remove heat from the cooling platform.

[0063] Figure 8B It shows Figure 8A The cooling platform is in a situation where a small internal leak 860 occurs, but it only reaches the visual leak detection layer 854. As a result of the leak 860 reaching the visual leak detection layer 854, color is released into the water, and the return line 812 will show that the water is colored, thus indicating an internal defect or failure. The visual leak detection aspect of this embodiment is very useful for component manufacturers, as it allows testing of the cooling platform without any electrical sensors and associated circuitry. Furthermore, this aspect is useful for system suppliers, as it allows them to identify the location of leaks and pinpoint faulty points or units without requiring multiple sensors, especially when multiple cooling units are assembled together. Similarly, system suppliers such as OEMs and ODMs also benefit from this aspect due to the ability to provide a complete testing system. Moreover, full rack-level testing can be performed without any physical sensors, and leaks can still be accurately located.

[0064] The cooling platform may pass all initial leak tests, but leaks may still occur at later points during normal operation due to factors such as thermal cycling or corrosion. Figure 9A As shown Figure 8A The cooling platform shown is in normal operating condition without any leaks. Conversely, Figure 9BThe illustration shows a scenario where a leak 862 occurs and reaches the electrical leak detection layer 852. In this case, if the transparent return line is not covered by an insulator, the visual leak detection layer 854 will release its colorant, thereby changing the color of the water in the return line and enabling visual identification of the leak. Furthermore, the electrical leak detection layer 852 will release its nanoparticles or chemical reagents, thereby altering the chemical or electrical properties of the water in the return line 812. At this point, the sensor 820 will detect the change in the chemical or electrical properties of the water in the return line 812, thus indicating an internal leak.

[0065] Figure 9B The aspects illustrated can be particularly useful during normal operation of a production system. Visual leak detection may not function properly in a cluster of machines with thousands of units, making it difficult to observe all return lines or making them invisible due to insulation. Therefore, an electrical leak detection layer enables leak detection in a real-world production environment. Sensor locations can be customized for individual modules, a cooling module within a chassis, or an entire rack. It should be noted that because embodiments of this disclosure provide multi-level leak detection and prevention, system reliability is increased, thereby reducing the number of sensors required in the system. The sensors themselves can be designed for nanoparticle-based detection, chemical-based detection, or optical detection using light diffraction. If it is based on chemical detection, the electrical leak detection layer 852 can include chemical reagents instead of nanoparticles. For example, the electrical leak detection layer 852 can include chemical reagents that alter the chemical properties of water, and the sensor will be a chemical-based sensor.

[0066] Figure 10A As shown Figure 8A The cooling platform shown is in normal operating condition without any leaks. Conversely, Figure 10B The illustration shows a scenario where an internal leak 864 occurs and reaches the water-swellable layer 850. At this point, the colorant from the visual leak detection layer 854 has dissolved into the water flow. Similarly, nanoparticles or chemical reagents from the electrical detection layer 852 are also released into the water flow, triggering an alarm. However, to prevent the internal leak from gradually becoming an external leak, the swelling layer 850 is provided to absorb water from the leak and expand, thereby creating a barrier that confines the leak to the area of ​​the water-swellable layer.

[0067] Figure 11A As shown Figure 8A The cooling platform shown is in normal operating condition without any leaks. Conversely, Figure 11BAn internal leak 864 is shown and the internal leak 864 exceeds the water swell layer 850. At this point, the colorant from the visual leak detection layer 854 has dissolved into the water flow. Similarly, the nanoparticles or chemical agent from the electrical detection layer 852 are also released into the water flow, triggering an alarm. In addition, although the swell layer 850 absorbs water from the leak and swells, the leak still exceeds the water swell layer 850. At this point, the leak reaches the conventional seal ring 830 and remains within the confines of the seal ring 830.

[0068] From Figures 8A to 1 IB the description, it can be seen that no water leaks outside of the cooling table, thus avoiding any damage to the electronic equipment. Thus, the reliability of the cooling system is improved, thus enabling a reduction in the cost of the leak sensors and associated electronics, as the number of leak sensors can be reduced. This is exemplified by the embodiment shown in Figure 12 In Figure 12 , the supply manifold 970 provides cooling water to a plurality of interconnecting lines 916, which deliver the cooling water to a plurality of cooling tables 900, which can be connected in any arrangement of parallel and / or series. The returning hot water is collected by the return manifold 980 and directed to a return line. Ideally, each cooling table can have its own electrical leak sensor 920, however, this can unduly increase the cost and complexity of the system. Instead, the sensor 920 can be provided in line with the end of the return manifold 980 and / or the return manifold 980 itself (as shown by the dashed line). In addition, the main return line 913 can include a window 914, enabling a visual check to detect a color change of the water or placement of an optical sensor. Such a window 914 can also be useful for a server or system vendor who receives the cooling modules from a cooling vendor and then assembles the modules into a system. The system vendor will perform a full test prior to shipping to the end user, thus the window 914 is useful for the system vendor to check the final product prior to shipping.

[0069] Figure 13is a conceptual illustration of a method for configuring a leak detection and prevention apparatus according to embodiments. In block 10, it is illustrated that a visual leak detection layer I can be used during testing by the cooling component manufacturer and system supplier. Testing can be performed at the component level, system level, and rack level (before the insulation is installed on the water pipes). As shown in block 12, electrical leak detection sensors can not be needed during these tests, as visual inspection is sufficient. This simplifies testing at the system and rack level, and as shown in block 14, even on full rack level testing, visual detection is fast and accurate. Block 16 indicates that during system operation, leak detection is achieved by using leak sensors that detect the presence of nanoparticles or chemical agents that are released from an electrical leak detection layer II. Block 18 indicates that the sensors can identify the location of the leak within the system.

[0070] Thus, by embodiments of the present disclosure, a leak detection and prevention apparatus is provided that includes a visual leak detection layer containing a water soluble colorant, an electrical leak detection layer containing a water dispersible electrical detection agent, and a leak prevention layer containing a water-swellable material. The visual leak detection can include a compressed colored powder configured to dissolve upon contact with water. The electrical leak detection layer can include electrically conductive nanoparticles or chemical agents that are dispersible upon contact with water, for example, forming a solution, colloid, or suspension that can change the chemical, electrical, and / or optical properties of the water.

[0071] Figure 14 A process for manufacturing a seal is shown. The process begins at 11, forming a core, typically in a closed loop form (e.g., circular, rectangular, square, etc.). The core is formed of a water-swellable material. At 13, an electrical detection layer is formed on the core. This can be done, for example, by coating or impregnating the core with a detection agent, such as electrically conductive nanoparticles or a chemical change material. At 15, a visual detection layer is formed on the core, for example, by coating the core and electrical detection layer with a compressed colored powder.

[0072] According to further embodiments, a seal is provided that includes a core forming a ring, made of a water-swellable material; an electrical detection layer disposed on the core, including a dispersible agent that disperses into water and causes a change in a chemical, optical, and / or electrical property of the water upon contact with water; and a visual leak detection layer disposed on the electrical detection layer, and including a colorant that is soluble in water.

[0073] According to further embodiments, a seal is provided that includes a core forming a first ring, made of a water-swellable material; an electrical detection layer forming a second ring that is smaller than the first ring, including a dispersible agent that disperses into water and causes a change in a chemical, optical, and / or electrical property of the water upon contact with water; and a visual leak detection layer forming a third ring that is smaller than the second ring, including a colorant that is soluble in water.

[0074] A cooling stand is provided having a first block and a second block in contact with each other at a mating surface, a chamber defined between the first and second blocks, the mating surface incorporating a channel, a sealing ring located within the channel, the sealing ring comprising: a first layer for visual detection of a leak by incorporation of a water-soluble colorant; a second layer for electrical detection of a leak by a sensor, the second layer comprising a dispersible agent that disperses into water and causes a change in a chemical, optical, and / or electrical property of the water upon contact with the water; and a third layer made of a water-swellable material that swells upon contact with water. The orientation of the three layers can be arranged so that a leak from the chamber first reaches the first layer, then the second layer, and finally the swelling layer. The layers can form separate components placed side-by-side, with the first layer forming an inner ring, the second layer forming an intermediate ring, and the third layer forming an outer ring, all concentrically surrounding the chamber, or can be incorporated into a single sealing ring.

[0075] A cooling system for a server includes a plurality of cooling stands and a plurality of liquid lines having end portions attached to barbs, wherein each of the cooling stands and at least one of the barbs incorporate a leak detection and prevention seal, the leak detection and prevention seal comprising: a visual leak detection layer comprising a water-soluble colorant; an electrical leak detection layer comprising a water-dispersible electrical detection agent; a leak prevention layer comprising a water-swellable material; and at least one sensor for detecting a change in a chemical, electrical, and / or optical property of a cooling liquid returning from the cooling stand. The visual leak detection can comprise a compressed colored powder configured to dissolve upon contact with water. The electrical leak detection layer can comprise electrically conductive nanoparticles or a chemical agent that is dispersible upon contact with water, for example, forming a solution, colloid, or suspension that can change a chemical, electrical, and / or optical property of the water.

[0076] A method for leak detection and prevention is provided comprising: interposing a seal into a cooling stand, wherein the seal has a visual leak detection layer comprising a water-soluble colorant, an electrical leak detection layer comprising a water-dispersible electrical detection agent, and a leak prevention layer comprising a water-swellable material; mounting the cooling stand onto a test fixture, supplying water to the cooling stand through a transparent line; visually inspecting the transparent line to detect a color change in the water; when no color change is detected, mounting the cooling stand onto a cooling system of a circuit; mounting an electrical sensor onto the cooling system; monitoring the electrical sensor for an electrical signal indicative of a leak detection.

[0077] In the foregoing specification, the implementation of the application has been described with reference to specific exemplary embodiments thereof. It is evident, however, that various modifications will occur to those skilled in the art in view of the foregoing description that do not part from the true spirit and scope of the present application as set forth in the claims. Thus, the specification and drawings are illustrative only rather than restrictive.

Claims

1. A seal for a cooling system installed in a server rack, comprising: Visual leakage detection layer, including water-soluble colorant; Electrical leakage detection layer, including water-dispersible electrical detection agent; as well as An expansion layer, comprising a water-swellable material; the expansion layer is a leak-proof layer; The seal is located inside the sealing ring of the cooling platform in the cooling system. The positioning of the visual leak detection layer, the electrical leak detection layer, and the expansion layer ensures that leaks from the chamber of the cooling platform first reach the visual leak detection layer, then the electrical leak detection layer, and finally the expansion layer. The electrical leakage detection layer uses sensors located at the return pipeline attached to the cooling platform to electrically detect the leakage.

2. The seal according to claim 1, wherein, Visual leak detection includes compressed coloring powder configured to dissolve upon contact with water.

3. The seal according to claim 1, wherein, The electrical leakage detection layer includes one of conductive nanoparticles or chemical reagents that can disperse and alter the chemical, electrical, and / or optical properties of water when in contact with it.

4. The seal according to claim 3, wherein, The electrical leakage detection layer comprises copper nanoparticles.

5. The seal according to claim 3, wherein, The electrical leakage detection layer includes a chemical modifier.

6. The seal according to claim 1, wherein, The visual leakage detection layer, the electrical leakage detection layer, and the expansion layer are combined into a single ring, wherein the expansion layer forms the core of the ring, and the visual leakage detection layer and the electrical leakage detection layer are disposed above the core.

7. The seal according to claim 6, wherein, The electrical leakage detection layer is impregnated into the core.

8. The seal according to claim 1, wherein, The visual leakage detection layer includes a first strip, the electrical leakage detection layer includes a second strip surrounding the first strip, and the expansion layer includes a third strip surrounding the second strip.

9. The seal according to claim 8, wherein, The first belt includes compressed coloring powder.

10. Cooling platform, including: A first block and a second block, the second block being attached to the first block at a mating surface, a cavity being defined between the first block and the second block, and the first block and the second block forming a channel in the mating surface; The inlet is barbed to supply fluid to the chamber; The outlet barb forms a fluid loop from the chamber; as well as A seal, disposed in the channel, comprises a first layer for visual detection of leaks from the chamber by incorporating a water-soluble colorant; a dispersible agent that disperses into the water upon contact with water and causes changes in the chemical, optical, and / or electrical properties of the water; a second layer for electrical detection of the leak by a sensor; and a third layer made of a water-swellable material that expands upon contact with water, the third layer being a leak-proof layer. The cooling platform includes a sealing ring that is concentric with and positioned around the sealing element; The positioning of the first layer, the second layer, and the third layer ensures that the leak first reaches the first layer, then the second layer, and finally the third layer. The sensor is positioned at the return line attached to the cooling platform, which is connected to the cooling platform via a barb at the outlet.

11. The cooling platform according to claim 10, further comprising an annular seal disposed on the barb of the water outlet, the annular seal comprising: The first annular layer uses a water-soluble colorant to visually detect leaks; The second annular layer, which electrically detects leaks via sensors, incorporates a dispersible agent that disperses into water upon contact and causes changes in the chemical, optical, and / or electrical properties of the water; and the third annular layer, made of a water-swellable material that expands upon contact with water.

12. The cooling platform according to claim 10, wherein, The first layer, the second layer, and the third layer are combined into a single ring.

13. The cooling platform according to claim 12, wherein, The single ring includes a core made of the water-swellable material forming the third layer, wherein the first and second layers are disposed above the core.

14. The cooling platform according to claim 10, wherein, The first layer, the second layer, and the third layer form three concentric rings, with the first layer forming the ring closest to the chamber.

15. The cooling platform of claim 10, wherein the sensor is configured to detect changes in the chemical or electrical properties of water flowing from the fluid loop of the chamber.

16. A method for manufacturing seals for cooling systems and cooling equipment, comprising: The core layer is formed of a water-swellable material; An electrical leakage detection layer is formed on the core layer by a dispersible agent, which disperses into the water upon contact and causes changes in the chemical, optical, and / or electrical properties of the water; and A visual leakage detection layer is formed on the electrical leakage detection layer using a water-soluble colorant. The core layer is a leakage prevention layer; the seal is located inside the sealing ring of the cooling platform in the cooling system. The positioning of the visual leak detection layer, the electrical leak detection layer, and the core layer ensures that leaks from the cooling platform's chamber first reach the visual leak detection layer, then the electrical leak detection layer, and finally the core layer. The electrical leakage detection layer uses sensors located at the return pipeline attached to the cooling platform to electrically detect the leakage.

17. The method according to claim 16, wherein, Forming the electrical leakage detection layer involves applying conductive nanoparticles or chemical modifiers onto the core layer.

18. The method according to claim 16, wherein, The visual leakage detection layer comprises compressed coloring powder.

Images