Filtration system for coolant distribution unit

Abstract

A coolant distribution unit includes a cabinet having walls, a door, a primary inlet, a primary outlet, a secondary inlet, and a secondary outlet. A heat exchanger assembly is positioned within the cabinet. First and second flow paths extend through the heat exchanger from respective primary and secondary inlets to respective primary and secondary outlets. A first screen is positioned between the primary inlet and the heat exchanger. The second flow path includes a second screen, first and second pumps arranged in parallel, and first, second and third filters arranged in parallel and located downstream of the first and second pumps. A human-machine interface is mounted on the cabinet, and a controller positioned in the cabinet is in electrical communication with the human-machine interface, each of the human-machine interface and the controller being electrically coupled to a power supply.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 709,224, filed October 18, 2024, and U.S. Provisional Patent Application No. 63 / 709,247, filed October 18, 2024, the entire contents of each of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to a filtration system for a coolant distribution unit. Summary of the Invention

[0004] In some embodiments, this disclosure provides a coolant distribution unit comprising: a cabinet having a plurality of walls, a door, a primary inlet, a primary outlet, a secondary inlet, and a secondary outlet. A heat exchanger assembly is positioned within the cabinet. The heat exchanger assembly includes a heat exchanger, a first flow path, and a second flow path. The first flow path extends from the primary inlet through the heat exchanger and to the primary outlet. The first flow path includes a first filter positioned between the primary inlet and the heat exchanger. The second flow path extends from the secondary inlet through the heat exchanger to the secondary outlet. The second flow path includes a second filter, a first pump and a second pump arranged in parallel, and a first filter, a second filter, and a third filter arranged in parallel and downstream of the first pump and the second pump. A human-machine interface is mounted on the cabinet. A controller is positioned within the cabinet and is in electrical communication with the human-machine interface. A power supply is electrically connected to the human-machine interface and the controller.

[0005] In some embodiments, this disclosure provides a coolant distribution unit comprising: a cabinet supporting a primary inlet, a primary outlet, a secondary inlet, and a secondary outlet; a heat exchanger assembly located within the cabinet, the heat exchanger assembly including a heat exchanger; a first flow path extending from the primary inlet through the heat exchanger and to the primary outlet, the first flow path including a first filter positioned between the primary inlet and the heat exchanger; and a second flow path extending from the secondary inlet through the heat exchanger and to the secondary outlet, the second flow path including a second filter, one or more pumps, and one or more filters arranged in parallel and downstream of the one or more pumps; and a filling branch fluidly communicating with the second flow path.

[0006] In some embodiments, this disclosure provides a coolant distribution unit comprising: a cabinet supporting a primary inlet, a primary outlet, a secondary inlet, and a secondary outlet; a heat exchanger assembly at least partially located within the cabinet, the heat exchanger assembly including a heat exchanger; a first flow path extending from the primary inlet through the heat exchanger and to the primary outlet, the first flow path including a first filter positioned between the primary inlet and the heat exchanger; and a second flow path extending from the secondary inlet through the heat exchanger and to the secondary outlet, the second flow path including a second filter, one or more pumps, and one or more filters disposed downstream of the one or more pumps; wherein the ratio of the filters to the pumps is greater than 1:1.

[0007] In some embodiments, each of the first, second, and third filters includes a shut-off valve and an exhaust port, such that while the coolant distribution unit is in operation, one of the filters can be isolated and then replaced.

[0008] In some embodiments, a first manifold is positioned between the first and second pumps and the first, second, and third filters, and a second manifold is positioned downstream of the first, second, and third filters. In these embodiments, fluid flows in parallel through the first and second pumps into the first manifold, and then the fluid flows in parallel through the first, second, and third filters into the second manifold.

[0009] In some embodiments, the first flow path further includes a first removable filter upstream of the heat exchanger. The first removable filter is removed after a set time period has elapsed or after a signal from the controller indicates that the first removable filter should be removed.

[0010] In some embodiments, the first flow path includes a bypass passage and a valve that allow fluid to bypass the first filter.

[0011] In some embodiments, the second flow path includes a bypass passage and a valve that allow fluid to bypass the second filter.

[0012] Other aspects of this disclosure will become apparent from consideration of the detailed description and accompanying drawings. Attached Figure Description

[0013] Figure 1 This is a perspective view of the coolant distribution unit.

[0014] Figure 2 This is a front perspective view of the coolant distribution unit with the wall panels and doors removed.

[0015] Figure 3 This is a rear perspective view of the coolant distribution unit with the wall panels and doors removed.

[0016] Figure 4 This is a rear view of the coolant distribution unit with the wall panels removed.

[0017] Figure 5 This is a side view of the coolant distribution unit with the wall panels removed.

[0018] Figure 6A This is a schematic diagram of the heat exchanger assembly of the coolant distribution unit.

[0019] Figure 6B This is a schematic diagram of the heat exchanger assembly of the coolant distribution unit.

[0020] Figure 7 This is a perspective view of the filter assembly of the coolant distribution unit.

[0021] Figure 8 This is a cross-sectional view of the connector of the coolant distribution unit.

[0022] Figure 9 This is a schematic diagram of the coolant storage unit and the filling rod.

[0023] Figure 10 This is a perspective view of a portion of the coolant distribution unit and the filling rod. Detailed Implementation

[0024] Before explaining any embodiment of this disclosure in detail, it should be understood that this disclosure, in its application, is not limited to the details of the construction and arrangement of the components set forth in the following description or shown in the following drawings. This disclosure can have other embodiments and can be practiced or implemented in various ways.

[0025] Figure 1 A coolant distribution unit 10 is shown, configured to distribute coolant to one or more servers, processors, or other high-heat components. The coolant distribution unit 10 includes a cabinet 15 and a human-machine interface (HMI) 20. The cabinet 15 includes wall panels 30 and doors 25 housing the components of the coolant distribution unit 10. These doors 25 can be opened by an operator to access the components within the cabinet 15. The HMI 20 shown includes a touchscreen; however, other embodiments include one or more keypads and / or screens to allow a user to interact with the coolant distribution unit 10.

[0026] Figures 2 to 5 The coolant distribution unit 10 is shown with door 25 and wall panel 30 removed for clarity. The coolant distribution unit 10 includes a power supply 35, a controller 40, a heat exchanger assembly 45, a primary inlet 50, a primary outlet 55, a secondary outlet 60, and a secondary inlet 65. The power supply 35 is connected to a power source (i.e., an electrical outlet and / or a battery) and selectively directs power to various components within the coolant distribution unit 10, such as valves, sensors, pumps, etc. The controller 40 is electrically connected to the HMI 20, the power supply 35, and other components within the coolant distribution unit 10, such as valves, sensors, pumps, etc. Figure 6A and Figure 6B This is a schematic diagram showing a heat exchanger assembly 45. The heat exchanger assembly 45 includes a heat exchanger 70, a first flow path 75, and a second flow path 80. The heat exchanger 70 is configured to allow a first fluid flowing along the first flow path to remove heat (i.e., reduce its temperature) from a second fluid flowing along the second flow path.

[0027] A first flow path 75 extends from the primary inlet 50 through the heat exchanger 70 and then to the primary outlet 55. The fluid exiting the primary outlet 55 is directed into a building cooling system (such as a roof-mounted heat exchanger). The building cooling system cools the first fluid and then directs the cooled first fluid back into the primary inlet 50. The first fluid is then heated by a second fluid in the heat exchanger 70. When the first fluid leaves the primary outlet 55, it is returned to the building cooling system to be cooled again.

[0028] A second flow path 80 extends from the secondary inlet 65 through the heat exchanger 70 and then to the secondary outlet 60. After exiting the secondary outlet 60, the second fluid is directed to one or more servers and / or other data center components to absorb heat and thus cool them. After absorbing heat from the one or more servers and / or other components, the second fluid is directed back to the secondary inlet 65. The second fluid is then cooled by the first fluid in the heat exchanger 70. When the cooled second fluid exits the secondary outlet 60, it is returned to the one or more servers and / or other data center components to be reheated.

[0029] The first flow path 75 includes: a first filter screen 85 and a first removable filter 90 upstream of the heat exchanger 70; and one or more pumps through which the first fluid flows. The first filter screen 85 and the first removable filter 90 are configured to filter particles from the first fluid upstream of the heat exchanger 70. In some embodiments, a bypass path 95 selectively allows fluid to bypass the first filter screen 85 and the first removable filter 90. In some embodiments, the first removable filter 90 is positioned within the first filter screen 85. In these embodiments, the first removable filter 90 can be removed from the first filter screen 85 and replaced with a different screen and / or filter. In some embodiments, replacing the screen and / or filter can filter out particles finer than those of the first removable filter 90. In some embodiments, the first removable filter 90 is positioned in series with a finer screen and / or filter. The finer screen and / or filter can remain in place while the first removable filter 90 is removed. After the coolant distribution unit 10 has been installed and activated, the first removable filter 90 is utilized for a period of time and then removed after that period has elapsed. In some embodiments, the first removable filter 90 remains in place until a sensor indicates that the first fluid has reached the desired filtration level. The first removable filter 90 provides the additional benefits of cleaning the fluid flowing through the building cooling system and removing any debris that may have accumulated in the coolant distribution unit 10 during manufacturing, shipping, and installation.

[0030] The second flow path 80 shown includes: a second filter 100; a first pump 105a and a second pump 105b; a first manifold 110; a plurality of filters 120a, 120b, and 120c; and a second manifold 125 upstream of the heat exchanger 70. The second filter 100 filters out particles upstream of the first pump 105a and the second pump 105b. The particles filtered by the second filter 100 include particles generated during manufacturing, shipping, and installation, as well as any particles accumulated by the one or more servers and / or other data center components. In some embodiments, the second filter 100 may be omitted. In some embodiments, a bypass passage 130 and a valve 135 selectively allow fluid to bypass the second filter 100. In some embodiments, the valve 135 is closed until a sensor indicates that the second fluid has reached a desired filtration level. In other embodiments, the valve 135 is closed for a set period of time after the coolant distribution unit 10 is activated. After the appropriate signal from the sensor or the set time period has elapsed, the controller 40 sends a signal to open the valve 135, allowing the second filter 100 to be bypassed.

[0031] In the illustrated embodiment, the first pump 105a and the second pump 105b are connected in parallel and propel fluid into the first manifold 110. In the illustrated embodiment, three filters 120a, 120b, and 120c are present in parallel, receiving fluid from the first manifold 110 and directing the fluid into the second manifold 125. Each filter 120a, 120b, and 120c includes a dedicated shut-off valve and an exhaust port. These filters can be isolated and replaced one at a time while the coolant distribution unit 10 is in operation. There are more filters than pumps, so the filter-to-pump ratio is greater than 1:1 (i.e., 3:2 or 1.5:1). While closing the shut-off valve of one filter (e.g., 120a) to allow replacement of that filter, fluid flows through the other two filters (e.g., 120b, 120c), causing the system to operate at a 1:1 filter-to-pump ratio. This allows the desired system performance to be maintained while one of the filters 120a, 120b, or 120c is replaced. When one of the filters is isolated, the other two filters provide approximately 66% of the total filter area, thus maintaining performance. In some embodiments, a single pump can be used instead of the first pump 105a and the second pump 105b. Unless one filter is taken offline for maintenance or replacement, the single pump will move fluid through all three filters 120a, 120b, and 120c. When one of these filters is taken offline, the single pump will move fluid through the other two filters.

[0032] The secondary cooling loop 80 includes an expansion tank branch 140. The expansion tank branch 140 includes an expansion line 145 connected to a tank manifold 150, with a first expansion tank 155 and a second redundant expansion tank 160 fluidly connected to the tank manifold 150. Excess coolant in the secondary cooling loop 80 can flow into or out of the expansion tanks 155 and 160, depending on the conditions of the CDU 10 (e.g., expansion of the secondary coolant based on heat transferred from the server to the secondary coolant, the server's offline / underutilized state, etc.). The tank manifold 150 includes an exhaust port 165.

[0033] The secondary cooling loop 80 also includes a filling branch 170 in fluid communication with the secondary cooling loop 80. The filling branch 170 includes a filling port 175, a filter 180, a first pump 185, a reservoir 190, a second filter 195, and a second pump 200, the second pump 200 being connected to the secondary inlet line 101 of the secondary cooling loop 80, for example, between a level sensor 205 and a pump manifold 105. The first pump 185 and the second pump 200 generate secondary coolant flows from the filling port 175 through the first filter and into the reservoir 190, and from the reservoir 190 through the second filter 195 to the pump manifold 105. The filters 180 and 195 filter out larger diameter particles that may be present in the secondary coolant. The reservoir 190 includes a level sensor 210 and a breather valve 215. The reservoir 190 may be filled with secondary coolant as a maintenance fluid inclusion option, in which the second pump 200 may operate in the opposite direction to pump secondary coolant from the secondary cooling loop 80 into the reservoir 190 to remove secondary coolant from a portion of the secondary cooling loop 80, thereby completing maintenance of the filter assembly, pump assembly, etc. It should be understood that by recovering secondary coolant from the secondary cooling loop 80, secondary coolant can be saved for further use, while reducing the risk of introducing additional contamination.

[0034] refer to Figure 7 Each of filters 120a, 120b, and 120c (120a is shown) includes a housing 220 that supports and at least partially encloses a filter medium (not shown) coupled to an end cap 225, which is clamped within the housing 220 by a clamp 230. A handle 235 extends from the end cap 225 to facilitate handling of the filter medium for removal and replacement. The end cap 225 includes a vent 240, and the housing 220 includes a discharge port 245 to allow secondary coolant to be discharged from the filter medium and the housing 220 prior to maintenance, thereby reducing the amount of secondary coolant lost during filter maintenance operations, such as filter replacement.

[0035] refer to Figure 8The heat exchanger assembly 45 includes one or more joints formed as modular joints 250 between piping sections and / or other components of the system (pumps, filter housings, heat exchangers, etc.). Modular joint 250 includes flange ends 255, 260 (connected in other embodiments by clamps 265 or fasteners) and a seal 270 (e.g., O-rings, gaskets, etc.) positioned between the flange ends 255, 260. In this embodiment, the following joints are formed as modular joints: a joint between the housing 220 of filters 120a, 120b, 120c and isolation valve 275; upstream and downstream joints of filter screen 85; and a joint between the first pump 105a and the second pump 105b and downstream check valve 280. It should be understood that by using modular joints instead of welded joints, upstream or downstream components of the modular joints can be more easily maintained or removed if they are no longer needed / desired in CDU 10, allowing for more flexible configurations for different use cases (for easier assembly or other reasons).

[0036] refer to Figure 9 and Figure 10 After testing prior to assembly and shipping, CDU 10 is filled with a predetermined amount of secondary coolant. Then, during installation at the facility, CDU 10 is filled again with additional secondary coolant to adequately cool remote locations within the facility (e.g., servers located in areas far from CDU 10). Secondary coolant is added to CDU 10 via fill port 175 using filler rod 285, which is coupled to fill port 175 and fluidly connected to coolant storage unit 290. For example, coolant can be added during startup or maintenance. Filler rod 285 includes filter 295 (e.g., a large-particle filter to prevent larger diameter particles from entering CDU 10).

[0037] This article discloses various filtration configurations that enhance the operation of the coolant distribution unit 10.

Claims

1. A coolant distribution unit, comprising: The cabinet has multiple walls, doors, a primary entrance, a primary exit, a secondary entrance, and a secondary exit; A heat exchanger assembly positioned within the cabinet, the heat exchanger assembly including Heat exchanger; A first flow path extends from the primary inlet through the heat exchanger and to the primary outlet, the first flow path including a first filter screen positioned between the primary inlet and the heat exchanger; as well as A second flow path extends from the secondary inlet through the heat exchanger to the secondary outlet, and the second flow path includes a second filter, a first pump and a second pump arranged in parallel, and a first filter, a second filter and a third filter arranged in parallel and located downstream of the first pump and the second pump. A human-machine interface, which is installed on the cabinet; A controller, which is located in the cabinet and is in electrical communication with the human-machine interface; as well as A power supply that is electrically connected to the human-machine interface and the controller.

2. The coolant distribution unit according to claim 1, wherein, Each of the first, second, and third filters includes a shut-off valve and an exhaust port, such that while the coolant distribution unit is in operation, one of the filters can be isolated and then replaced.

3. The coolant distribution unit of claim 2 further includes a first manifold and a second manifold, wherein the first manifold is positioned between the first pump and the second pump and the first filter, the second filter and the third filter, and the second manifold is positioned downstream of the first filter, the second filter and the third filter, such that fluid flows in parallel through the first pump and the second pump into the first manifold, and then the fluid flows in parallel through the first filter, the second filter and the third filter into the second manifold.

4. The coolant distribution unit according to claim 2, wherein, The ratio of filter to pump is greater than 1:

1.

5. The coolant distribution unit according to claim 1, wherein, The first flow path also includes a first removable filter upstream of the heat exchanger, the first removable filter being configured to be removed after a set time period has elapsed or after a signal from the controller indicates that the first removable filter should be removed.

6. The coolant distribution unit according to claim 4, wherein, The first flow path further includes a bypass passage and a valve, the bypass passage and the valve being configured to selectively allow fluid to bypass the first filter.

7. The coolant distribution unit according to claim 1, wherein, The second flow path also includes a bypass passage and a valve, the bypass passage and the valve being configured to selectively allow fluid to bypass the second filter.

8. A coolant distribution unit, comprising: The cabinet supports a primary inlet, a primary outlet, a secondary inlet, and a secondary outlet; as well as A heat exchanger assembly positioned within the cabinet, the heat exchanger assembly including Heat exchanger; A first flow path extends from the primary inlet through the heat exchanger and to the primary outlet, the first flow path including a first filter screen positioned between the primary inlet and the heat exchanger; as well as A second flow path extends from the secondary inlet through the heat exchanger to the secondary outlet, and the second flow path includes a second filter, one or more pumps, and one or more filters arranged in parallel and located downstream of the one or more pumps. A filling branch is fluidly connected to the second flow path.

9. The coolant distribution unit according to claim 8, wherein, The one or more pumps include a first pump and a second pump, and the one or more filters include a first filter, a second filter, and a third filter.

10. The coolant distribution unit according to claim 8, wherein, The heat exchanger assembly includes a plurality of pipe segments defining a first flow path and a second flow path, and the plurality of pipe segments are in fluid communication with the heat exchanger, the first filter, the second filter, the one or more pumps, and the one or more filters. A plurality of joints are defined between the plurality of pipe segments and at least the first filter, the second filter, the one or more pumps, and the one or more filters, wherein one or more of the joints are modular joints.

11. The coolant distribution unit according to claim 10, wherein, The modular connector includes: a first flange and a second flange; a seal positioned between the first flange and the second flange; and a clamp connecting the first flange and the second flange.

12. The coolant distribution unit according to claim 8, wherein, The one or more filters include a housing and an end cap, the housing receiving a filter medium and the end cap being attached to the housing and sealing the filter medium.

13. The coolant distribution unit according to claim 12, wherein, The handle extends from the end cap.

14. The coolant distribution unit according to claim 12, wherein, The exhaust port is connected to the end cap.

15. The coolant distribution unit according to claim 12, wherein, The outer casing supports the discharge valve.

16. The coolant distribution unit of claim 8, further comprising an expansion tank branch fluidly connected to the second flow path, the expansion tank branch including an expansion tank configured to receive excess fluid from the second flow path.

17. The coolant distribution unit according to claim 8, wherein, The filling rod can be attached to the filling portion of the filling branch to receive coolant from the coolant storage unit.

18. The coolant distribution unit according to claim 17, wherein, The filling rod includes a filter.

19. The coolant distribution unit according to claim 8, wherein, The one or more filters include at least a first filter and a second filter, the first filter and the second filter being configured to maintain filtration performance when the first filter or the second filter is bypassed.

20. A coolant distribution unit, comprising: The cabinet supports a primary inlet, a primary outlet, a secondary inlet, and a secondary outlet; as well as A heat exchanger assembly, at least partially located within the cabinet, the heat exchanger assembly comprising... Heat exchanger; A first flow path extends from the primary inlet through the heat exchanger and to the primary outlet, the first flow path including a first filter screen positioned between the primary inlet and the heat exchanger; as well as A second flow path extends from the secondary inlet through the heat exchanger to the secondary outlet, and the second flow path includes a second filter, one or more pumps, and one or more filters disposed downstream of the one or more pumps. The ratio of the filter to the pump is greater than 1:1.

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